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Bridge Green Technologies & Investments

Waste Tire Recycling Factory Sultanate of Oman, Feasibility Study

(December, 2013, Total 21 Pages)

(Total xx Pages)


1) Introduction The most important subject of 2000s is the environment and recovery technologies because it is known in whole world that what we consume gives very big damages to the environment and recycling in the environment takes hundreds of years. One of the biggest waste items: Used Vehicle Tires

Our world is full with waste tires of millions of tones. They are a big environmental hazard. They can’t be destroyed. They can’t be disposed of. They cause fire hazard and very dense insect reproduction. The amount of CO2 released to atmosphere during fire is also very dreadful. There are no a lot of alternatives for destroying the tires. The methods used until now are:

Breaking the tires apart (Shredding & Crashing) The waste tires pass through shredding machines. They are broken apart at different sizes. They are used either as ground filling material or ground coating material by pressing. Its economic value is low. Burning the Tires It is forbidden to burn them outdoors. However the cement factories having burning license can burn these waste tires. In order to have this license, the cement factories should make huge investments. Its economic value is low. Rubber Coating Because the waste tires which can be coated are in the waste tire scope after using and can’t be coated again, it should not be considered as a method for disposing the tires. Besides, the decrease in the new tire prices and the renewal opportunities is decreasing the coated tire usage every day. Other Usage Methods The waste tires are used as bumper in pier edges, boat sides, areas like speedways. This usage method is even not thousandth.


The tire producers have to collect the waste tires up to a certain ratio of their production and/or sales capacities or this will be mandatory very soon in all countries but recycling of the waste tires collected can’t be obtained with the methods above. Against all problems, the wastes are a good opportunity and income source. Recycling will be one of the major businesses in the future. Yet the future is already came. 2) Solution: New Recycling Method; Thermal Dismentalment

A new era has started in recycling of waste tires. Now with a very special technology that Bridge Green Technologies and Investments has developed will turn waste tires into 4 major component raw materials. Basically the process will bring us raw materials with sales value. After processing 1000 tons of waste tire, at the end you get in total 1000

tons of raw material. No harm to atmosphere, no harm to flora, no harm to nature. Here are the 4 raw materials: Carbon Black %40 Major ingredient of the tire and rubber

manufacturing and rubber related industries and also printing industry

Tire Oil %40 Major ingredient of the mineral oil manufacturing, fuel oil 6

Steel Scrap %20 Raw material for all metalworking factories Gas Higher calories compared to natural gas The gas will be used for the thermal process of the factory. The other three raw materials will be subject to sales. The revenue of the factory will be come from the sales of Carbon Black, Tire Oil and Steel Scrap. The input of the factory is waste tires. It is very cheap obtain or nearly with zero cost in some places.

Thermal Dismentalment

It is the process of decomposing of carbon based materials into its components in an oxygen free and controlled setting.

It is the process of breaking chemical links of a substance with heat energy.


3) The definition of Process and the Factory Majorly, the factory is a chemically processing facility. The system works continuously. The system is also works in a closed circuit environment. Factory operates all year round, with 3 shifts & 24 hours working hours. The factory will not operate 25 days in a year for maintenance and repair purposes. Except the taking out the side steels of the tires and some part of the packaging, all the process at the factory is machine driven and automated. System can be monitored from the screens with computer assisted control programs. The Proses Flow is as follows:


A sample layout of factory. It is changing from land to land.

Definition of the project in Sultanate of Oman The definition and subject of this project is related with recycling and recovery of the waste tires. It is planned that a new waste tire recycling and recovery facility is start from scratch using BGTI technologies. The project will be performed in a factory where it is designed according to the needs of Oman and it is planned to construct in Industrial Zone in Muscat. A closed area of 1500 m2 will be used. For the storage of waste tires, 20000 m2 open and flat area will be used inside the factory campus. The process of turning the tires worn out into steel wire, carbon black, pyrolytic oil raw materials, the main components of the tires, will be performed with the facility planned to be established. The waste tires, worn out, to be procured from the Oman market through collection channels of Local Partner shall be store inside the factory area. The tires stored first will be separated as steel wire and mechanically and stored for putting up for sale.


