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GoodRich offers vertical pyrolysis plant from Russia. It is designated for processing & utilization of used tyres, industrial rubber wastes, medical wastes, oil processing & refinery wastes, oil sludge, soft roofing materials, e-waste, rubber fabric, textile wastes including oiled rags, paper, cardboards, wood shavings, coconut shells, latex rubber wastes etc.<\/p>\n
The main processed products are liquid pyrolysis oil, carbonaceous residue (pyro-carbon), metal cord (in case of tyre processing) & pyrolysis gas. \u00a0The gas is used in the process.<\/p>\n
Vertical pyrolysis is a new technology. The manufacturer started operations in Russia 3 years back & since then sold more than 50 units. The plant is certified by the Russian State ecological department as suitable to process as many as 904 types of wastes in Russia. The plant is certified to operate in Europe also.<\/p>\n
Process description –\u00a0 <\/strong><\/p>\n \u00a0<\/strong>Crushed raw material is loaded into a heat-resistant stainless steel vessel (retort) of 2.5 m3<\/sup> capacity. The retort is placed into the Furnace. Preliminary retort heating (approximately 30-40 minutes) is made using liquid fuels (around 10 litres of diesel \/ furnace oil \/ pyrolysis oil). When the temperature inside the retort reaches to 300\u00b0C, thermal decomposition process starts.The temperature & pressure values are shown in the control panel & there is a pressure valve for safety precaution.<\/p>\n The generated gas is supplied to the heat exchanger for condensing into pyrolysis oil. A part of the un-condensed gas, after multi-stage purification, is supplied to the burner. Thus, from the starting of the pyrolysis process until its termination, the burner fully operates on pyrolysis gas. The pyrolysis process lasts for approximately 10-11 hours.<\/p>\n When the pyrolysis process is completed, the first retort is taken out from the furnace & placed for cooling and the second retort (already loaded with the raw material) is placed into the furnace.<\/p>\n Approximately 5-6 hours later, the cooled retort (containing pyro-carbon & metal cord) is unloaded by over-turning. Further, the retort is placed into a pit for loading the next raw material lot. Metal cord is separated from the pyro-carbon manually or by a magnetic separator(in case of tyre processing).<\/p>\n \u00a0<\/strong>Advantages of Vertical Pyrolysis Unit \u2013<\/strong><\/p>\n Technical features & Equipment list \u2013 <\/strong><\/p>\n \u00a0<\/strong>Complete set and technical features of Pyrolysis plant –<\/p>\n Pyrolysis module (pyrolysis furnace)\u00a0 – \u00a0 Efficiency, 2-4 tons\/24 hours<\/p>\n Retort with a lid (2 units) \u00a0 – \u00a0 \u00a0 Power consumption, 3 KW<\/p>\n Refrigerator (heat exchanger) \u00a0 \u00a0– \u00a0 Dimensions,\u00a0\u00a0\u00a0 4000\u04453000\u04457000 mm<\/p>\n Collector-separator \u00a0 –\u00a0\u00a0\u00a0\u00a0 Voltage, 220 or 380 V<\/p>\n Centrifugal separator \u00a0 – Current frequency, 50 Hz<\/p>\n Liquid fuel burner<\/p>\n Gas burner<\/p>\n Pump for pyrolysis oil<\/p>\n Water pump<\/p>\n Compressor for the burner<\/p>\n Pyrolysis gas purification module<\/p>\n Service platform<\/p>\n Control panel<\/p>\n Scheme of the Pyrolysis Plant \u2013<\/strong><\/p>\n Recovery of final products from various raw materials \u2013<\/strong><\/p>\n Approximate recovery figures \u2013<\/strong><\/p>\n 1)\u00a0\u00a0 Recycling of used tyres \u2013<\/p>\n Pyrolysis oil \u2013\u00a0\u00a0 37-40%<\/p>\n Carbon –\u00a0\u00a0 38-40%<\/p>\n Steel cord \u2013 3-8%<\/p>\n 2)\u00a0\u00a0 Plastics processing \u2013<\/p>\n Polyethylene, polypropylene, polystyrene-<\/p>\n Pyrolysis oil \u2013 65-75%<\/p>\n Pyro carbon \u2013 15-25%<\/p>\n Polyurethanes –<\/p>\n Pyrolysis oil \u2013 50-55%<\/p>\n Pyro carbon\u00a0\u00a0 35-40%<\/p>\n 3)\u00a0\u00a0 Oil sludge \u2013<\/p>\n Pyrolysis oil – 44%<\/p>\n Carbon – 18%<\/p>\n Gases – 25%<\/p>\n 4)\u00a0\u00a0 Waste oil & oil slime \u2013<\/p>\n Pyrolysis oil – 80%<\/p>\n Pyro-carbon – 10%<\/p>\n Gases – 10%<\/p>\n Notes:<\/strong><\/p>\n 1)\u00a0\u00a0 The heat value of pyrolysis oil is 9,000-10,000 kcal\/kg.