BIODIESEL PYROLYSIS PLANT

TEAM NAME : KRISHNA

TEAM MEMBERS:

NISHANT MITTAL 3RD YEAR BTECH, PETROLEUM

MANIKHANDHAN.P.R 3RD YEAR BTECH, PETROLEUM
ROHIT SHARMA 3RD YEAR BTECH, PETROLEUM

COLLEGE:

SCHOOL OF PETROLEUM TECHNOLOGY,

PANDIT DEENDAYAL PETROLEUM UNIVERSITY, GANDHINAGAR, GUJRAT
 Vision:
To become Indias one of the prominent business tycoon.

Objecti
ve:
To convert waste (tyre or plastic) to black gold (biodiesel) with no
harm to environment.
Goal
:

To make India energy sufficient country.

Ownership
type:
Private organisation
INTRODUCTION
Around the world, there are initiatives to replace gasoline and diesel fuel due to the impact of fossil fuel crisis,
hike in oil price and stringent emission norms. Millions of dollars are being invested in the search for alternative
fuels. On the other hand, the disposal of waste tyres from automotive vehicles is becoming more and more
complex.

Waste to energy is the recent trend in the selection of alternate fuels. Fuels like alcohol, biodiesel, liquid fuel from plastics
etc are some of the alternative fuels for the internal combustion engines. In order to prevent waste rubber and in particular
discarded automobile tyres from damaging the environment, it is highly desirable to recycle this material in a useful
manner. However, the total quantity of tyres currently recycled in a given year (excluding reuse, retreading, or combustion)
is less than 7% of the annual tyre generation rate in the world.

The use of Tyre pyrolysis oil as a substitution to diesel fuel is an opportunity in minimizing the utilization of the natural
resources. Several research works have been carried out on the pyrolysis of waste automobile tyres. Pyrolysis is the process
of thermally degrading a substance into smaller, less complex molecules. Pyrolysis produces three principal products: such
as pyrolytic oil, gas and char. The quality and quantity of these products depend upon the reactor temperature and design. In
the Pyrolysis process, larger hydrocarbon chains break down at certain temperatures in the absence of oxygen that gives
end products usually containing solids, liquids and gases.
 Product description

Pyrolysis is the decomposition of organic compounds under oxygen free (anaerobic) atmosphere that
produces gas, oil, carbon black and steel.
Efficient industrial Pyrolysis is a process to treat the rubber and industrial plastic wastage as well.
As a result of pyrolysis of wastage tyres one obtains.


FUEL OIL (45% to 50%)

The main oil product produced by our recycling application is the fuel oil that
is widely used for industrial and commercial purposes. The oil has 45% to 50% of
the amount of recycled scrap tyres, which will be carried with licensed tanker
trucks.

C ARBON BLACK (30 % to 35%)

Carbon Black is the main product recycled by Pyrolysis technology. The amount of recycled
carbon black is 30% to 35% (depending on the type of tyres) of the total amount of scrap tyres recycled
in the system. Carbon black is used as raw material or main ingredient in many industries and the
chemical structure of carbon black strengthens, lengthens the endurance, and improves the coloring
features of the materials.
Carbon black produced by Pyrolysis process (CBp) is more economical compared to carbon black
produced primarily from petroleum and is more price-efficient to be used as an ingredient in the
industries listed;

Electric cable jacketing

Conveyor band
 Carrier Bands
Hose and doormat

Black nylon bag, Plastic pipes

Rubber additive
Automotive spare parts
Black colorant in rubber materials
Industrial rubber products
Fire fighting
Steel wire (10-15 %)

Tyres contain steel wires and the amount range of 10% to 15% of the total tyre wastage. All
of the steel present in the tyre can be detached after the Pyrolysis recycling process is
completed. Valuable steel wires are pressed and sold to steel and scrap dealers.

Non-Condensable gases arise during the pyrolysis process. There are some
advantages such as..

It has higher calorific value as compared

to natural Gas.
It can be replaced where natural gas and
propane are stored.
The high energy gas may be utilized as a source of energy
for the Pyrolysis process.
The amount of gas generated in the system is 5% to 8% of the total
amount of recycled tyres and considering the 10 ton scrap tyre/day
recycling capacity, the facility generates 500 - 800 m/day gas, which
has an enormous energy potential when evaluated.
Operational strategy
Pyrolysis is a thermo chemical decomposition of organic material at elevated
temperatures in the absence of oxygen. Pyrolysis typically occurs under pressure
and at operating temperatures about 430 C (800 F).

Pyrolysis is a special case of thermolysis, and is most commonly used for organic
materials, being, therefore, one of the processes involved in charring.
In general, pyrolysis of organic substances produces gas and liquid products and
leaves a solid residue richer in carbon content. Extreme pyrolysis, which leaves
mostly carbon as the residue, is called carbonization.

The process is used heavily in the chemical industry, for example, to produce
charcoal, activated carbon, methanol, and other chemicals from wood, to convert
ethylene dichloride into vinyl chloride to make PVC, to produce coke from coal, to
convert biomass into syngas, to turn waste into safely disposable substances, and
for transforming medium-weight hydrocarbons from oil into lighter ones like
gasoline.

These specialized uses of pyrolysis may be called various names,

such as dry distillation, destructive distillation, or cracking.
Machine Process
Process Details-

Machine Type - Batch Process System.

Feeding Material - Scrap Tyre or Plastics.

Fuel - Wood, Gas, Coal or Oil.

Reactor Capacity - 5/10/12 tons.

