Szirmay Rókus. Pirolízis technológia.

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Table of Contents

Jan. 2013

1.Whole System Introduction……………………………………………………………….……3

1.1Whole System flow chart………………………………………………………………….…...4

1.2Input and Output Ratio…………………………………………………………….………….4

2.Machine List and Description of Each Part…………………………………………………...4

2.1Automatic Tire Shredder System…………………………………………………….…….....4

2.1.1Brief introduction of Automatic Tire Shredder System…………………………………...4

2.1.2Detailed Flow Chart and Process Description……………………………………………..5

2.1.3Machine List and Description……………………………………………………………....6

2.1.4System Requirements and Specifications……………………………………………….….7

2.2Automatic Semi-Continuous Pyrolysis System……………………………………………....7

2.2.1Brief Introduction of Automatic Semi-Continuous Pyrolysis System ……………….…..7

2.2.2Detailed Flow Chart and Process Description……………………………………….…….8

2.2.3The normal cycling time of the full pyrolysis process……………………………….…….9

2.2.4Reactor Temperature Graphic in One Batch………………………………………….….10

2.2.5 Machine List and Description……………………………………………………….…….10

2.2.6 System Requirements and Specifications………………………………………………...11

2.3Carbon Black Refining System………………………………………………………………12

2.3.1Brief Introduction of Carbon Black Refining System……………………………………13

2.3.2Machine List and Description………………………………………………………….….13

2.3.3System Requirements and Specifications…………………………………………………14

3.Test Reports, Layout Drawings…………………………………………………………….....15

3.1CSP-20 Plant Feasibility Report………………………………………………………….....15

3.2SGS Test Report of Tire Oil………………………………………………………………....16

3.3Size Test Report of Carbon Black……………………………………………………….......18

3.4Carbon Black Specification after Grinding…………………………………………...……20

4.Commercial Terms………………………………………………………………………..…...20

4.1Price……………………………………………………………………………………….….20

4.2Payment……………………………………………………………………………………....20

4.3Delivery Time…………………………………………………………………………….…..20

4.4Installation and commissioning Time………………………………………………….…...21

5.Reference Photo of the plant…………………………………………………………….…....21

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1. Whole System Introduction

CSP-20 semi-continuous tire pyrolysis system is the newest generation pyrolysis system worldwide, It can process with 20Ton waste tires in 24 hours, and covert the waste tires into steel wires(18-25%), tire oil (35-40%) and carbon black (25-30%). The tire oil has high calories value, and it is a good fuel for heating boiler in all kinds of industry like power industry, cement industry, chemical industry etc, the market price is about US$500-700 per ton. The black tire oil also can be improved to transparent light yellow color after distillation process. The pyrolysis carbon black (CBP) can be made to briquettes, used as fuel directly, the market price is about US$100 per ton. There are more profitable solutions to enhance the carbon black quality, for example, to grind the carbon black to 350 mesh, 500 mesh, 700 mesh, 1000 mesh, up to 2500 mesh etc. Which can increase its surface area hugely, this make it can be applied as rubber reinforcing agent and master batch carbon black for rubber and plastic products like tires, rubber belt, PVC etc. The market price is between US$500-800 per ton. A new process is under developing which can remove the ash content from the carbon black, to reduce the ash content less than 4%. It can compete with virgin carbon black after reduce the ash content less than 4%. Price can go up to US$1000-2000 per ton.

The complete system contain following 4 parts: (1) Shredder system: Pre-treating waste tires, crush the whole tires into small size of 5-10mm. (2) Pyrolysis system: This part can extract oil and carbon black from tire rubber granule through pyorlysis reaction.

(3) Carbon black milling sytem: This part can mill the tire carbon black up to 2500mesh. (350 mesh-2500 mesh).

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(4) Carbon black pelletizer system: This part can change the fine carbon black powder into uniform round pellets, we call it Wet granulation.

1.1 Whole System flow chart 1.2 Input and Output Ratio

2. Machine List and Description of Each Part 2.1 Automatic Tire Shredder system 2.1.1 Brief introduction of Automatic Tire Shredder System This automatic tire shredder system could process about 1.5Ton/Hour(Maximum tire diameter size =1200mm) whole tire(car and truck tire) into rubber granule 1.2Ton/Hour (Rubber granule size 5-10mm),separating and collecting steels 0.8Ton/Hour. To process with 20Tons waste tires, need to work 14 hours a day.

