“Bringing You & Technology Together“

5th

GENERATION

“WASTE TYRE RECYCLING PLANT”

Registered Office: 520-527 Poddar Arcade, Khand Bazaar,

Varachha Road, Surat 395 006 (Guj) India

Contact Numbers: +91 261 2554150/51/52 Fax: +91 261 2554149

10 TON PLANT PROJECT REPORT

Company Profile:

Anjali Exim with its unique renewable technology has come up with a concept of setting new

standard in renewable energy that includes using of waste tyres as a raw material and producing

green fuel oil, carbon black, steel and gas. With global warming and utilization of rubber, it has

now become necessary to recycle the waste and convert it in fuel oil in such a way that it is

environment friendly. This is a unique technology and can be change energy market scenario in a

big way.

Anjali Exim has a team of experienced and expert recycling, consulting and marketing

Professionals that work hard for obtaining renewable energy from the waste. Our professionals

have worked in different countries. We are also working in the sector of laser systems, solar

panel, and textile and construction business.

World Market Scenario:

Billions of wastages are available in all over the world. We can’t burn or land fills that tyres due

to pollution problems. There is no any other use of these waste tyres. So, we at Anjali Exim have

found a solution for this wastage tyre. We separate all content from wastage tyres and make it

complete renewable process.

Features of the plant:

� 100% wastage tyre recycling is achieved (No churn left after the process)

� No chemical ingredients are used in process (environment friendly)

� During and after the process; no soil, water or air pollution is observed.

� Creates economically valuable products out of wastage tyres (These are an industrial

product that have a good market value and demand)

� The most cost-effective wastage tyre recycling technology in the world.

� Raw material (wastage tyre) is cheap and easy to provide. These are the by-products of

tyre production.

� Each recycled ton of tyres preserves 10 tons of CO2 that is a major green house gas.

� The process can be applied to all rubber based materials.

� The system creates an alternate source of energy to replace petroleum products and

natural gas.

� System gives the opportunity to governments and local administrations to deal with the

wastage tyre problem to a great extent.

� The process of Pyrolysis has duration of 4 to 12 hours, depending on the quantity and

size of tyre (car tyre, truck tyre, etc.). During the process different vacuum values are

applied in pre-determined temperatures and in different phases. Different gases are

obtained and the condensed gas is stored as a fuel-oil in tanks.

The Features of the Fifth Generation Plant

Item. Picture. Features.

Catalyst

Room

Two catalyst room, in this way, can

speed up the process of pyrolysis.

Horizontal

Condensor

Two horizontal condenser, the cooling

area of one horizontal condenser can be

equaled with more than three vertical

condensers. And also, the cooling way is

longer than vertical condenser, in this

way, the oil output will be guaranteed.

Vertical

Condensor

Another two length cooling pipes, the

cooling area can be equaled with one

vertical condenser, in this way, the

cooling result will be better than our

fourth Generation.

Anti back

devices

Two anti back fire devices, it is our

second water seal, and also reuse the

exhaust gas as burning material, two anti

back fire device, more safety, more

energy saving.

The exhaust

Gas

From the picture, you can see the

exhaust gas, it is white, no pollution,

even if you put a white towel on it you

cannot see any black. It can meet the

emission standard of international

required.

The Perfect Solution (Pyrolysis Process):

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 wide

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.

� CARBON 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% to 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.

� GAS (5% to 8%)

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 m³/day gas, which has an enormous energy potential

when evaluated.

5th Generation Plant Photo:

PYROLYSIS CARBON BLACK TEST REPORT:

PYROLYSIS FURNACE OIL TEST REPORT:

Technical Detail:

� This is a batch process system.

� The wastage tyres are fed into the reactor vessel and heated under controlled conditions

of temperature and pressure.

� The process will bring about molecular restructuring of the rubber under the pyrolysis

process as the result; furnace oil in gaseous form is produced along with other gases.

� These vaporized gases are passed through heat exchanges, where in the furnace oil is

condensed into liquid form.

� During the process, carbon black and steel are also generated.

