Fabhind Private Limited

Main Equipment List 

• Carbon Drag Conveyer
• Carbon Drum In Put Screw
• Carbon Our Out Screw
• Carbon Silo -30 Kl
• Chips Feeding Systems
• Common Scrubber 8 Reactor
• Cooling Blower 7.5 Hp
• Cooling Tower 70 Tr With 3 Hp Motor
• Drag Conveyer
• Dual Inbuilt Scrubber Tank
• Dabble Drum Magnate Separator
• Etp-20000 Effluent Treatment Plant-5000 Per Day-I
• Feeding Elevator
• Feeding Hopper
• Filler Elevator
• Heavy Chimney 15 X 05-100 Ft-Auto Ignition
• Nitrogen Plant 20 Nm3/Hr Plant-I
• Oil Tank 3.7 Kl
• Oil Tank 37 Kl
• Oil Tank 6 Kl
• Oil Water Separator Tank 16 Kl
• Pipe Condenser-10-8-6 Pipe -With Water Tank
• Pipe Screw 12 Inch
• Presser Blower  3 Hp
• Presser Blower  5 Hp
• Pyro Gas Balloon  Systems-600 Nm/3
• Rc-12-Inbuilt Fire Unit 28 X 865 X 750 Mm
• Reactor Our Put Screw
• Rfc-15 - Reactor With Cover
• Screw 15 Feet 12 Inch Pipe
• Tp Chimney Blower 75 Hp-New
• Tp Gas Tank
• Tp Heavy Oil Tank 03 Kl
• Tp Insulation Tank-450
• Tp Water Seal Tank-1200
• Tyre Plant Control Panel For 15 Ton
• Vt Pipe Condenser 16 X 3"-6 Nos Pipe Systems
• Water Jacketed Pipe

A continuous waste tyre pyrolysis plant offers a sustainable and efficient solution for recycling discarded tyres, converting them into valuable resources: pyrolysis oil, carbon black, steel wire, and combustible gas. 

Advantages of continuous pyrolysis plants

Environmental Friendliness: Compared to traditional disposal methods like landfilling or incineration, continuous pyrolysis significantly reduces waste and minimizes harmful emissions. The process is conducted in a sealed environment, eliminating gas leakage and dust release. Modern plants often include advanced exhaust gas treatment systems (desulfurization and denitrification, electrostatic precipitator, and activated carbon dust collectors) to meet stringent emission standards like those in the EU.

High Efficiency & Capacity: These plants are designed for uninterrupted, 24-hour operation with high processing capacities, making them suitable for large-scale waste tyre recycling.

Automation: Continuous pyrolysis plants utilize PLC control systems for automatic feeding, temperature control, and discharge, requiring minimal labor.

yrolysis Oil: Can be used as fuel in industries, for power generation (refined into diesel), or sold directly.

Carbon Black: Can be used as a raw material for rubber products, coatings, and inks, or further processed into higher-quality recovered carbon black (rCB).

Steel Wire: Can be sold as scrap metal for recycling.

Combustible Gas (Syngas): Recycled back into the plant to fuel the pyrolysis reactor, making the process energy self-sufficient. 

Typical working process

Tyre Collection: Waste tyres of various sizes are collected.

Shredding & Steel Wire Removal: Tyres are shredded into small pieces (e.g., 3-5 cm or <15 mm) and steel wires are extracted, crucial for the continuous operation and purity of the rubber material.

Feeding: Shredded tyre chips are transported to a sealed silo and then continuously fed into the pyrolysis reactor using screw conveyors. An inert gas (like nitrogen) system can be used to displace air in the feeding system, enhancing safety and process stability.

Pyrolysis: The reactor is heated (e.g., by burning fuel oil, LPG, natural gas). As the reactor rotates and heats up to around 300°C, the tyres undergo pyrolysis, decomposing into oil gas. Hot flue gases can be recycled to improve thermal efficiency.

Oil & Gas Collection: The hot oil gas enters a manifold system to separate heavy impurities. The condensable components are cooled in a multi-stage condensing system using circulating water, resulting in liquid pyrolysis oil, which is collected in storage tanks. Non-condensable components, mainly syngas, are piped to the combustion system to fuel the burner, achieving energy self-sufficiency.

Waste Flue Gas Treatment: Flue gases from the heating process undergo a series of treatments, including heat exchangers for cooling, a chemical tower for desulfurization and denitrification, and electrostatic precipitators and activated carbon dust collectors for purification, ensuring compliance with environmental standards before discharge.

In India, the Central Pollution Control Board (CPCB) has introduced Standard Operating Procedures (SOPs) for the recycling of waste tyre scrap, emphasizing the use of the Advanced Batch Automated Process (ABAP) and continuous pyrolysis processes. For capacities exceeding 60 tonnes per day (TPD), only continuous pyrolysis plants are permitted. These plants are subject to strict monitoring and adherence to CPCB guidelines for safe and environmentally sound operation. Regulations specify requirements such as minimum land area, treatment of outputs (TPO and charcoal), waste gas treatment systems, wastewater treatment systems, and hazardous waste management authorization. 

