Pyrocrat Systems LLP - Pyrolysis Plant

8/20/2019 Pyrocrat Systems LLP - Pyrolysis Plant

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Harnessing

Technology togenerate

Quality Fuel from

polymer waste.


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Sustainable Energy Recovery from Waste

We harness

technology to build

waste plastic & tirepyrolysis plants that

are: Environmentally

Compliant, Safe &Economically Viable


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Pyro = heat. Lysis = break

down.

Pyrolysis is chemical reaction.

This reaction involves

molecular breakdown of larger

molecules into smaller

molecules in presence of heat.

Pyrolysis is also known asthermal cracking, cracking,

thermolysis, depolymerization,

etc.

During pyrolysis plastic and tire

breaks down into smaller

molecules of pyrolysis oil,

pyrolysis gas and carbon black.

What is Pyrolysis Reaction?


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Pyrolysis Reaction

• Long Chain Polymer

– Waste Plastic

– Waste Tyre/rubber

– Crude Oil Sludge

• Short Chain Polymer

– Hydrocarbon Gas

– Pyrolysis oil

– Carbon Black

Heat +

Catalyst

C-50,000 to C-2,00,000 C-1 to C-4 & C-5 to C-23


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What is Pyrolysis oil?

» Pyrolysis oil is a Hydrocarbon liquid manufactured bybreaking plastic and tire molecules

» Used as replacement to diesel in: electric generators,boilers, diesel pumps, furnaces, hot watergenerators, hot air generators, thermic fluid heateretc.


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Waste Plastic/Tire to Fuel Technology

» We have successfully developed

a process & catalyst to

– Produce industrial diesel grade

fuel from waste plastic & tires

– Maximise plant efficiency by:

• reducing reaction from 600OC to

375-425O

C• Reduces reaction time from 90mins

to 15-45mins


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What is Pyrolysis Plant?

This process can be used for effectively energy recovery from municipal solid

waste, waste plastic and tires.

Pyrolysis Plant falls in these categories of projects: Waste to Energy, WasteManagement, Energy Recovery from Waste, Plastic and Tire Pollution Control.

Pyrolysis Plant is waste management industry that converts waste plastic &

tires into Pyrolysis Oil, Carbon & Gas. Pyrolysis oil can be used for generating

electricity.


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Raw Material Options

Waste Tires

Mixed plastic (HDPE, LDPE, PE,PP, PS, ABS, etc)

Municipal Solid Waste sorted

out plastic

Packaging Waste Plastic

Post-Consumer Plastic Waste

Paper Recycling Mill Plastic

waste

Crude Oil Sludge etc.

Both plastic & tire can be used

as raw material

No need for segregation&

cleaning

Tolerance: 5% of dust +

5% moisture

PVC < less than 1%

PET < less than 15%


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Finished Products & Yields

TIRE asRaw Material

Oil

charcoal

Gas

PLASTIC asRaw Material

Oil

charcoal

Gas

5 to 8 %

Carbon Black

70 to 90 %

Pyrolysis Oil30 to 35 %

Carbon Black

40 to 45 %

Pyrolysis Oil

Note: Gas generated is reused in process as source of heat for conducting the reaction. Oil yield is

increased to the amount of non-plastics like dust, impurities, additives etc. in raw material are reduced.


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Pyrolysis Plant Business Economics

• Key Finished Product:

– 7000 to 9000 lit of Oil from10,000kg of plastic –OR-

– 4000 to 5000lit of Oil from10,000kg of tires

•

As on December 2015: – Oil production cost is

approx. US$ 0.3 per lit

– Oil selling cost is approx.US$ 0.51 per lit

• Email us to get detailedfinancial projections

• Investment pays back in 2

to 4 years

Convert waste plastic & tires into

high quality oil used widely inindustrial burners.

This oil can be fired in electricgenerators to produce electricity

at approx US$ 0.12 per unit.

Pl t C it i T P D 3 6 12


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Land, Building

& Power

requirements

Plant Capacity in Tons Per Day: 3 6 12

Plant Capacity in Tons Per Annum: 900 1800 3600

RESOURCES

Raw material Plastic/Tire (kg/day) 3,000 6,000 12,000

Catalyst additive "A" consumption (kg/day)

(Yr 2013 market price is USD 2.2/kg)30 60 120

Catalyst additive "B" consumption (Kg/Day)(Yr 2013 market price is USD 4.5/kg)

3 6 12

NaOH Reagent consumption by off gas cleaning

system (scrubber) (Kg/day)0.5 1 2

Water requirement per day (lit) 200 400 600

Electrical connection (HP) 60 85 120

Personnel: Per 24 Hrs

Plant Head 1 1 1

Unskilled workers 6 8 8

Skilled Operators 3 3 3

Land Area (m2) 600 1000 1800

Built-up Factory Shade Area (m2) 250 500 750

Machinery:

Machinery Approx. Weight (MT) 60 100 200

Machinery Manufacturing time (Months) 3 3 4

Factory Installation time (Months) 1 1.5 1.5

OUTPUT

Pyro oil output with Plastic as raw material (lit/day) 2100 4200 8400

Pyro oil output with Tire as raw material (lit/day) 1350 2700 5400

Carbon black output (Plastic as raw material)

(Kg/day)540 1080 2160


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Charcoal Specifications & Applications

Applications: Charcoal soil enrichment, Solid fuel, Paintindustry, ink industry, filler in plastic recycling, formanufacturing high value products like activated charcoal etc.

