DIY pyrolysis oven - diagrams and practical models, video. DIY tire pyrolysis

Tire recycling - what is it + process technology + risks and difficulties associated with business + step by step process opening of the plant + financial calculations.

Capital investments: 3,265,000 rubles
Payback period: approximately 1 year

Every year the number of car owners increases, so the problem of tire recycling is becoming more and more urgent.

Used wheels are simply thrown into a landfill, and as you know, rubber takes about 150 years to decompose.

But the planet, in contrast, is not rubber, so such actions have a negative impact on the environment.

That is why tire recycling- this is not just a solution to an environmental problem, but also a great idea for starting a truly useful business.

Recently, you can notice this trend - many people do not want to start their own business due to the fact that many niches have already been simply filled.

But in this case the entrepreneur will have:

• minimum competitors;
• access to cheap or even free raw materials;
• opportunity to start a sought-after business.

Tire recycling: what is it?

According to statistics, only a fifth of tires are sent for recycling.

The rest of the tires are disposed of or continue to decompose in the ground in landfills.

As for tire recycling, it is carried out in four ways:

In the production of tires, various valuable polymers are used that can withstand enormous loads during vehicle operation.

Since during use car tires their chemical composition does not change, this means that they can be used for new production.

From one ton of tires you can get:

• 700 kg of rubber, which can be used for various purposes;
• 270 kg of soot and 450 kg of toxins that will enter the atmosphere.

Therefore, the choice is obvious: it is better to recycle used tires and get paid for it than to simply burn them, causing harm to the environment.

Based on the chosen method of tire processing, you can obtain different products:

The process of converting tires into crumb rubber

So, the process consists of the following stages:

1. Tire preparation: To do this, worn tires undergo a visual inspection for the presence of unnecessary parts.
2. Removing unnecessary parts: removing nails, stones, splinters, bead wire.
3. Cutting tires into strips and further crushing them into pieces up to 4 mm in size.
4. The resulting parts are sent to a magnetic separator, where the remaining metal cord is removed.
5. The resulting rubber particles are ground to a crumb size of 1 mm.

Subsequently, the resulting crumbs can be converted into fuel/gas/fuel oil.

But such processing requires additional equipment and even greater capital investments.

How to open a tire recycling plant: a step-by-step process

1. market analysis - study of competitors and business prospects;
2. business registration - choosing the organizational and legal form of the future enterprise and obtaining the necessary permits;
3. search for premises - a tire recycling workshop must comply with sanitary, epidemiological and fire safety standards;
4. selection of equipment - its purchase, installation and configuration;
5. recruitment of qualified personnel who can work on purchased equipment;
6. searching for points of sale - conducting marketing research and searching for buyers;
7. financial plan - calculation of capital investments and income forecast;
8. identifying possible risks - assessing negative factors and searching for ways to minimize them.

Market analysis and business relevance

In many CIS countries there are no places to store used tires, which is why not many people think about starting such a business.

Statistics show that the annual number of used tires tends to one million tons.

The increase in cars is about 5-7%, which confirms the constant increase in raw materials for processing.

Where to get raw materials?

You can enter into agreements for the supply of used tires with enterprises that own cars, and also create tire collection points.

Thus, tire recycling is relevant because:

• solves an environmental problem and also reduces the area of ​​​​areas intended for storing used tires;
• creates a new product that other industries need.

Finding a place for production

The first stage of implementing a business idea is to find suitable premises.

It must be large so that it can accommodate the production itself and warehouses for storing raw materials and finished products, as well as equip utility rooms for workers.

The room itself must comply with the following standards:

• area of ​​at least 150-200 sq. m.;
• distance from the residential area - at least 300 meters. It is better to choose industrial zones that are located away from the city;
• availability of communications - electricity, water supply, sewerage, ventilation.

The premises need to be repaired in accordance with all SES and fire inspection standards.

Business registration

To do this, you can either LLC, after which it will not be registered with the tax authorities.

According to the Law of the Russian Federation “On Licensing individual species activities" tire recycling does not require licensing, as it belongs to waste hazard class V.

But still, it is better to consult with specialists on this issue, who will also help you collect all the necessary documents to obtain various permits.

After registering a business, it is necessary to obtain permits from the Sanitary and Epidemiological Station, environmental and fire services.

Tire recycling equipment

Interesting fact:
Initially, car tires were light in color, mostly white or beige. And the familiar black color appeared already at the end of the nineteenth century, after manufacturers began adding carbon to the rubber base.

The most important point in starting a tire recycling business is purchasing the necessary equipment.

Firstly, this is the largest expense item in capital investments, and secondly, the entire production process will depend on it.

To create a line for processing tires into crumb rubber, you need to purchase the following equipment:

The approximate cost of a production line varies from two to five million rubles.

Recruitment

The state looks like this:

Staff responsibilities include:

• Director - control over the production process, administration of activities;
• Sales manager- searching for buyers and concluding trade deals with them;
• Accountant - maintaining and preparing reports;
• Shift manager - production control and accounting, production reporting;
• Operator - production of products, cleaning of the workplace;
• Loader - loading/unloading raw materials and received products.

Financial plan for tire recycling production

It is worth noting that recycling tires requires quite a lot of starting capital, because in fact this will be a full-fledged production, which requires the purchase of serious and expensive equipment.

Capital investments in opening a tire recycling plant are:

To maintain a business, you need to invest in it monthly (this includes fixed and variable expenses):

The cost of the products received is:

• crumb rubber - 14,000 rub./t;
• scrap metal - 6500 rub./t;
• textile cord - 600 rub./t.

As a result, you can get the following income:

From the data obtained, we can say that the business will pay off in about one year.

Where and how to sell?

As mentioned above, the range of applications for crumb rubber is wide.

Potential buyers may be:

• for the production of rubber tiles or roofing;
• manufacturers of sports surfaces for training fields and playgrounds;
• tire manufacturers;
• shoe factories;
• sanitary ware manufacturers.