Waste tire pyrolysis plants convert discarded tires into valuable resources through a process called pyrolysis. This thermochemical process involves heating waste tires in an oxygen-free environment to break down the rubber polymers into smaller molecules. 

Key products

·         Pyrolysis Oil: A high-calorific value liquid that can be used as industrial fuel, refined into diesel or utilized as a chemical feedstock.

·         Carbon Black: A solid residue used as a filler in rubber and plastic products, a pigment in inks and coatings, or processed into activated carbon.

·         Steel Wire: Recovered from the tires and sold as scrap steel.

·         Syngas: A combustible gas used to heat the pyrolysis reactor, potentially achieving energy self-sufficiency for the plant. 

Types of plants

·         Batch Type: Process waste tires in batches, with reactor cooling and discharge between cycles. Suitable for smaller operations.

·         Continuous Type: Operate continuously with automated feeding and discharge systems, handling large volumes of waste tires without interruption. Higher efficiency and automation but more expensive. 

Benefits

·         Environmental Protection: Reduces landfill waste, minimizes the environmental impact of tire disposal, and avoids harmful emissions associated with incineration.

·         Resource Recovery: Converts waste tires into valuable products, contributing to a circular economy and reducing reliance on fossil fuels.

·         Economic Opportunities: Creates new businesses and employment opportunities in waste management and resource recovery. 

Challenges and considerations

·         Initial Investment: High setup and operational costs can be a barrier to entry, particularly for smaller businesses.

·         Regulatory Compliance: Pyrolysis plants must adhere to strict environmental and safety regulations.

·         Technological Limitations: Need for specialized equipment and skilled personnel can hinder adoption.

·         Market Volatility: Fluctuating prices of raw materials (waste tires) and end products (oil, carbon black) affect profitability. 

Feasibility and future trends

Despite the challenges, the waste tire pyrolysis plant market is growing with projected growth at a compound annual growth rate (CAGR) of 15.3% from 2026 to 2033. Advancements in technology and growing government support for sustainable waste management are driving this expansion. 

fabhind

waste tyre pyrolysis plant

• main reactor 

 made with  bq plate 516-70 gr  capsule type (with two site dish end)--2. 6 miter x 6. 6  miter 16 mm plate door size 1500 mm

   front door front side carbon removal system attechmen extra price

• reactor cover 

    cover 3 mm ms sheet with insulated cera wool 1260 temp 25 mm two layer

• reactor electric motor 

    motor -1 nos 7. 5 hp 960 rpm motor for process and 2 nd  7. 5 hp 1440 rpm motor ( standard make )

• reactor gear box

    heavy helical gear box

•   condenser pipe unit

     ms pipe 6 inch -16 nos for condenser with  2 nos carbon holding tank 5 mm thickness.

•  insulation tank

     ms plate 800 mm x 1550 mm x 5 mm with cerawool insulation and  aluminum sheet

• water seal tank

      ms plate 1000 x 1800 mm x 5 mm with 4" jacketed for coolant.

• gas tank

     ms plate  800 mm x 1550 mm x 5 mm

• oil tank

     ms plate  2800 x 1350 mm x 5 mm 7. 4 kl (3. 7 kl -02 nos )

• water coolant pipe

      water coolant pipe with jacketed 5 mm pipe 15 feet ( 8'' pipe x 15 feet  & 16" x 10 feet )

• scrubber coolant pipe

     scrubber coolant pipe 10 inch 5 mm with 1'' pipe 10" x 15 feet

• wet scrubber round tank for draft control

      scrubber  tank(dust tank)5 mm ms plate with coolant pipe 800x2800 mm

• draft- chimney blower

      dust blower with 5 hp 1440 rpm motor  for chimney                

• steel puling wire-rope hoist

      wire rope hoist  with  4" gear box with 3 hp  motor and 60 feet 10 mm  wire rope

• fire brick & castable cement 

        fire brick & castable cement  550 nos fire brick and castable cement - 5+5 bags for fire chamber

• control penal board       

       reactor control penal board with digital temp indicator & presser  penal board with solenoid valve

• submersible pump

     submersible pump 5 hp "atlas"  brand  for water circulation

• oil gear pump

    oil gear pump "atlas"  brand 3 hp gear pump for oil transfer

• mud pump 

    mud pump "atlas" brand 3 hp for water scrubber systems

• draft chimney 

     draft chimney 

• fire gas fire blower 

      fire gas blower for reactor gas burner 

• gas burner 

    extra gas burner -2 nos for excess gas burning

• cooling tower  

      cooling tower -capacity 70 tr -3 hp motor

• hardware and fitting 

According to the semi Continuous pyrolysis technology, the equipment we recommend in this proposal is the FAB Semi Continuous Plant updated equipment of our company. It’s the new developed process, including Semi Continuous feeding system, Semi Continuous rotating pyrolysis system, Semi Continuous slagging system, Semi Continuous cooling system, smell removal system, Semi Continuous tail gas recycling system, Semi Continuous smoke cleaning system as well as PLC automatic control system, etc. The whole pyrolysis process is running under a completely sealed environment and on very high automatic control level, no need manual operation for feeding & slagging. The fully automatic and mechanical process makes sure the working environment is totally safe and clean.