Total processing

capacity of whole

tire 20Ton/Day

Tire oil

7Ton/Day

(7800L/Day)

Carbon black

6Ton/Day

Steel wire

5Ton/Day

Pyrogas

2Ton/Day

Whole waste tire Part III: CBP Milling System

(Grinding carbon black to fine size

350-2500 mesh)

Part IV: CBP pelletizing system

(Forming round granulate from

carbon black powder)

Part I: Shredder System

(Crush the tires into 5-10mm

wire free rubber granule)

Part II: Pyrolysis System

(Change rubber granule into

oil, carbon black, pyrogas)

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2.1.2: Detailed flow chart:

Process Description: Step1. : Pulling out of wires from tire sidewall with machine of SW-1200 double way wire

puller

Capacity: 30-50PCS/Hour, One operator needed for this machine.

Step2. : Shredding whole tire without bead steel wire into chips with the size of 50mm x 50mm

by using the big shredder machine LP-1200 Shredder.

Capacity: 1.5Ton/Hour

This machine needs 1 worker to load whole tire into feed-in conveyor to the hopper. Step3. : Crushing 50mm x 50mm rubber crumbs into 5-10mm rubber granule with machine of

GP-1000 granulator

Capacity: 500kg/Hour

We recommend 2 sets of GP-1000 Granulator to make 1.0Ton/Hour rubber granules

Step 4: Collecting and removing steel scraps from rubber granules with machine of CX-2000

Steel magnetic separators

Step 5: Conveying rubber granule into buffer tank for further processing of pyrolysis system.

Processing capacity in 14 hours 21Ton Waste Tires

Rubber granule 5-10mm 16Ton

Steel wires 5tons

Whole tire

Step 1: SW-1200 Debeader Pulling out of tire bead wire

Step 2: LP-1200 Shredder Shredding whole tire into 50mm x

50mm tire chips

Step 3: GP-1000 Granulator

Crushing 50mm x 50mm rubber chips into

5-10mm granulate

Step 5: Automatically screw conveyor Transferring rubber granule to buffer

tank for feeding to pyrolysis system

Steps4: CX-2000 Steel magnetic separator Separating and collecting steel wires from rubber granule

Rubber granule buffer Silo

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2.1.3 Machine List and Specifications (1) LS-1200 Single Hook Wire Puller (Debeader) 1 Unit.

(2) LP-1200 Shredder 1Unit

(3) GP-1000 Granulator 2 Unit (4) Auxiliaries

CX-2000 Magnetic Separator 2 Unit.

PD-1, PD-2, PD-3, PD-4, PD-5 Conveyors 10 Unit.

Material Distributor 1 Unit Dust Collector 1 Unit

Specification:

Max capacity of dealing tires(kg/h) 1500

Power of main motor(KW) 11

Working pressure(MPa) 15

Cylinder reciprocation distance(mm) 1300

Dimension(mm) 6000 x 2800 x 3700

Weight(kg) 1400

Specification:

Max capacity of dealing tires(kg/h) 3000

Size of feed‐in materials Below 1200mm diameter

Size of output materials(mm) 50x50

Power of main motor(KW) 75

Rotational speed of screen(r/min) 4~9

Power of screen(KW) 5.5

Dimension(mm) 6000 x 2800 x 3700

Weight(kg) Approx 16000

Specifications:

Dimension of cutting rotor[D*L](mm) 400x1000

Size of feed‐in materials (Mesh) 50x50/25x100

Size of discharged materials (mesh) 3~5

Capacity(kg/h) 500‐800

Power(KW) 75.75

Dimension(mm) 2650x1950x2100

Weight(kg) 5600

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2.1.4 System Requirements and Specifications (1) Size of feed-in tire: No more than Diameter 1200mm x Width 300mm.

(2) Size of output: 5-10mm rubber granule

(3) Max Input Capacity: 1.5Ton/hour waste tires

(4) Customer-supplied auxiliary equipment List

Rubber Granule Buffering Storage Tank: Volume 30-40 m3.

Cooling Water pool: Volume 10m3.

(5) Plant running Requirements:

Workers requirement: 2 operators per shift

Installation for space requirement is approx 700sqm (50mX14m), and approx 6m height.