It is also worth paying attention to the fact that this industry is supported by the state, so to promote your business you can contact local authorities that cooperate with manufacturers of sports equipment.

The video below shows the process of processing tires into crumbs:

What risks and difficulties may accompany the tire recycling business?

Equipment malfunction

To minimize this risk, it is necessary to constantly check the equipment and consistently maintain the production line, and replace damaged parts.

This also includes employee training and advanced training.

Late deliveries of raw materials

Already at the stage of installation and setup of the production line, it is necessary to look for reliable suppliers and enter into long-term contracts with them.

Disruptions in the sale of finished products

Here, as in the previous paragraph, it is necessary to conclude long-term contracts with buyers, which stipulate delivery times and the quantity of products sold.

Improper storage of finished products

Crumb rubber is “afraid” of high humidity, so it is necessary to ensure dry air in warehouses.

Tire recycling- this is not just a relevant and promising business, but also a sought-after business that, in addition to material benefits, will benefit the environment.

The main advantages of such production are the low cost of raw materials and the minimum of competitors.

These factors allow you to create a profitable and profitable business.

Useful article? Don't miss new ones!
Enter your email and receive new articles by email

Sometimes a profitable project can contribute to a solution environmental problems. Tire recycling as a business: profitability, reviews and business plan with calculations to help a new entrepreneur.

Description

Global volumes of waste plastic, glass and rubber amount to millions of tons. Therefore, the need for enterprises for processing recyclable materials increases every year. The problem is that the equipment for this is expensive.

Treatment plants are even more expensive, without which the plant pollutes with emissions environment nothing less than trash. It is much easier and cheaper to open new landfills for waste disposal, especially in Russia with its vast expanses.

Experts believe that if you focus on small volumes of recycling, tire recycling activities can be economically profitable.

There are several options for tire recycling ideas:

1. Grinding into crumbs. The resulting substance is used for automobile parts, as a substrate for road construction, for filling sports equipment, and for repairing bridges.
2. Tire restoration. The worn tread is removed from the tires and a new one is applied. A cold or hot technological method is used. Significant savings Natural resources, because to manufacture one tire “from scratch”, 30 liters of oil are needed, and when manufactured using the retread method - 5 liters.
3. Pyrolysis. At very high temperatures Fuel, gas, carbon black and steel cord are obtained from tires. The technology is unstable, expensive and takes a long time to pay off.
4. Complete destruction by burning. This releases energy that can be used in production.

The first two technologies are environmentally friendly; when using pyrolysis and combustion, harmful substances are released into the atmosphere. “Dirty” production will require lengthy and expensive coordination with environmental protection services, as well as the installation of special treatment facilities.

And given the relative innovation of tire retreading and the skeptical and wary attitude of consumers, your best bet is to get into the tire crumb business.

The main difficulties in implementing the project are obtaining raw materials and marketing finished products. In a sparsely populated area there will be problems with both, so production should be launched near a metropolis.

Business plan

The implementation diagram looks like this:

• registering an enterprise and obtaining permits to operate;
• study of technology;
• production location planning;
• purchase of equipment;
• purchase of raw materials;
• hiring workers;
• sales of finished products;
• financial calculations.

When working with recyclable materials, competition is insignificant and you don’t have to do detailed market research. Numerous service stations and tire shops are stable suppliers of used tires, and with high construction rates there is always a demand for recycled products.

You can download a ready-made business plan for tire recycling at.

Registration and permissions

A tire recycling business can be registered as an individual entrepreneur (RUB 800) or (RUB 4,000).

Waste tires belong to waste hazard class 4 - low-hazard substances. To carry out activities for the collection, transportation, processing, disposal, neutralization, disposal of waste of class 1-4, a license issued by Federal service on supervision in the field of environmental management.

The validity period of the license is unlimited, the cost of obtaining is 7,500 rubles.

In addition to the license, it is necessary to obtain work permits from the Sanitation Station and the State Fire Supervision Authority.

Technology

The process of recycling tires by shredding occurs as follows:

1. Collection of tires.
2. Sorting and selection of recyclable tires. Removing thorns, nails and other foreign elements.
3. Cutting tires into small pieces.
4. Loading the material onto a conveyor and then into a special installation, where the rubber is crushed and the metal components of the tire are removed.
5. From the shredder, the crumbs enter the rotary crusher, where they undergo another stage of grinding and purification from impurities.
6. To obtain the purest possible rubber, the material is further processed in a separator.
7. The crumbs are sorted into fractions on a vibrating sieve.
8. To obtain an especially fine powder, the crumbs are passed through a grinder.
9. Packaging of products ready for shipment.

For storage in a warehouse, it is necessary to provide room temperature and dry air, since high humidity has Negative influence for recycled material.

In addition to crumb rubber, the recycling process leaves behind the textile component of tires and metal wire, which can be scrapped.

Room

A tire recycling business should not be located close to residential areas. It is best to rent part of a workshop from an industrial enterprise in an industrial zone. In this case, you will not have to deal with bringing the premises into compliance with fire and sanitary standards.

The size of the mini-factory should be approximately 300 square meters. m. to accommodate everything necessary equipment, a warehouse for raw materials, a warehouse for finished products and a change house for workers.

The premises must have proper communications - electricity, water supply, heat supply and sewerage.

Equipment

The most expensive part is purchasing equipment for production. To ensure uninterrupted technological process, you will need the following machines and accessories:

• equipment for removing the bead ring from the tire;
• tire cutting machine;
• devices for grinding rubber into crumbs of different fractions;
• conveyor for feeding material;
• magnetic separator – 2 pcs.;
• air separator;
• vibrating sieve for different degrees of crumb filtration - 2 pcs.;
• bunker for collecting crumbs;
• storage bin for metal wire;
• dust cleaner;
• electrical panel;
• loader.

In addition, you need to purchase:

1. Containers for packaging crumb rubber.
2. A vehicle if you plan to independently deliver products.
3. Workwear and protective equipment for workers.
4. Computer and office equipment for record keeping.