The Advantages of the FAB Semi Continuous pyrolysis machine

·         Our Reactor has 360 Degree outside rotating system which allows it to heat proper way so it has long life,

·         Spiral Flats are designed in to the reactor which helps running the material by its inner wall. The raw material direct contacted with the heat transfer surface and received immediate heat and evenly distributed.

·         Reactor can be loaded by steel wire free tyre chips and It can also separate the carbon black from hair steel wires at the time of carbon discharge. It has hair steel in wires it can be collected by hair steel magnet separator machine. Hence it will be collected directly to the carbon bags if it doesn’t have hair steel in it.

·         Gas & oil burner can be used for extra flue uncondensed gas for secondary heating process of the pyrolysis reactor, which will reduce production cost and customer revenue. The flue gas after combustion is treated by dual wash scrubber system as per environment standards. Ii is using evaporated flue gas for heating process of reactor, where we recycle extra heat for the proce

Pyrolysis Technology Safety Evaluation

FAB Semi Continuous Tyre Pyrolysis Plant Item Parameters

Material Feeding Conveyor

Material Loading Dual Airlock System

Material Feeding & Carbon Output Screw

Reactor Gland Pusher

Carbon Unloading System

Carbon Unloading Dual Airlock System

Carbon Removal Jacket Screw

Carbon Cooling System

Carbon Steel Removal System

Gas Controlling System

• MAIN REACTOR 

 Made with  BQ Plate 516-70 GR  Capsule Type (with two site dish end)--2.6 Miter x 6.6  Miter 16 MM Plate Door Size 1500 MM

   FRONT DOOR FRONT SIDE CARBON REMOVAL SYSTEM ATTECHMEN extra Price

• REACTOR COVER 

    Cover 3 MM MS Sheet With insulated cera wool 1260 Temp 25 MM Two layer

• REACTOR ELECTRIC MOTOR 

    Motor -1 Nos 7.5 HP 960 RPM Motor for Process and 2 nd  7.5 HP 1440 RPM Motor ( Standard make )

• REACTOR GEAR BOX

    Heavy Helical Gear Box

•   CONDENSER PIPE UNIT

     MS Pipe 6 Inch -16 Nos For condenser with  2 nos carbon holding Tank 5 MM Thickness.

•  INSULATION TANK

     MS Plate 800 MM x 1550 MM x 5 MM With cerawool insulation and  aluminum sheet

• WATER SEAL TANK

      MS Plate 1000 X 1800 MM X 5 MM with 4" Jacketed For coolant.

• GAS TANK

     MS Plate  800 MM x 1550 MM X 5 MM

• OIL TANK

     MS Plate  2800 X 1350 MM X 5 MM 7.4 KL (3.7 KL -02 Nos )

• WATER COOLANT PIPE

      Water Coolant pipe with Jacketed 5 mm pipe 15 feet ( 8'' pipe X 15 feet  & 16" X 10 feet )

• SCRUBBER COOLANT PIPE

     Scrubber Coolant Pipe 10 Inch 5 MM with 1'' pipe 10" X 15 Feet

• WET SCRUBBER ROUND TANK FOR DRAFT CONTROL

      Scrubber  Tank(Dust Tank)5 MM MS Plate with coolant pipe 800X2800 mm

• DRAFT- CHIMNEY BLOWER

      Dust Blower with 5 HP 1440 RPM Motor  For chimney                

• STEEL PULING WIRE-ROPE HOIST

      Wire Rope Hoist  with  4" Gear box with 3 HP  Motor and 60 Feet 10 MM  wire rope

• FIRE BRICK & CASTABLE CEMENT 

        Fire Brick & Castable cement  550 Nos Fire Brick and castable cement - 5+5 bags For fire chamber

• CONTROL PENAL BOARD       

       Reactor Control Penal board with digital temp indicator & Presser  penal board With solenoid valve

• SUBMERSIBLE PUMP

     Submersible pump 5 HP "Atlas"  Brand  for water Circulation

• OIL GEAR PUMP

    Oil Gear Pump "Atlas"  Brand 3 HP Gear Pump for Oil transfer

• MUD PUMP 

    Mud Pump "Atlas" Brand 3 HP for water scrubber systems

• DRAFT CHIMNEY 

     Draft Chimney 

• FIRE GAS FIRE BLOWER 

      Fire Gas blower for Reactor Gas burner 

• GAS BURNER 

    Extra Gas burner -2 Nos for Excess Gas Burning

• COOLING TOWER  

      Cooling Tower -Capacity 70 TR -3 HP Motor

• HARDWARE AND FITTING