Specifications Analysis

MethodCharcoal from

Tyre

Carbon black grades

HAF(N330) SRF(N754)

Iodine Adsorption Number, mg/g ASTM D-1510 176 82 24

DBP Absorption, cm3/100g ASTM D-2414 78 92-102 50-65

CTAB Surface Area, m2 /g ASTM D-3765 68 74-90 23-39

pH – Value ASTM D-1512 9 7-9 7-10

Heating Loss, % max ASTM D-1509 1.5 2.5 1.5

Ash Content, % max ASTM D-1506 10 0.5 0.5

Average Particle Size, nmMICROSCOPE

ELECTRONIQUE300 mesh


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Prevent Plastic to Fuel Technology

• Operational in Europe + 18locations in India

– 10MT of waste plastic to

6000 to 9000lit oil(Pyrolysis)

– 7000lit of Oil to 1MW/hr

(Power Generation)


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Fully Automated & Skid Mounted


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Patent Pending Technology..

Process and design

patent applied in India &

Europe Technology..

P t C tifi ti


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Pyrocrat Certifications

1) CE Certified 2) ISO certified


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Research &

Development• State of art catalyst lab for

finding right catalyst

combination for the given rawmaterial locally available:

– Higher oil yield & quality

– Lower Carbon yield

• Software used for plant design

– FEMAP with NASTRAN(Simulation)

–

Aspentech (Simulation) – Solid Edge ST6 + ZW Cad

(Design)


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Health Safety Environment & Quality

We give top priority to health and safety

» Airlock feeding

» Low pressure operation (300mmWC)

» Carbon removal by screw (closed system)

» No direct heating or reactor» Certified firing systems

» Scrubbing system – no SPM, Chemical or thermal

emissions exceeding limits


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Ease of operation and maintenance

» Fully automated plant

» Ease of cleaning without

dismantling

» No manual handling of

carbon black

» No heating and cooling

cycles

» Automated firing system


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Customer Care is Our Core Value

» Spare Parts Supply» Catalyst Suggestion for New Type of

Plastic Waste

» Trouble Shooting

» Performance & Efficiency Audit» Supply of Equipment

» Undertake repair of Equipmentmanufactured by Pyrocrat

» Plant/ Equipment Life Extension Services» Recommissioning

» Preventive Maintenance

» Supply of Catalyst as the case may be


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Warranty

– 5 years from the date ofsupply against manufacturingdefect

Staffing – Will supply all necessary

skilled/unskilled workers in

case intimated about 4months in advance


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We use high end engineering software

simulation to design robust machines.


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We use high end engineering software

simulation to design robust machines.


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Superior oil quality through unique catalyst


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Key Advantages of

PyrocratPatented Technology

Leading Pyrolysis Research &

Development since 2007

More than 15 references

Both plastic and tires can beprocessed in same reactor


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Project Guarantees:Guaranteed 100% per annum Production Capacity | Guaranteed 300

working days per Annum | 100% Environmental Compliance + Zero

Industrial Effluent Technology | 1 year warranty of against manufacturing

defects | Back to back manufacturer’s guarantees for critical parts

Investment Protection with Patented Technology:Application # 1727/MUM/2014

Fully Automated with PLC + SCADARemotely accessible | Controlled from Control Room + Pyrocrat Office.

Raw Material Flexibility:Both Tire and Plastic can be processed in same reactor | Can process low

density plastics like carry bags, Paper recycling mill waste plastic, MSW

sorted out Plastic, Packaging material waste etc.

Proven & Efficient for Non-stop operation:Technology Operational across 17 Locations at 100% Efficiency | Standard 1

year spare with supply |

1 in use + 1 standby provision of all pumps


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Certifications:ISO 9001:2008 Certified | CE Certified (Confirmation of European

Standards)

Quality & Transparency with clients:Quality Assurance Plans & Material Test Reports| 3rd Party Inspection

Reports | Online Product Manuals & Technology Improvements

Plug and Play Design:Standardized & Pre-assembled Equipments for timely project completion |

Skid Mounted Designs for Quick Installation & Production

Professionalism:CE Certified & ISO 9001:2008 Certified | 110 Employees including strong

team of more than 50 Project Engineers | Speedy Technology

Developments & Dedicated ‘After Sales Support’ department

Safety 1st:Multiple layers of safety incorporated in plant design & automation |

Unique low pressure pyrolysis technology | Use of top quality of

construction material and makes


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www.pyrolysisplant.com

Google+ Hangouts ID: [email protected] | Skype ID: pyrocratsystems

+91-22-275-990-10 | +91 99306 55477

J-103 & 105, 1st Floor, Tower No. 7, Railway Station Commercial Complex, Sector 1A, C.B.D.

Belapur Navi Mumbai Maharashtra State India PIN: 400 614

If you would like to invest in wasteplastic & tire to oil plants, you are invited

to visit our operational pyrolysis plant.

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Pyrocrat Systems LLP - Pyrolysis Plant