Raw materials

Used car tires for recycling can be purchased:

• at stations and;
• at large motor transport enterprises;
• at a recycling collection point, or open your own waste tire collection points.

The big advantage of tire recycling as a business is that the cost of old tires is very low, sometimes you can get it for free, and in some cases you can earn money for recycling.

Hiring workers

Depending on the volume and schedule of work, production will require:

1. Shift supervisor - 2 people.
2. Equipment operators - 4 people.
3. Loaders - 2 people.
4. Driver - 1 person
5. Receiver at the tire collection point - 1 person.
6. Product distributor - 1 person.
7. Accountant - 1 person.

To save money, some of the functions of accounting, sales and general management can be taken over by the business owner.

Since the business is specific, and workers will have to deal with waste, the company will most likely have a high staff turnover.

Sales of products

The main consumers of the mini-plant are construction organizations and enterprises for the production of building materials. List of manufactured products including crumb rubber for improvement technical characteristics wide enough:

• roofing moisture-resistant coating;
• railway sleepers and gaskets;
• filler;
• shoe soles;
• road surface;
• paving slabs;
• fiber concrete;
• various rubber products.

Wire from tires obtained as a result of processing is handed over to scrap metal collection points.

Financial calculations

The main initial investment in the idea of ​​a processing business is the purchase of equipment. Manufacturing technology cannot be organized in a handicraft way, so a full set of machines is required to complete the production line.

The amount of capital investment consists of the following costs:

The amount of monthly production costs is approximately equal to:

On average, the recycling line can recycle 3 tons of tires per day. From this amount of raw material, approximately 2 tons of crumb rubber and 800 kg of steel cord are obtained. The price of crumbs depends on the fraction, on average it is 17 rubles/kg. Scrap metal is accepted at 6.5 rubles/kg.

There is also additional income from accepting tires for recycling from delivery companies, at 1,500 rubles per ton. Presumably, this is 20% of the total volume of incoming tires.

The total monthly income of the mini-factory is:

With annual expenses (including initial investments) of 9,010,000 rubles. and an income of 14,436,000 rubles, a business with the given parameters will pay for itself in six months.

For a very long time now, the governments of many developed countries put on the agenda environmental situation in modern cities. Every year, hundreds of thousands of waste polymers are thrown into landfills, thereby polluting the environment. But many organic matter, in particular, car tires that have become unusable can be reused. By purchasing new or used processing equipment rubber tires, everyone has the opportunity to build not only a profitable, but also extremely useful business. It is a mistake to believe that every processing enterprise is something large-scale and requires large investments. Not at all - having a clear plan, you can meet a minimum of funds, while organizing an effective, profitable stable income shop.

Our business assessment:

Starting investments – from 6,000,000 rubles.

Market saturation is low.

The difficulty of starting a business is 7/10.

Opening a mini plant for processing car tires in Russia is not very difficult; the main thing is to know which way to approach the implementation of the planned project. As in any other market segment, there are nuances here that are extremely important to pay attention to. And the initial task of anyone who has seriously decided to organize their own business is to draw up a business plan for processing car tires, which would reflect the important stages of launching a production enterprise.

We can distinguish 2 areas of business - processing raw materials into crumbs and into liquid fuel. Each of these options is good and profitable in its own way. The only difference here is the size of the starting investment and the technological process.

Why is recycling old tires profitable?

Tire recycling as a business has become so interesting to investors and entrepreneurs not even because of the usefulness of the idea itself, but because of the positive aspects that can be noted when talking about this direction.

Why is it profitable to recycle used tires?

• Available raw materials. Material for further processing will be supplied to the workshop either at a very low price or completely free of charge.
• Simplicity of technology. Despite the fact that obtaining fuel from tires, from the point of view of physical and chemical processes, is a rather complex process, modern equipment makes the technological scheme extremely simple.
• Huge market. With established sales channels, finished processed products will be immediately shipped to customers.
• Environmental friendliness. It would seem that recycling old car tires should be a very dirty process, but no - in the end, only the final product and some associated components that are not hazardous to human health are obtained. The only harmful factor is the increased noise level.
• Opportunity to receive preferential business conditions. The state today encourages innovators in every possible way and provides businessmen with subsidies and loans with “pleasant” interest rates.

But recycling of used tires is characterized by more than just positive aspects– there are also negative ones. For example, it will be very difficult to find regular wholesale customers. Therefore, in order to avoid equipment downtime, you should launch an advertising campaign at the business planning stage and begin producing products immediately “for a ready buyer.”

The business idea for recycling used tires is very promising, and all the difficulties that arise when preparing to launch a workshop are completely solvable.

Recycling tires into crumbs: what is needed for this?

Having decided to choose this line of business, the entrepreneur must solve the primary problem - buy equipment for processing tires into crumbs. There are a lot of machines on the market that can perform the task - grind tires into powder and crumbs of various sizes.

This business development scenario is especially good due to its simple technology and huge market.

Production line for processing tires into crumb rubber

Each line operates using a specific technology:

• Removing the seat ring and metal from the tire.
• Cutting tires into strips of a certain width.
• Removing the second seat ring.
• Cutting the tape into blanks.
• Grinding of tapes to obtain crumbs or powder.
• Cleaning up the crumbs.
• Removing textile cord.
• Warehousing of the finished product.

There is another way to grind worn tires - cryogenic technology. It consists of freezing the raw material and further crushing it. And despite the extremely high efficiency of the method, it is not used in our country, since the equipment for carrying out the process is prohibitively expensive - about 30,000,000 rubles.

The equipment presented on the market differs from each other in many respects - configuration, power, degree of automation. But the “average” line for processing tires into crumb rubber consists of the following list of machines and devices:

• Seal ring cutter.
• Seat ring squeezer.
• Tire cutter into strips and blanks.
• Abrasion machine.
• Vibrating sieve.
• Seperators.
• Transporters.