Circuit cooling water requirement: 10M3/H to cool down system.

The total rated power: 250 KW,

(6) Loading Containers: 4X40HQ

2.2 Automatic Semi-Continuous Pyrolysis System 2.2.1 System brief introduction CP-20 Semi-continuous Pyrolysis system minimum capacity/Day is 15Ton/Day rubber granule under normal

condition. The steel wire rate is about 25%, so we can get 15Tons rubber granule from 20Tons waste tires after

removing the steel wires.

After getting rubber granules size 5-10 mm from Automatic tire shredder system, first we transport these 5-10mm

rubber granules to a buffer tank as backup, the volume of buffer tank is about 40M3.

Then we convey rubber granules to hopper of pyrolysis system from rubber granule buffer tank automatically, the

rubber granule goes into pyroysis reactor through automatic screw conveyor from hopper.

When loading 5Ton rubber granule(the quantity of loading rubber granule could be controlled by speed of

conveyors), we stop loading, shut down inlet and turn on natural gas burners to heat reactor.

When heating, the sensor of temperature and pressure detect each main parts in real time, the results show on the

displays of control panels.

The cold start heating mode is burning gas (oil etc), before emission of pyrogas, we burn natural gas to heat reactor,

normally 2 hours later we start to burn pyrogas to heat reactor.

Normally in 24 hours, one system could pyrolysis at least 15Ton rubber granule, To process 15Ton rubber granule,

it needs natural gas about 600CMB,

System capacity in 24 hours (*Input raw material are rubber granules 5-10mm)

Processing capacity

15Ton/Day

Tire oil 8 Ton/Day (9000L/Day)

Carbon black

5Ton/Day

Pyrogas

2Ton/Day

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2.2.2 Detailed Flow Chart and Process Description

Rubber granule in

buffer tank

Step 1. (Conveyor)

Conveying rubber granule into

hopper of loading

Step 2. (Pyrolysis conveyor)

Conveying rubber granule into reactor

Step3.(Pyrolysis reactor with fume

purification system )Heating reactor with

Natural gas and pyrogas

Step 4. (Oil gas cooling system)

Cooling down hot oil gas into liquid oil and

pyrogas

Carbon black to be discharged to buffer

tank for further processing

Step 5. (Liquid oil tank)

Collecting and stocking oil

Pyrogas to be returned back to burn heat

reactor as fuel

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Step 1.: Conveying rubber granules from buffer tank into hopper of Auto-Feeding system

Feeding speed: 5Ton/20Minutes Step 2.: Loading rubber granules reactor of pyrolysis system through the auto-feeding system. Feeding speed: 5Ton/20Minutes The 2 conveyers in step 1 and step 2, working in the same time for loading the rubber granule into reactor. Step3.: Heating pyrolysis reactor, close down auto-feeding system, run natural gas burners to heat

reactor. There are 8 sets of natural gas burners and 4 sets of pyrogas burners to heat each reactors,

about heating 2 hours of natural gas firstly, the oil gas will start come out from reactor, after cooling down, the non-condensable gas is separating and washing purification, then the clean non-condensable is returned back to the burners, then switch on the pyro gas burners, and switch off the natural gas burners.

The flue gas after burning of natural gas or pyrogas, comes from gas burning room, firstly goes to one fume buffer pipe to reduce gas pressure, then goes into Alkali washing cabinet, to wash off acid fume, after that fume to rise up through chimney, where installed 4 sets of water powerful sprays to wash fume completely, finally the fume becomes clean and un-harmful and release into open air.

Step 4.: Oily gas comes from reactor, firstly goes through gas buffer tank, after pressure reduction, oil gas goes through cooling system(water cooling method), after cooling, most condensable oil collected and stock in oil tanks, small amount of non-condensable pyrogas goes to gas purification tank (water seal tank) to be washed cleanly. After purification, pyrogas can be burned through the pyrogas burners to heat reactor.

Step 5.: Oily gas becomes liquid and collected and stored in buffer tank, with outlet transferred to oil trucks.

