Caravan Tyre Pyrolysis Proposal Ver 7

Caravan Global
Caravan House, Plot 10, Sector 24, Turbhe Sion Panvel Road, Navi Mumbai 400705 Email : sanjeev.caravan@gmail.com Ph : 91-9322210577
Company profile:
Caravan Group is a forty year old business house engaged in various business verticals from logistics to manufacturing. We have over 1000 employees across 25 offices all over the country. We have come up with a concept in renewable energy, that uses waste tyres as a raw material and produces fuel oil, carbon black and steel. With global warming and shortage of fuel, it has now become necessary to recycle waste and convert it to fuel oil in an environment friendly way. This is a unique technology and can change energy market scenario in a big way. Caravan has a team of experienced experts in recycling. Our professionals have worked in different countries.
Introduction to scrap tyre problems:

Billions of waste tyres are available all over the world. We cant burn or land fill them due to pollution problems. There is no other use of these waste tyres. So, we at Caravan are proposing solution for this waste problem.
Features of the plant

100% waste tire recycling is achieved (no waste 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 waste (all of the products are industrial raw materials that have a market value). The most cost-effective waste tire recycling technology in the world. Raw material (waste tire) is cheap and easy to provide. These are the by-products of tire production. Each recycled ton of tire preserves 10 tons of CO2 that is a major greenhouse gas. The process can be applied to all rubber based materials. The system creates an alternative source of energy to replace petroleum products and natural gas.
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Caravan Global
System gives the opportunity to governments and local administrations to deal with the waste tire problem to a great extent. System prevents the spread of diseases caused by waste tires. We deliver plants with capacities of 5 ton /day and its multiples. The process of Pyrolysis has duration of 4 to 12 hours, depending on the amount and type 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 fuel-oil in tanks.
The perfect solution

Pyrolysis is a process to treat the rubber and industrial plastic waste Pyrolysis is the decomposition of organic compounds under oxygen free environment that produces gas, oil, carbon black and steel. Below is the output percentage and use of the end products.
1) FUEL OIL (40 to 45%)

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 40%-45% of the amount of recycled scrap tyres, which will be carried with licensed tanker trucks.
2) CARBON BLACK (30 to 35%)

Carbon Black is the main product recycled by pyrolysis technology. The amount of recycled carbon black is 30%-35% (depending on the type of tyre) of the total amount of scrap tires 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 application (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; Page 2 of 12
Caravan Global
Electric cable jacketing Conveyor band Carrier Bands Hose and doormat Black nylon bag Rubber additive Automotive spare parts Heat isolation Black colorant in rubber materials Plastic pipe Industrial rubber products Fire fighting
3) STEEL WIRE (10 to 15%)

Tyres contain steel wires and the amount ranges from 10% - 15% of the total tyre weight. 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.
4) GAS (10 to 12%)

Non-Condensable gases arise during the recycling application which; Has a higher calorific value compared to natural gas Can replace natural gas and propane when stored Can be used as energy resource in gas burners, also used in pyrolysis system The amount of gas generated in the system is 12 to 15% of the total amount of recycled tires and considering the 10 ton scrap tire/day recycling capacity, the facility generates 1400 - 1500 m/day gas which has an enormous energy potential when evaluated.
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Caravan Global
Project requirements (for 4-5ton/day capacity)

1) power requirements 50hp 2) man power Technical 1 Manager 2 Worker -4 For 24 hour operation. 3) 4) 5) 6) 7) land required 1500 sq.meter constructed shed 1500 sq.feet water required 300liter/day installation period 15 days Delivery time 1 month.
Warranty period- we give 1 year warranty for manufacturing defects. Service: one year free service. After one year work on AMC.
Technical process flow

This is a batch process system. Waste tyre is fed into the reactor vessel and heated under controlled temperature and pressure. The process brings about molecular restructuring of rubber, as a result; furnace oil in gaseous form is produced along with other gases. These vaporized gases are passed through heat exchangers, where the furnace oil gas is condensed into liquid form. During the process, carbon black is generated. The heat exchanger uses coolant water, as the condensing medium and this water is recirculated. These systems can be operated 24/7
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Caravan Global
Flow chart of the process and diagram of our model xy-7 and photo of the plant is as given below.
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Caravan Global
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Caravan Global
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Caravan Global
Equipment Technical Parameter