It will be quite problematic to independently assemble such a line from separate machines; it is much more practical to buy a ready-made one. But here the priority for a novice entrepreneur will be the issue of cost, since the price of equipment for processing tires into crumbs is quite high. Even the simplest device with minimal power (up to 100 kg/h) will cost an entrepreneur no less than 1,500,000 rubles. And the cost of more productive (up to 1000 kg/h) lines is much higher - 3000000-10000000 rubles. The following brands of equipment are popular among entrepreneurs: ATR 500, RDK 500, EcoStep 500, Eldan lines.

To equip a “young” workshop, it is hardly worth buying an expensive, high-performance tire processing machine. To start a business, an average power (200-500 kg/h) will be quite sufficient - this way, the equipment will not be idle in the absence of raw materials or customers.

When organizing a tire recycling enterprise, many entrepreneurs are faced with the problem of finding premises. The fact is that the line, despite the absence of harmful emissions into the atmosphere, is very noisy. And therefore, the supervisory authorities have quite strict requirements for the location of the enterprise - away from residential areas.

Recycling tires into liquid fuel: what is needed for this?

The entire technology based on pyrolysis is carried out automatically, and the process is divided into the following stages:

• Sorting of raw materials received into the workshop.
• "Cutting" tires.
• The crushed raw materials decompose in a reactor under the influence of high temperatures.

After all the technological stages, the output is several semi-finished products - gas, steel cord, liquid fuel.

Each product obtained during the processing process finds its own application. The gas is reused during subsequent cycles, thereby saving on fuel. And steel cord and diesel are sent for storage with subsequent shipment to customers.

Processing by pyrolysis is carried out using special lines, the standard equipment of which is as follows:

• food storage containers,
• pyrolysis unit,
• conveyors,
• separators for cleaning steel cord.

Pyrolysis line for processing tires and rubber goods

And the most expensive equipment of all is the pyrolysis plant. This is what the entrepreneur pays for when he equips a workshop for converting tires into diesel fuel.

The price of a line for processing car tires to produce diesel oil, depending on productivity, may be different. On average, to purchase a high-quality line with a capacity of up to 5 tons per day and its commissioning, a minimum of 5,000,000 rubles will be required.

There are few ways to save on equipping a workshop - either get equipment from China or buy used machines.

A powerful pyrolysis plant for tire recycling can operate in continuous mode, showing the following output for final products:

• For fuel – 2 t/day.
• For steel cord – 0.5 t/day.
• For gas – 1 t/day.

Provided the line is fully loaded, the yield of liquid fuel will be 40% of the weight of the original rubber raw material.

Considering that the standard line is quite large in size, some difficulties may arise when choosing a suitable room.

Where to get raw materials?

Tire processing technology allows the use of raw materials of any degree of wear. But these tires still need to be obtained somewhere. And in the absence of well-established supply channels, a beginner in this business may encounter certain problems.

What are the possible options here?

• Buying tires from auto repair shops, services, and private owners.
• Collecting tires from landfills.
• Organization of collection points for waste tires from the population.
• Removal of used tires from the territory of enterprises.

It turns out that the processing of used rubber tires can be carried out both from free raw materials and from purchased ones. Moreover, there is much more free material - hundreds of kilograms of raw materials can be collected daily from the city landfill alone. But this is not enough for the uninterrupted operation of the equipment, so buying tires for recycling also has a place. The raw materials are inexpensive - many companies, realizing that a certain type of enterprise is today interested in worn-out tires, began to ask for a certain amount for them, albeit purely symbolic. And accepting used tires for recycling for a small compensation from the private population will not only stock up on raw materials, but also attract the attention of city residents to the environmental situation.

Problems of marketing crumb rubber and liquid fuel

As in any other line of business, it is important to establish distribution channels as quickly as possible. And the priority, of course, is wholesale customers.

In fact, there are a lot of consumers of the resulting products. Crumb rubber is actively used in many industrial sectors - construction, automotive and even textiles. And the resulting fuel oil will be taken away production workshops, where you can use secondary technical oil as fuel.

And if you have already found reliable sales channels, know who benefits from selling the resulting products, and have established your own stable enterprise, share your experience of processing tires into crumbs with newcomers who plan to develop in the same direction.

How much can a business earn?

Practice has already shown that mechanical and pyrolysis processing of tires and rubber goods, when done correctly, brings a stable profit.

When calculating expected income, you need to estimate how much initial investment will be required. To organize a “medium” workshop, it is imperative to provide for:

• purchase of equipment and its commissioning,
• preparing the premises for production,
• preparation of the raw material base,
• hiring.

The monetary minimum that you need to focus on when opening a workshop is 6,000,000 rubles.

The price of a mini plant will pay off the faster the sooner reliable sales channels are found. To calculate profits, the following figures are taken: the wholesale price for crumbs is from 15,000 rubles/t, the wholesale price of processed diesel is from 6,000 rubles/t.

DIY pyrolysis oven

The essence of pyrolysis (translated from ancient Greek πῦρ - fire, heat; λύσις - decay, decomposition) is the process of thermal decomposition of organic and non-organic substances. organic compounds In a narrow sense, this is the decomposition of organic natural compounds in conditions of lack of oxygen (wood, petroleum products, etc.). In an expanded broad sense, this is the process of decomposition of any compounds into lighter molecules that make up the substance or elements under the influence of an increase in temperature. For example, such hydrogen telluride decomposes already at a temperature of about zero degrees Celsius.

Many people are interested in how gases can be used to start the afterburning process in furnaces in order to use the equipment more efficiently

Pyrolysis boilers and furnaces today are especially actively studied not only by academic engineers, but also by amateur researchers and practitioners. The unfading desire to make them with your own hands is perhaps a characteristic of our time. This is not surprising, because we really want to make long-burning heating equipment as efficient (and as cheap as possible!) and to maximize their technical results. You can talk about this for a long time and interestingly. But, as it is rightly said, it’s better to see it once... In the video below you can see with your own eyes how a relatively simple pyrolysis installation of an independent developer processes various types of plastic and rubber into gas condensate (the so-called pyrolysis liquid) plus gas. The latter can be used for combustion in a boiler furnace, it is also suitable for heating a retort, and the liquid can be pumped into containers for later use for domestic needs. Pyrolysis liquid is also used for combustion in boilers and stoves.