2.2.3 The normal cycling time of the full pyrolysis process

First batch we load 5.5Ton rubber granule in 20minutes and heat about 6hours 40minutes to finish the first batch, then load again 5Ton rubber granule in 20minutes and heat about 5 hours 40minutes to finish second batch, after these 2 batches, we discharge carbon black from pyrolysis reactor to carbon black buffer tank to cool down and wait for next carbon black further process. Normally process 2 batches of rubber granule pyrolysis, we discharge carbon black once, the process time for each batch are shown in following table. Batch No. Process name Process capacity Process lasting time

1. Loading and pyrolysis rubber granule 5.5Ton 7Hour

2. Loading and pyrolysis rubber granule 5Ton 6Hour

Discharging carbon black from pyrolysis reactor 2.5Ton 2.5Hour

3. Loading and pyrolysis rubber granule 5.5Ton 7Hour


Discharging carbon black from pyrolysis reactor 2.5Ton 2.5 Hour

5. Loading and pyrolysis rubber granule 5.5Ton 7 Hour


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According to the above table, in average time of 22.5 hours, the system can process 15.75Ton rubber granule. 2.2.4 Reactor Temperature Graphic in One Batch (Confidential) 2.2.5 Machine list and Description

Item Part Description Specification Manufacturing material Qty

(set) Application

1 Automatic Feeding Screw

Conveyor 22KW Carbon steel Q235 1 Feed rubber granule into Reactor

2 Rotation Reactor Ф2800X7100x16(mm) Carbon steel Q245R 1 Process raw material

3 Reactor Casing ø3300*6100(mm) steel Q235 and fire proof material 1 Keep reactor warm

4 Burning room Fire proof material 1 Heating system

5 Speed Reducer 5.5Kw 1 Driving system

6 Manifold Ф900X2500x10(mm) Carbon Steel Q235 1 Separator for oil gas

7 Heavy Oil tank Ф900X3000x6(mm) Carbon Steel Q235 1 Contain residual oil storage

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2.2.6 System Requirements and Specifications (1) Max Input Capacity: 15 Ton Rubber Granule





The total rated power: 75 KW,

(3) Customer-supplied auxiliary equipment List

Carbon black Buffering Storage Tank: Volume 30-40 m3.

8 Condenser for oil Ф820X3600 x 6(mm), 2.2KW Carbon Steel Q235 2 Convert oil gas into liquid oil

9 Oil Storage Tank Volume: 60M3 with outlets Carbon Steel Q235 2 Contain fuel oil

10 Acid washing tank Ф1500X2000x8(mm) Carbon Steel Q235 1 Wash fuel oil by acid

11 Oil filter 5kw 1 Filter the tire oil after acid

washing

12 Hydro Seal Ф900X3000x6(mm) Carbon Steel Q235 1 Clean waste gas

13 Waste Gas burning

system 1.5KW, 8 sets of gas burners Burner and draft fan 1

Burn pyrogas for reactor

heating

14 Extra gas burning system 0.5KW, 2 sets of gas burners Burners and draft fan 1 Burn extra gas

15 Condenser for flue Ф500X6000(mm), 2.2KW Stainless steel S321 1 Cool down the smoking

16 Draft Fan 7.5kw steel Q235 and stainless steel 1 For hot air system

17 De-dusting system with

ceramic Paul ring 3kw Carbon Steel Q235 2

Remove dust and sulfur from flue

gas, capacity=5m3/h

18 Carbon black

auto-discharger 7.5KW Carbon Steel Q235 1 Auto discharge the carbon black

19 Carbon black screw

conveyor 5.5 KW Carbon Steel Q235 1 Transmit carbon black to elevator

20 Carbon black elevator 1KW Carbon Steel Q235 1 Transmit carbon black to storage

tank

21 Carbon black buffer tank Volume=30M3 Common steel 1 For storing carbon black

(self-provided by buyer)

22 Carbon black screw

conveyor 3KW Carbon Steel Q235 1

Transmit carbon black to carbon

black grinder

23 Cooling Water Pool 100M3 1 Self-provided by buyer

24 Cooling Tower 60M3/H 2 Cooling down oil gas into liquid

25 Platform for maintenance Carbon steel Q235 1

26 Electric Control system 1 Control system

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Cooling Water pool: Volume 60m3.

(4) Loading Containers: 1X40FR + 2X40HQ+1X20GP

2.3 Carbon black Refining System 2.3.1 System brief introduction

From 1 Set of 20Ton/Day continuous tire pyrolysis system, can produce about 6Ton/Day coarse carbon black.