� The heat exchanger uses coolant water, as a condensing medium and this water is re-

circulated through process.

� These systems can be operated 24/365.

AZ – 150 Tyre Recycling Plant:

AUTO FEEDAR:

CARBON REMOVAL SYSTEM:

Process Flow Chart:

Scrap Tire

Stocking

Pyrolysis Unit

Oil Carbon Black Steel Wire Gas

Storage Sleve Sleve Burning Unit

Transfer to

Refinery

Carbon Black Storage Chimney

Storage

Magnet

Grinding System

Packing

Stowing

Sale to Market

Pressing

Transfer to

Scrap Dealer

Technical Parameter:

Project ( Dimension : 6.6 *2.6m)

Sr. No. Equipment Specification

1 Equipment Model AZ-150

2 Material Plastic rubber (tyres) life garbage

3 Structure Horizontal tyre revolves

4 Capacity For One Batch About 8-10 tons wastage tyres

5 Oil Yield 45%-50%

6 Carbon Black 30%-35%

7 Steel Wire 10%-15%

8 Gas 5%-8%

9 Work Pressure Normal

10 Main Engine Rotation Speed 0.4 RPM

11 Fuels Choice Coal, Wood, Gas, Oil

12 Power About 35 HP

13 Cooling Method Water

14 Cooling Water Consumption(T/H) Cyclic

15 Type Of Drive External Annual Gear Drive

16 Heating Method Direct

17 Type Of Installation With Foundation

18 Operating Mode Intermittent Operation

19 Reactor Dimension (MM) (Long*Diameter) 6600*2600

20 Reactor Weight About 22000 Kg.

21 Total Weight About 32 MT

5th

Equipment List

D = Diameter L = Length H = Height W = Wide

Name Weight Size (MM) Quantity Picture

Reactor 22000kg D2600*6600 1

Catalyst Chamber H2100*L1800 1

Oil Water

Separator D1200*H2100 1

Oil Tank D1000*L3200 2

Horizontal

Condenser D1050*L400 2

Vertical

Condenser 300kg D800*L2600 1

Anti-back fire

device 50 kg D400*H1350 2

Buffer Tank 50 Kg D550*H1350 1

Negative Pressure

Device 890 Kg H2050*W2000 1

Water Jet Flue D500*L4000 1

Dust Removing

device 2000kg H1250*L2950 1

Draught Fan L950*W800 1

Chimney 200kg 1

Auto Feedar 400Kg L4700*W1200*H2150 1

Releted link pipe

Difference Between Fourth Generation And Fifth Generation Tyre Pyrolysis Plant

Name 5th

Generation Tire Pyrolysis Plant 4th

Generation Tire Pyrolysis

Plant

Catalyst

Chamber

We call the 5th

catalyst chamber “double chamber “. This design could add the molecular

sleve , which increase the oil quantity, beside these are two catalyst chamber could reach

double effect of catalytic pressure and remove the slag from the oil gas.

Oil Water

Separator

The Oil Water Separator new design could have the colling cover that cool the gas so that

decrease the temperature of the oil gas, than the oil gas could be more easily collected in

next stage.

Condenser

The condensers are changed as horizental , this could incersase the colling area, so that

more oil gas could be colleted , thes the oil yiekd are higher the oil yield rate could reach

53%.

Oil Tank

The oil capacity is bigger than tha 4th

generation and it could be equipped with the

automatic pumping system.

Anti – back

fire Device

Double anti-back fire device could be recyeled the tail gases more sufficently so that the

reactor could burn more gases us fule to save energy and will not pollute the air , so that

more enviromental friendly. Also there are two pipes colling the tall gas to that more safe, as

the fule gas are usally methane , eathane, hydrogen etc, if the temperature is so high then it

easy to blast.

Carbon

black

Removing

Equipment

Our R&D department invent this bucket elevator to lift the carbon black into the come pool

automatically, there is no need manpower ot lift, and also there is a screw conveyor to cool

the hot carbon black then this save time to collect the carbon black.