The pyrolysis installation prepared for work is presented on video by the author-developer himself, who filmed the processes in detail in action and, having analyzed the technical characteristics and features of his brainchild, openly shared his own thoughts and conclusions on this issue.

The plus is that the author actually made this installation and put it into action. The developer himself identified significantly more disadvantages. However, see for yourself, this is extremely interesting:

The author of this design shared his thoughts. There is a sound grain in them, but there are also many shortcomings that opponents pointed out to the developer. The conclusion is this: the design is purely theoretical, it is not ready for practical operation.

teplolivam.ru

Recycling of tires, tires, waste rubber goods into liquid pyrolysis fuel, pyrolysis, reactor.

Material on practical experience in the manufacture of pyrolysis plants for waste processing.

I will describe the manufacture and operation of a small reactor for processing waste tires, which was conceived as an experimental one for testing the parameters and examining the fuel.

The beginning of production is, of course, documentation, drawings and sketches that are tied to manufacturing capabilities, here I took such opportunities as plasma cutting and manufacturing parts using the shell method, pretty good quality, the only thing is not cheap. Some drawings and sketches:div>

So what do we see in the assembly shop after the finished parts have been delivered:

Assembly and preparation for launch:

Well, then the tests and work: Loading the raw materials after the shredder, a lot of very non-metallic cord, the percentage of rubber is less because part of the rubber was taken away, the raw materials were bought in Slantsy, ready-made, visible in bags, it gives a small amount of fuel, and all the raw materials are not processed. ..

you can see a “lump” in the middle, the effect is not very good... When loading cut tires... but here the experiment on solid tires is much better, and the fuel is normal in the area of ​​35 percent yield and is completely recycled.

carbon burns in “crackers”, can also be used as fuel, in principle, an analogue of hard coal with the same ash content...or wood, new wood, the ash content of 3 percent immediately reaches 12-20, and of course there is a lot of sulfur, the sulfur “goes” not into the fuel ..there, according to measurements, sulfur is up to 0.8 percent incomplete, sulfur remains in carbon where it is up to 4-something percent. This coal is a good raw material for the synthesis gas reactor, which is in the previous description.

Here is the fuel, light - this is the light fraction of it, quite a bit, closer to the gasoline fraction.

Well, here are various fuel tests obtained both at this installation and earlier at the first reactors.

Well, there is something about coal:

These tests came from the installation that I designed for Melitopol back in 2007, in my opinion. Several photos of the installation, its appearance is certainly not presentable, they were apparently made from what was at hand .. but it worked well according to their reviews:

This is the carbon that comes from tires.

This is a metal cord, it is usually sold as scrap metal, preferably, of course, pressed:

It's like general form of that furnace in Melitopol, the same one according to my design was supposed to be built in Yekaterinburg... but the crisis of 2008 prevented it, so to speak... So everything remained unfinished, a few sad photographs from Yekaterinburg:

The only thing that in Yekaterinburg they did the project not in length but indoors:

I got distracted a little, but let's continue, in fact, pyrolysis is not only valuable fur... sorry, not only the recycling of tires, for example, when experimenting with milk cartons and others like Tetropack:

the result is essentially ash and foil, it does not burn, the only question is where to put it and how to separate it, foil from ash... conclusion, using this technology it is possible to make equipment for annealing, say, wires, small-section electrical wires, while the insulation becomes plastic into carbon, and copper and aluminum and other metals can be turned into non-ferrous metal... that is, there is the use of pyrolysis technology not only in the processing of tires but also in the processing of waste from the automobile industry, etc.... by the way, we also obtain liquid fuel from polyethylene, but I was not faced with this particular task. Regarding the maximum permissible emissions, maximum permissible emissions.. this is a very complex question.. the difficult thing is not that they are higher than the maximum permissible concentrations when processing tires.. the point is that there is no equipment to carry out the analysis.. or it’s beyond the pale at prices. But the analysis was done on experimental equipment in Israel, by my acquaintances in this area, I do not have documentary evidence... all the money was spent and decent, but there are assurances... his assurances that according to the German emission standard (in Israel they copied the German standard), there are exceedances No!!! This is already good... Video of this installation in action:

Tel: 8-911-281-95-62 Suslov Mikhail Borisovich. LLC "Ecosintez"El. mail: Website: www.suslovm.narod.ru

ecostrat.livejournal.com

Pyrolysis plant for processing tires. Pyrolysis

Pyrolysis of tires, tires, plastics and other waste allows the disposal and processing of toxic waste into fuel, carbon and steel cord. The pyrolysis plant is simple and effective. Investments in pyrolysis equipment pay off in less than a year; when purchasing equipment on lease, the payback period is reduced to several months. The pyrolysis plant does not require numerous personnel. To service a horizontal pyrolysis installation, 3-4 people are required at the time of loading (3 - 5 hours depending on the volume) and a person on duty during operation. The service life of a pyrolysis reactor made of heat-resistant steel with a thickness of 16 -18 mm is about 7-8 years. The reactor can be supplied from heat-resistant stainless steel. After 7-8 years of operation, the reactor is replaced with a new one. The remaining installation components do not require replacement. The installation uses Siemens automation.

It is possible to lease equipment for 2 - 5 years, down payment 10 -15%, increase in price 5 -12% per year, currency - rubles.

Pyrolysis of waste. Depending on the temperatures and materials, low-temperature pyrolysis and high-temperature waste pyrolysis plants are used.