First the carbon black goes through one steel wire magnetic separator to remove micro scale steel wires, then carbon black goes into Super fine impact miller to grind into super fine size (maximum size 325mesh), the fine size of carbon black powder could be 325mesh to 2500mesh with different capacity. For example if to make 325mesh, the capacity could be 1200Kg/hour, if to make 500mesh, the capacity could be 800Kg/Hour, etc.

The ash content is about 14% The processing capacity of super fine impact miller to make different size of carbon black(Same raw

material)

After get super fine size carbon black, we use wet granulation method to pellet the super fine carbon black into small granules, for example size 1-3mm, the capacity of granulation system could be 1Ton/Hour.

To wet granulate one Ton carbon black into small granules, it costs about 150kg fresh water. Finally automatically pack these 1-3mm carbon black granules into 20Kg/Bag or 500-1000Kg/Bag. The whole process is working under sealed condition, no fumes emits in working room.

Item Input raw material Output carbon black size

(Mesh)

Processing capacity

(Kg/Hour)

1 Coarse carbon back 325 1200

2 Coarse carbon black 500 800





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2.3.2 Detailed Flow Chart of Carbon Black Refining System

2.3.3 Machine list and Description

Milling System:

Sn. Part Description Power(KW) Qty(set) 1 Material Elevator 3 1

2 Feed-in Screw Conveyor 1.5 1

3 Magnetic Separator 3 1

4 Super Fine First Milling Machine 75 1

5 Super Fine Second Classify Machine 18.5 1

6 Cyclone Collector 1.5 1

7 Bag Dust Collector (180 bag) 3.3 1

8 Draft fan 37 1

9 Electrical control board 1

10 Pipe Line 1

11 Lubricating Oil Station 0.37 1

11 Screw Air Compressor 5 1

Coarse carbon black in

buffer tank

Step1: (Steel magnetic separator)

Removing steel wire

Step2: (Super fine impact miller)

Grinding coarse carbon black into

325mesh-2500mesh

Step3: (Conveyor)

Conveying fine carbon black into buffer

tank

Step4: (Carbon black granulator)

Mixing fine carbon black and water to

granulate into wet granules

Step5: (Dryer)

Drying wet granules into dry granules

Step6: (Auto Weighing packing machine

Packing dry granules into 25kg/Bag or

500-1000kg/Bag

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Pelletizing System Sn Part Description Power Qty

1 Auto‐Weighing feeder 1.5KW 1

2 Main pelletizing machine 45kw 1

3 Bucket Elevator 1.5KW*2 2

4 Long Tumble dryer 5.5KW 1

5 Cyclone dust collector 1

6 Low pressure blower 1.5‐2.2kw 1

7 Control Board 1

8 Burner 1

9 Air transportation system 7.5KW 1

10 Auto‐weighing package machine 5.5 1

2.3.4 System Requirements and Specifications (1) Max Input Capacity: 1 Ton/H carbon black





The total rated power: 218.37 KW,

(3) Loading Containers: 4X40HQ

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3.1 Feasibility Analysis Report

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3.2 SGS Test Report of Black Tire Oil

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3.3 Size Test Report of Carbon Black 500 mesh

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1000 mesh

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3.4 Carbon Black Specification after Grinding

4. Commercial Terms 4.1 Price Term Shredder system: US$ 170, 00.00 FOB Lianyungang Port, Installation cost: US$6000 Pyrolysis System: US$ 185, 00.00 FOB Lianyungang Port, Installation cost:US$8000 Carbon Black Milling System: US$160,000, FOB Qingdao Port, Installation cost: US$4000 Carbon Black Pelletizing System: US$125,000.00, FOB Qingdao Port, Installation cost: US$4000 Total: FOB Price US$60,000.00, Total installation cost: US$22000 4.2 Payment Term By T/T or L/C, 30% deposit, 65% paid before loading after inspection, 5% after installation. 4.3 Delivery Time 100 DAYS after the seller received the 30% deposit.

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4.4. Installation and Commissioning Time Shredder system: 45 days. Pyrolysis System: 60 days. Carbon black milling: 20 days. Carbon black pelletizing: 20 days. 5. Reference photos of running automatic tire shredder system

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ESC

Pleasant cooperation!

Szirmay Rókus. Pirolízis technológia.

Technology

Transcript of Szirmay Rókus. Pirolízis technológia.