Electric

Controller

5th

generation electric has two function, one is the control the power and another showing

the temprature of the oil out, 4th

generation electric could only control the power.

Project Planning & Implementation (For the 10 ton/day capacity):

Land Requirement : 1500 sq. meters

Construction Shade : 40Ft * 80 Ft = 3200 Sq.Feet

Water Required : 100 liter per day

Power Requirement

Without Autofeeder : 20 hp

With Autofeeder : 35 hp

Man Power Planning : Manager-2

Technical-1

Worker-4

Capital investment:

Other Arrangements to be made by Client Storage tank Of oil (Available locally),Civil Work, Local Worker & labor

Terms & Condition: Delivery Time :Chinese plant 30 days from your order confirmation

Installation Period :15 days

Warranty Period :1 Year

After Sales Service :1st

Year Free Service after then AMC Based…

Installation, Training & :Inclusive in price.

Particular Investment

Building and land (1500sq.meter with 600sq.meter shade) Depend on the area

CHINESE PLANT

Price of the Plant (Ex – Factory China) 5th

Generation With

Auto feeder

( Dimension:2.6*6.6MT)

70,000 USD

Price of the Plant (Ex– Factory China) 5th

Generation Without

Auto feeder

( Dimension:2.6*6.6MT)

64,000 USD

Custom Duty 26%, Fright, Container Clearing Charges,

Transportation Extra.

Shredder Price ( 2 ton/ hr Capacity) Rs. 25 Lakhs

This does not include the rate of interest on capital investment.

Estimated Operational Cost and Return on Investment:

The analysis is based on the conjecture of 10 tons/day capacity unit operating for 300 days a

year;

Raw material waste Tyre: 8 ton per day*300 days = 2400 ton/ year.

Total output:

• Carbon black (35%) - 840 Ton (Rs 1,000 per Ton in India)

• Furnace oil (45%) - 1080 Ton (Rs 38,000 per Ton in India)

• Steel (12%) - 288 Ton (Rs 12,000 per Ton in India)

• Gas (8%) - 192 Ton (We are not considering price of it right now)

Total Earning: (Yearly) (Unit: Tons)

Sr. No Product Output (%) Output (Ton) Price Per ton. Total Income

1 Carbon Black 35% 840 1,000 8,40,000

2 Furnace oil 45% 1080 38,000 4,10,40,000

3 Steel 12% 288 12,000 34,56,000

4 Gas 8% 192 --- 0

Total (A) 4,53,36,000

Total Expense: (Yearly) (Unit: Tons)

Sr. No Particular Quantity Price Total Cost

1 Waste Tyres 2400 10,000 2,40,00,000

2 Salary & Wages 9*12 Month 10000 10,80,000

3 Fuel (For Initial Use) 300 5000 15,00,000

4 Electricity + Water --- -- 7,20,000

5 Misc. Expense

(Bag Packing, Repairing, Renovation)

--- -- 9,50,000

Total (B) 2,82,50,000

Profit (Earning – Expense) (A-B) 1,70,86,000

Shredder Cost/ ton:

1) Cost of machine: Rs. 25 Lakhs

2) Capacity: 48 ton/ day.

3) Electricity consumption: 60 Hp.

4) Labour = 3

Estimated Operational Cost:

Capacity Utilization = 10 hr/ day

Total Expense: (Yearly) (Unit: Tons)

Sr. No Particular Quantity Price Total Cost

1 Electricity consumption 48 Hp Rs.11,00,000

2 Salary & Wages 3*12 Month 10000 Rs. 3,60,000

Total Rs. 14,60,000

Total Cost Rs. 14,60,000

• Plant require: 6000 ton/ Year.

• So, per ton cost of shredding is Rs. 243/ ton.

520-527, PODDAR ARCADE,

KHAND BAZAAR, VARACHHA ROAD,

SURAT, 395006

GUJARAT, INDIA. Phone: +91 261 2554152 Fax: +91 261 2554149

Web: www.anjaliexim.com

Email: info@anjaliexim.com

Thank You . . . !