Low-temperature pyrolysis is the process of waste decomposition without air access at temperatures of 300-600° C. This method is characterized by the maximum yield of liquid products. During the pyrolysis process we obtain fuel and other valuable waste. Our installations use a catalytic pyrolysis process to increase the efficiency and speed of the process. In the installations at the output we receive heavy and light fuel fractions, non-condensable fractions - gas is used to heat the pyrolysis furnace, therefore only initial heating is necessary for the pyrolysis furnace to operate. After the pyrolysis process begins, the released gas is used for heating. If you purchase 2 units and they work together, the excess gas in one pyrolysis unit is used to start the pyrolysis process in the second unit. There is no need for any additional form fuel in general. The pyrolysis plant is equipped with a 4-stage gas purification system. Price list for pyrolysis plants.

High-temperature pyrolysis occurs at temperatures of about 1000-1400 degrees and is characterized by maximum gas yield. High-temperature pyrolysis is one of the best ways to process municipal solid waste, solid waste, both in terms of environmental safety and the production of synthesis gas, slag, metals and other materials that can be found wide application V national economy. High-temperature gasification makes it possible to technically simply process municipal solid waste without its preliminary preparation, sorting, drying, etc.

Waste Equipment - Advantages of Pyrolysis:

• Pyrolysis equipment is the optimal solution for waste processing. Pyrolysis is little sensitive to the type of raw material and is capable of processing unsorted municipal solid waste, sewage sludge, oil residues, paper pulp, mixed plastics and shredded car residues, rubber and tires, wood waste, hospital waste, etc. The plant's automation adapts to changes in the composition of the waste .
• There is no combustion waste, the pyrolysis plant has excellent emissions of harmful substances such as dioxins, the level of which is lower than those established by the relevant legislation.
• The installation does not produce wastewater.
• No highly qualified personnel are required, the installation operates automatically.
• There is a large reduction in the volume of waste for disposal.
• Harmless production residues can be used further in the production of tires, road construction etc.
• The pyrolysis plant is easy to operate and maintain, and also the fact that the pyrolysis plant provides itself with the energy necessary for operation (required only for start-up), while the excess generated steam and/or electricity is supplied to an external consumer.

Pyrolysis machines are available in 2 versions: vertical and horizontal. From us you can purchase horizontal pyrolysis machines for processing waste tires, etc. and vertical machines for processing waste oil and petroleum products.

Advantages of horizontal pyrolysis plants:

• The material is mixed in the reactor, which accelerates the pyrolysis process.
• No crane beams are needed to unload retorts.
• The workshop may have a smaller height.
• Big sizes loading doors of the installation.
• Possibility of automating loading; the loading device can have a diameter equal to the machine door.
• Fully automatic carbon unloading, a device for unloading steel cord, a small number of maintenance personnel (3-4 people), especially high savings are obtained with high installation productivity or the purchase of 2 or more units.

Pyrolysis of rubber and tires.

Rubber pyrolysis and recycling of car tires is the most popular area where horizontal pyrolysis plants are widely used. Large reactor volume from 12 m3 to 50 m3, large loading doors from 2.2 to 2.8 meters in diameter, automatic unloading of the installation, and a small number of maintenance personnel make horizontal installations the most profitable to use for these purposes.

Pyrolysis of plastic.

• Plastic pyrolysis is another popular area for using pyrolysis machines. What is especially important is that plastic decomposes in a pyrolysis machine without the formation of dioxins. In this case, the yield of pyrolysis fuel is about 65% of the weight of the plastic. When supplied with a dechlorination unit, it is possible to process plastics with PVC impurities.

• Pyrolysis of waste

• In pyrolysis plants it is also possible to process cable residues, leather (pre-treatment equipment is supplied),

• Pyrolysis of waste oil and petroleum products

• It is possible to process waste oil in horizontal pyrolysis units 10 -15% of the unit load volume, in distillation units or in oil regeneration units.
• We offer 2 types of oil processing plants.

A series of distillation plants that allow you to process 5 to 50 tons of oil per day into standard summer diesel fuel and AI 92 gasoline.

Installations for regeneration of oil properties with a capacity from 62 to 2000 liters per hour. These installations make it possible to obtain oil with properties close to the original oil.

• As a result of pyrolysis, the following products are obtained:

The working process:

Raw materials are loaded into the loading inlet, and depending on the volumes and material, a loading conveyor can be supplied. Then, the reactor of the pyrolysis machine is heated with a gas or diesel burner, at the customer’s choice. When the temperature reaches up to 350 ° C to 400 ° C, the pyrolysis reaction begins in the reactor. Light and heavy components will be separated from the resulting oil gas. The light component is cooled in the condenser and accumulated in the fuel tank; flammable gases also remain in the system, which cannot be liquefied; they are returned to the heating system for combustion. The pyrolysis machine is equipped with a gas purification system in the heat supply system of the machine. We can offer you the following size range of Pyrolysis machines with different capacities:

We can offer you the following size range of Pyrolysis machines with different capacities:

№	Name	Power, kWt.	Reactor volume m3/hour	Load capacity tons.	Volume per day tons.	Number of downloads per day
1	LL-2200-6000	11	22	5 - 6	9 - 10	3 in 2 days	82000	92000	88000	98000	108000
2	LL-2200-6600	11	25	7	10 -11	3 in 2 days	84000	94000	91000	101000	111000
3	LL-2600-6000	16	32	8	8 -10	1 per day	110000	124000	118000	121000	131000
4	LL-2600-6600	16	35	10	10 - 12	1 per day	120000	134000	128000	142000	154000
5	LL-2800-6000	17	37	10	10 - 12	1 per day	125000	139000	135000	149000	164000
6	LL-2800-6600	17	40	12	12	1 per day	135000	149000	145000	159000	175000
7	LL-2800-7500	22	46	16	15 -16	1 per day	150000	165000	162000	177000	195000

* - price of a pyrolysis unit without adaptation to cold climates. Heating of the installation with coal, wood.

** - price of a pyrolysis unit without adaptation to cold climates. Heating of the installation with multi-fuel burners operating on diesel fuel, pyrolysis oil, and fuel oil.