 Process
The waste Tyre or plastic are feed into the reactor vessel and initial heat is
provided with the help of wood, gas, coal or oil under controlled conditions of
temperature and pressure. The process will bring about molecular
restructuring of the rubber and convert into the vapors and gases. This
vapors and gases will flow into vapor gas separating tank. Then, these
vaporized gases are passed through heat exchanger and convert that vapor
into liquid in the form of Tyre oil. During the process we also get pyro gases,
so we use this gases for heating of reactor in the later stage of the process
and we burn the exceed gases in the burning room.
During the process, carbon black and steel are also generated. The heat
exchanger use water for cooling as a condensing medium and this water is
re-circulated through process. We pull-out carbon black from reactor and put
into packing bag. The oil automatically collects in the machine storage tank.
At the end we pull out steel wires.

Why we need pyrolysis plant?

On one hand, with the modernization of the society, rubber industry is developing at a rapid
speed, rubber manufactures products are widely used, on the other hand, the pollutant of
waste rubber is increasing day by day and its decomposing is very difficult, which is called as
"Black Contamination". This has become a big threat to the environment. Compared to the
developed countries, we are still lack of experiences in treating the pollution; the capital and
the market are also big problems.

Nowadays, the output of tire in India is more than 1.3 billion, i.e. the third in all over the
world. The scrap tires for each year are 65 million, and are increasing steadily year by year.
So to set up a factory in each town, which could extract black carbon and tire oil from 65-
million scrap tire, it is easy to find the raw material.

Product and Raw Material Market

Since along with world economics progressing by leaps and bounds, the petroleum scarce
tendency has grown day by day, the energy has become the primary factor that restricts
various economy development of various countries, as the research says, the petroleum on
global land will be exhausted within 15 years. Seeking the need of new energy has become
the matter of concern for various countries.

In our country, we have massive land, large population, with the rapid development of
Market Economy, Auto Industry and Machinery Industry, the requirement of oil market
unceasingly grows, our country have become petroleum-import country from petroleum-
export country. Under such circumstances pyrolysis plant gives tire oil which is a substitution
to furnace oil which is derived from crude. Thus, it creates the valuable things out of waste.

Our final motto is to make a Green Society.

Waste Tyre Pyrolysis Plant Advantages :

For the waste Tyre pyrolysis plant the main raw materials are waste tyres &
plastic scrap, which can be easily available in any part of the world.

The raw material is cheaper.

We get valuable outputs from the process and that are fuel oil, carbon black
powder, scrap steel & gas.

It is feasible technology with small amount of investment, high availability of

raw materials, short recovery period and with our guidance, is the ideal choice of
investing.

There is 100% recycling of waste tires, no disposable materials are left at the
end of the process.
The output products have its demand in the market.

No catalyst used in our machine during process.

Access to best technology available in India at best price.

It is a pollution free process, thus making eco-friendly environment.

ORGANISATION STRUCTURE
 Financi
al strategy

Profit Calculation

TAKE WASTE TIRE OIL REFINING EQUIPMENT PROCESSING 10 TONS FOR EXAMPLE

NO. ITEM COST OF PER BATCH

1 10 TONS OF WASTE TIRES 10 TON *8RS = 80000 RUPEES/DAY

2 0.4 TONS OF COAL (1 *6930)*0.4 = 2772 RUPEES/DAY

3 WATER AND ELECTRICITY 1760 RUPEES /DAY

4 WORKERS 4*8000 = 32000/MONTH

5 ENGINEERS 4*15000 = 60000 RUPEES/MONTH

6 GUARD 2* 5000 =10000 RUPEES/MONTH

 TOTAL COST (ON HUMAN RESOURCE) = 102000 RUPEES/MONTH
= 4080 RUPEES/DAY

TOTAL EXPENDITURE = 88612 RUPEES/DAY

No commodity income/day

1 oil 10 ton * 45% * 35 rupees = 157500 rupees/day

2 coke 10 ton *35% *10 rupees = 35000 rupees/day

3 steel 10 ton*15%* 15 rupees = 22500 rupees/day

4 gross profit = 215000 rupees/day

5 net profit/day = 126388 rupees/day

6 net profit/month = 126338 * 25days =3159700 rs

/month
 net profit/year = 37916400 rupees/year (excluding tax)

ADDITIONAL COST :

PYROLYSIS PLANT SETUP = 80,000,00 RUPEES

LAND COST = 20,000,00 RUPEES
PAY OUT TIME = 4 MONTHS
 Projection of sale :

Sale to government as per their requirement of oil.

Sale of steel and coke to industries .

Gross
revenue =
64500000
rs/year
Margin: 37916400 rs/year (excluding tax)

Future growth:

Ever increasing demand of oil and price

hike of oil make
this project worth for future.

SWOT Analysis

STRENGTHS
1. Quite simple chemistry
2. Small volume bio-diesel machines are commercially available
3. Ever increasing demand of oil.
 WEAKNESSES
1. Timely availability of raw materials
2. Higher capital investment
THREATS
1. Potential for increase in cost of metha
2. Potential for increase in cost of sodium hydroxide (catalyst)
3. Large companies introducing 5% blend
4.
5.

Opportunity of Biodiesel:

1. Funding is currently available for bio-fuel production and research

2. Coke may be used as energy for running plant.

3. Ever increasing Crude oil price.

4. Employment generation capacity in rural areas.

5. Better Utilization of fallow cultivable waste land.

6. Having carbon credit value (Kyoto protocol)

7. With use of Biotechnology encouraging primary result.

8.

Threats towards Biodiesel:

1. Malpractice in input materials.

2. No sustainable Procurement Mechanism available in the Market.

EXIT PLAN
Invite for public bidding.
Advice the company taking our raw materials(coke and steel) to be a stakehold
partner.
Ask for aid from the government for future investments with low interest rate.