<\/p>\n 2)\u00a0 If there is water in the raw material, it cannot be separated from the oil. Usually, water has higher density & can settle down. The process of pyrolysis takes longer time when the raw material has more water.<\/p>\n \u00a0<\/strong>\u00a0<\/strong>Site requirement & utilities \u2013 <\/strong><\/p>\n A concreted plot of 5X5 metres is needed for placing the pyrolysis unit. Additional premises to store the raw materials & finished products, as well as to place the retorts for cooling, should be provided. The unit can be placed outdoors as well as indoors with additional ventilation. The chimney height should be at least 7 metres.<\/p>\n The unit operation needs circulating water (30-40 litres per minute or 10-15 m3\u00a0<\/sup>in storage) & electricity (3 KW). A hoisting device (monorail, crane or winch) with a loading capacity of 2 tons & lifting height of 7 metres is needed for loading & unloading the retort. Load-lifting mechanism costs 1,000,000 Roubles extra.<\/p>\n The equipment operates for 24 hours a day. Operating of 1-3 modules requires 2 trained operators. Maintenance is needed once in a week, for 10-12 hours.<\/p>\n Equipment price & Warrantee \u2013<\/strong><\/p>\n \u00a0<\/strong>–\u00a0 Price of the unit is 5,000,000 Roubles, ex-factory, Moscow. Transportation to St. Petersburg Port in a 40 ft. container costs 30,000 Roubles extra. Shipping weight is about 6 tons.<\/p>\n –\u00a0 Production capacity is 2-4 tons \/ 24 hours or 50-100 tons\/month.<\/p>\n –\u00a0 The equipment production time is 60 days.<\/p>\n –\u00a0 Equipment life is 10 years. Warrantee period is 1 year.<\/p>\n A Russian engineer will come to India for 4-5 days to assemble & to start the unit. The customer has to pay for the flight + accommodation and also a daily bata of 5,000 Roubles.<\/p>\n Additional Equipments \u2013 <\/strong><\/p>\n \u00a0<\/strong>Bead cutting device\u00a0<\/u>is designated for separating tire beads from treads for denser retort loading. The price is 300,000 Roubles.<\/p>\n \u00a0<\/u>Dumping device\u00a0<\/u>is for convenient retort overturning for carbonaceous residue unloading. The price is 200,000 Roubles.<\/p>\n Retort cooling station<\/u> is designated for more intensive retort cooling. The price is 250,000 Roubles.<\/p>\n Magnetic separator<\/u> is designated for extracting metal cord residue (more careful purification), which significantly increases its selling price. (they suggest separator producers).<\/p>\n Twin Pyrolysis Plant \u2013<\/strong><\/p>\n \u00a0<\/strong>The Twin Pyrolysis Plant can be purchased for 9,500,000 Roubles, having a capacity to process 4-8 tons per day.<\/p>\n The advantages of Twin Pyrolysis Plant are \u2013<\/p>\n 1)\u00a0 There is no need to use oil burners every time,to start the unit. The gas generated from the first unit can be used to heat the second unit. The process phase shift between 2 units can be chosen in such a way that the second unit goes through the stage of maximum gasification, when the first unit has the biggest necessity of fuel. It is also not necessary to install a gas holder for temporary storage of pyrolysis gas.<\/p>\n 2)\u00a0 Requirement of labourers & supervisors will be the same either for a single unit or for a Twin unit.<\/p>\n\n
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