*** price of a pyrolysis plant with a cooling system adapted to cold climates, without an outdoor pool.

*** price of a pyrolysis plant with a cooling system adapted to cold climates, without an outdoor pool. Heating of the installation with multi-fuel burners operating on diesel fuel, pyrolysis oil, and fuel oil.

**** - price of a pyrolysis installation with a cooling system adapted to cold climates, without an outdoor pool and a cooling system that allows the use of heat generated by the installation for heating the workshop. Supply ventilation system. Heating of the installation with multi-fuel burners operating on diesel fuel, pyrolysis oil, and fuel oil.

Standard operating cycle of a pyrolysis machine.

We provide a 1-year warranty on the machine, and a 14 mm thick stainless steel reactor. 3 years, other parts of the machine do not need to be changed throughout its entire operating period, with the exception of wearable components and parts.

The composition of the pyrolysis machine includes

1. Reactor heating system
2. Thermally insulated pyrolysis machine body
3. The pyrolysis reactor is made of stainless steel 14 mm thick.
4. Machine control panel.
5. Catalytic column
6. Container for the heavy fraction of pyrolysis oil
7. Pyrolysis gas cooling system
8. Container for the light fraction of pyrolysis oil
9. Water seal
10. Water cooling system. It is possible to use the heat generated during the pyrolysis process to heat the air in the workshop in winter
11. Built-in fan and valve system.
12. Chimney
13. Smoke exhaust fan
14. Exhaust gas purification system
15. Gas burner
16. Speed ​​reducer
17. Automatic soot removal conveyor
18. Service platforms
19. Roller for unloading steel (cord)

pyrolysisplant.ru

Pyrolysis of tires and tires

The problem of household waste disposal is quite acute today all over the world. Moreover, if with household waste While organic origin can be relied on by nature itself, it is the person himself who needs to worry about the issues of recycling polymers. The thing is that most of them, for example, car tires, do not decompose on their own, which means that if they are not destroyed, they will soon turn our planet into one big landfill.

Recycling of car tires this moment time is produced by several different ways.

Processing into crumbs. Recycling tires using shredding is the simplest and most common method in our country. It allows you to preserve the chemical and physical-mechanical characteristics of rubber. After grinding, rubber can be used in the construction of roads and structures. Also, grinding rubber allows it to be compactly stored and transported until further processing by pyrolysis.

Disposal of tires by burning. This method recycling was invented back in the days when humanity had not invented any alternatives to the destruction of rubber. Tires were burned mainly at cement industry enterprises, where they partially replaced fuels such as fuel oil and coal. Burning tires looks simply barbaric from an environmental point of view, since many harmful substances in the process of burning rubber do not disintegrate, but enter the atmosphere. Among these substances the most harmful are:

• benzopyrene
• furan
• dioxins

In addition, one ton of tires contains approximately 700 kg of rubber, which, thanks to new technologies, can be reused to produce fuel. Thus, it becomes clear that burning tires is a completely unjustified method, both from an environmental and economic point of view. A more correct method of recycling tires is pyrolysis. How does it happen?

Tire recycling by pyrolysis

Today, the pyrolysis method is used to obtain fuel from tire recycling. It is a process of thermal decomposition of organic compounds contained in tires without access to oxygen. Pyrolysis of tires today is the most economical and environmentally friendly method of their disposal, since it not only solves the issue of recycling recyclable materials, but also allows you to obtain fuel literally from garbage.

Low-temperature pyrolysis allows tires to be decomposed into their constituent components, each of which can be used in certain purposes. Recycling of tires using the pyrolysis method has been used for a long time in European countries, since in addition to environmentally friendly disposal, this type of processing can bring very good profit. So, what products can an ordinary tire recycling plant produce:

1. Carbon black, which is used as a filler in the production of non-responsible rubbers, conveyor belts, technical plates, and much more. It is also a pigment for the production of paints. Carbon black more Low quality widely used in construction (paving slabs, concrete products and bricks are made from it).
2. Thermolysis gas, which is an analogue natural gas. This gas is quite clean and can be freely used in mini-boiler houses to generate heat and electricity.
3. Pressed steel cord used for the needs of the metallurgical industry. It can be sold as scrap metal or as binding wire (subject to additional firing)
4. Synthetic oil, which is almost identical in composition to natural oil. If it is purified, it can replace many petroleum products.

All these products from a process such as tire pyrolysis are in demand in a variety of industries, so tire recycling is a fairly profitable business.

Pyrolysis of tires.

Disposal and subsequent recycling of tires is carried out in several stages:

1. Tires intended for recycling are sent to a raw materials warehouse.
2. Using a bead cutter, tires are cut into tread and beads (for maximum compact packing).
3. The retort is loaded with raw materials, then it is closed with a lid and placed in a pyrolysis oven, where it is heated to 450°C. During the thermal decomposition of rubber, pyrolysis gas is formed, which passes through the refrigerator, where it condenses into pyrolysis oil. To maintain the pyrolysis process, part of the resulting gas is supplied to the furnace burner.
4. Upon completion of the pyrolysis process, the retort is removed from the furnace, and the next retort with raw materials is loaded in its place.
5. After cooling, the retort is unloaded, and the metal cord is separated from the pyrolytic carbon.
6. Finished pyrolysis products are sent to a warehouse, where they are stored until direct shipment to the end consumer.

The advantages of pyrolysis of car tires are simply obvious to the naked eye:

• This recycling process is safe from an environmental point of view, and the processed products do not contain highly toxic substances.
• No waste during production - absolutely everything that is generated during the processing of tires is a liquid product.
• This processing of solid waste does not require significant energy consumption, and in general, it is very economical;
• It is possible to use the fuel obtained from rubber processing for internal technological processes.

Summarizing everything written above, we can say that tire pyrolysis is the only correct solution for recycling rubber for all those who think about the future of their children and care about the environment. And from a business point of view, pyrolysis is the most profitable method recycling old car tires.