No. Project dimension: 6.0*2.2m
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Equipment model Material Structure Capacity for one batch Oil yield (tire as raw materials) Carbon black Steel wire Gas Work pressure Main engine rotation speed Fuels Choice Power Cooling Method Cooling water Consumption(T/h Type of drive XY-7(full open door) Plastic rubber (tires)life garbage Horizontal type revolves About 5~6 tons tires 40%-45% 30 to 35% 10 to 15% 12 to 15% Normal Pressure 0.4 R/M Coal, wood, gas, oil About 50 kw Water cyclic External annular gear drive
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Caravan Global
14 15 16 17 18 19
Heating method Type of installation Operating Mode Reactor Dimension (mm) (Long * Diameter) Reactor Weight (KG Total Weight (MT
Direct With foundation Intermittent operation 60002200 About 8,000 About 30 MT
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Caravan Global
WASTE TYRE RECYCLING MACHINE COMPONENT LIST.

1) Pyrolysis reactor and inner tubes. 2) Gas chimney 3) Gas tank 4) Condenser 5) Cooling tower (not supplied) 6) Smoke pipe 7) Oil pipe 8) Oil tank - 2 9) Blower - 4 10) Draft fan 11) Motor 12) Power controller 13) Gas collection. 14) Vacum tank.
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Caravan Global
ESTIMATED OPERATIONAL COST AND RETURN ON INVESTMENT ANALYSIS

The analysis is based on the workings of 4 tons/day capacity unit operating for 250 days a year (a very conservative estimate, which can be exceeded very easily); Raw material waste Tyre: 4 ton per day*250 days = 1000 ton/ year Total output: 1) Carbon black - 350 Ton (35%) (Rs 10000 per Ton in India) 2) Furnace oil - 400 Ton (40%) (Rs 24000 per Ton in India) 3) Steel - 100 Ton (10%) (Rs 10000 per Ton in India)
Cost (Per No Of Ton)(Rs) Ton Total Income Yearly 10000 24000 10000 Total Expense Yearly Waste Tyre 5000 1000 83333 Per month 50,00,000 350 400 100 1500 No of Ton (in %) 35% 40% 10%
Item Carbon Black Furnace Oil Steel Total Income
Total Cost (Rs) 35,00,000 96,00,000 10,00,000 1,41,00,000
Employment Fee Fuel(used only for initial heating, then replace bye gas produced in the systems) Electricity + Water
7 Employee
10,00,000
4000
250
10,00,000 6,00,000
Misc Expenses(bag packing, repairing ,renovation ,travel) Total Expense Total Profit
6,00,000 82,00,000 59,00,000
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Caravan Global
Capital investment:
Price of the plant (FOB) building and land (1500sq.meter with 1500sq.feet shade) Storage tank of oil pulvelizer for carbon black Others Lnstallation Custom duty, freight charge (apprx.) 28 Lacs =depended on area. 1 Lacs 2 Lacs 2 Lacs 5 Lacs 10 Lacs
This doesnt include interest on capital investment Expected return on investment time period is less than 12 months.
Mr.Sanjeev Gupta
Office Address : Caravan House, Plot 10, Sector 24, Turbhe, Sion Panvel Road,
Navi Mumbai 00705 Factory : Plot 66, New Chemical Zone, Taloja MIDC, Taloja - 410208
sanjeev.caravan@gmail.com
Mob : 9322210577 ph: 91 -22-66187777 Fax: 91-22-66187700
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Caravan Tyre Pyrolysis Proposal Ver 7

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Caravan Global

Introduction to scrap tyre problems:

Features of the plant

The perfect solution

1) FUEL OIL (40 to 45%)

2) CARBON BLACK (30 to 35%)

3) STEEL WIRE (10 to 15%)

4) GAS (10 to 12%)

Project requirements (for 4-5ton/day capacity)

Technical process flow

Equipment Technical Parameter

Direct With foundation Intermittent operation 60002200 About 8,000 About 30 MT

WASTE TYRE RECYCLING MACHINE COMPONENT LIST.

ESTIMATED OPERATIONAL COST AND RETURN ON INVESTMENT ANALYSIS

Item Carbon Black Furnace Oil Steel Total Income

Total Cost (Rs) 35,00,000 96,00,000 10,00,000 1,41,00,000

6,00,000 82,00,000 59,00,000

Mob : 9322210577 ph: 91 -22-66187777 Fax: 91-22-66187700

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