• Comments on the article
• In contact with

ztbo.ru

Tire recycling by pyrolysis - efficient long-burning boilers

The rapid development of the automotive industry and the availability of cars leads to the fact that the number of used tires is growing every year. The accumulation of tires has a negative impact on the environment, since this kind of waste practically does not decompose naturally in nature and therefore cannot simply be buried in special landfills. To avoid man-made disaster Unnecessary tires should be disposed of.

There are several methods for recycling unnecessary tires, but the most promising and environmentally correct method is considered to be pyrolysis, implemented in special installations (pyrolysis ovens).

Schematic diagram pyrolysis furnace with basic elements

Today, pyrolysis boilers are used to recycle tires with great benefits and minimal impact on the environment.

What is pyrolysis?

Pyrolysis is a special physical and chemical process involving the decomposition of elements rubber tires under high temperature and without air access.

If tires are simply heated in an open atmospheric environment, they will first smolder and subsequently catch fire, releasing a lot of harmful substances into the atmosphere. When heating occurs without air access, there are no conditions for combustion. In this case, they begin to leak chemical reactions another type that allows ordinary rubber to be decomposed into several oil fractions, which, due to high temperatures, are in a gaseous state. They can be condensed to produce pyrolysis oil, as well as non-condensable pyrolysis gas. This gas can be recirculated into the reactor furnace to maintain cyclicity of the process and eliminate the need for additional fuel to operate the pyrolysis plant.

Thanks to this method it is possible to obtain waste-free technology recycling with minimal impact on the environment. If we compare the usual burning of tires with the pyrolysis process, it should be noted that the latter is several times more environmentally friendly and additionally makes it possible to obtain secondary raw materials.

Secondary products obtained from pyrolysis

Pyrolysis is a process that is not only environmentally friendly, but is also a highly practical technique that can be used to obtain various secondary raw materials.

In the process of recycling tires, carbon black is obtained using pyrolysis, which can be used as a filler in the production of various rubberized products such as transport belts, seals, technical plates, etc. Carbon fractions of lower quality are used in construction as additives in the production of various products from concrete, sidewalk slabs, etc.

Pyrolysis gas obtained during recycling resembles natural gas and can be used to generate thermal energy, as well as in small power plants to generate electricity.

The metal cords that remain from tires can be reused in metallurgical production for smelting and the production of other metal products.

The resulting synthetic oil has a composition reminiscent of natural raw materials and can replace many petroleum products.

punkti-priema.ru

Pyrolysis recovery plant | processing of tires, tires, plastics

Pyrolysis plant "Pirotex" is equipment operating using the closed pyrolysis method, designed for processing and disposal of rubber and polymer-containing waste, oil sludge and waste oils. Unlike open pyrolysis plants, when recycling rubber goods and waste tires in a closed pyrolysis plant, the output is a larger volume of liquid fuel.

The Pirotex pyrolysis installation is highly environmentally friendly - there is an absolute minimum of emissions. The equipment is automated as much as possible, which made it possible to reduce human labor to elementary operations - loading and unloading the crucible from the furnace.

Recycling tires in the Pirotex pyrolysis unit allows you to obtain higher quality recycled products. Mini tire recycling plant is also used as equipment for processing plastics, oil sludge and waste oils.

Layout of the Pirotex pyrolysis plant

The Pirotex pyrolysis installation can serve as both the main and only equipment, and as part of a processing line, if the goal is to organize:

• plant for the processing and disposal of used car tires, tires, rubber waste
• business for recycling waste rubber goods, plastics, plastic bottles, PET, polyethylene
• an enterprise that processes waste oil and oil sludge

The resulting pyrolysis products can be used as follows:

It is hard to imagine modern world no cars. Their number is constantly growing, and at the same time the number of car tires that have become unusable is also increasing. Their disposal is problematic, since they are highly flammable and do not naturally decompose. Currently, only 20% of old tires are recycled. That's why this type activities is very relevant, especially for big cities, so this is a good and modern business idea.

Why recycle old tires? In addition to recycling environmentally dangerous products human life, this issue is relevant in the field of oil production. It is no secret that natural oil reserves are irreplaceable. And from 1 ton of tires, where the net weight of rubber is about 700 kg, you can produce 400 kg of finished raw materials. When processed, about 30-40% of the raw materials yield pyrolysis oil, used in boiler houses. By processing pyrolysis oil, we obtain high-quality fuel oil, diesel fuel, and gasoline.

A significant advantage of this business is that there are no expenses required to purchase raw materials. And in some cities, authorities also finance the recycling of car tires.

To organize this activity, it is necessary to find a suitable territory located at a sufficient distance from the residential sector (at least 300 m). On the territory it will be necessary to equip a warehouse for raw materials, a site for the preparation and processing of raw materials, and a warehouse for finished products.

Equipment will need to be purchased: a tire shredding unit (hydraulic shears), a reactor - pyrolysis unit, and tanks for the resulting products. The reactor is installed in an open area. It is possible to recycle about 5 tons of tires per day. During processing, gas is released on which the reactor operates. To work on it, two workers who have received special training will be required.

The cost of this installation varies depending on the technical characteristics and ranges from 1 to 10 million rubles. More expensive installations not only make it possible to obtain pyrolysis oil from recycled tires, but also process it further into diesel or gasoline distillate. The installations also differ in their processing capacity - 5-20 tons per day.

The average cost of opening this business is about 5 million rubles: purchase of a pyrolysis unit, hydraulic shears, 2 tanks per 10 thousand liters, other tools and materials, delivery and installation of equipment, and other associated costs.

At fully loaded equipment per month, the output is 60 tons of pyrolysis oil. The price on the wholesale market is 9.5 thousand rubles. per ton. With this volume, monthly revenue will be 570 thousand rubles. Business profitability – 50%. Provided the equipment is loaded to full capacity, the initial investment will pay off in 16 months.