The tires, cleaned of the wire, shall be taken into the shredding (crashing) unit and taken into piece with requested sizes and made ready for pyrolysis. It will be disintegrated as carbon black, pyrolytic oil vapor and as under heat (650-‐720 °C) in the pyrolysis reactor. After the process, carbon black will be taken from the reactor; raised to requested norm in the improvement unit (grinding, sieving, and sizing) and transferred into the automatic weighting and packaging unit and made ready for selling. The other product emerging under the high temperature during pyrolysis reaction is the gas and oil vapor mixture. This product emerging in gas form shall be passed through the heat exchangers and condensers and first the gas and oil vapor shall be separated. The gas (methane and butane mixture) to be purified will be put into recycling and used for meeting the needs of heating all facility, central heating and kitchens with the heat energy of the reactor. By this way the facility will become self-‐sufficient for the heat energy needs. Some storage will be made. In cases where, electric production is not in question, the gas, other than using in all processes of the facility, is not considered as sellable products. Oil vapor, after separated from the gas, will be condensed in the condensers and it will be ensured that it turns into pyrolytic oil. The pyrolytic oil shall be placed on impermeable ground; stored in tanks. It will be put into selling. The product percentages to be obtained by the pyrolysis processes of tires, worn out, with an amount of 20.000 tons/year put into the facility can be defined as below: Waste Steel Wire: It has ratios between about 13% and 15% of the tire amount depending on the production criteria of the tires put into the recovery. A steel wire production of about 3.000 tons annually will be performed based on these ratios. Pyrolytic Carbon Black (CBp): It happens to be approximately 35% – 38% of the tire amount to be put into recovery. The carbon black production of approximately 7.000 tons annually will be performed based on these ratios. Pyrolytic Oil: it happens to be approximately 40% of the tire amount to be put into recovery. The pyrolytic oil production of approximately 8.000 tons annually will be performed based on these ratios.


The pyrolytic oil formed in the facility will be placed on an impermeable ground and also stored in the impermeable tanks under which there are impermeable overflow tanks. This oil will be sold afterwards. A gas emission in a ratio between 10% and 12% of the amount of the tire, worn out, to be entered recovery will occur. Approximately 2.000 m3 gas production will be performed annually based on this ratio. All of the gas equivalent to natural gas mentioned shall be stored and used for production in the processes of the facility. 4) Operation Period: Because this mentioned project will operate based on the demand from Sultanate of Oman and international markets and since recycling and recovery needs and phenomena are adopted more every day, no time limitation is taken into account. It is planned that the production will continue as long as the operability is obtained in the factory and facility and the demand continues. 5) Timing Table: It is planned that the production will be started within about 6 – 7 months after the signing of the contract of the project. This planning may extend depending on the transportation, customs procedures, weather conditions, the readiness of the plant’s preliminary preparations, the availability and the completeness of the finance and similar variables and conditions which can’t be controlled by BGTI.

Phases/Months 1 2 3 4 5 6 7 8 9 10 11 12

Implementation Project

Manufacturing

Mounting

Activation of Factory

Support, Monitoring, Improvement


6) The Necessity of the Project Socially and Economically: It is called recycling that the wastes which can’t be used again are passed through various physical and/or chemical processes; turned into secondary raw material, and again included in the production process. In other words, it can be defined as the waste materials, become out of use by using in any way, which can be recovered is recovered again to the production processes as a raw material by means of various recycling methods. Starting from this purpose, this project is wanted to be actualized for the purpose of protection of natural resources, obtaining energy savings, decreasing waste amounts, and making investment to the future, also to the economy. Pyrolysis subjects the material to the thermal disintegration without burning the material with controlled, indirect high heat in an oxygen free environment. The waste tires will be separated into four materials, which are the main components, as steel wire, carbon black, gas and pyrolytic oil by means of the pyrolysis process. Of the products to be obtained: Steel wire: is not a waste. It is a semi-‐product requested by the arc and induction furnaces and it will be recovered for the country’s economy by means of the project planned to be realized. Pyrolytic carbon black: is not a waste. It is one of the main admixture and filling materials of the rubber and paint industry. It is imported from abroad because it is not produced in Oman. The project itself by producing Carbon Black itself will also bring benefit to the economy of the country. Additionally, it will bring advantage and economic value to the country by exporting this material. Methane and butane mixture with natural gas properties: it has a calorific value higher than LPG and will be used for meeting the energy needs inside the facility. In addition to these, it is planned to employ various number of personnel during construction phase of the facility planned. It is also planned to employ nearly 41 personnel during operation stage.


This is the indication that the facility will make contribution to the economy of the region and country in employment dimension. 7) The properties of all units in the scope of the project and the processes realized in all units for all activities: Weighting and storage: After the tires worn out are brought to the facility with vehicles and the weighting process is made in bascule, they will be stored in the storage area to be determined. It is adequate that the storage area is at least 8000 m2 at most 20000 m2. Stock storage areas can be in different areas. In the storage area; The necessary water depot, pump, generator, fire cabinet and hoses with 30 m intervals, and hydrants and fire extinguishing tubes in the building entrance shall be placed, Tire batches shall be stored such that they are organized. Besides, a road distance shall be left which won’t hinder the entrance and exits of the vehicles in case of emergencies. The area will be surrounded with a building material with a height of at least 1,5 meters. The electricity and lightening poles will be made according to the regulations related with installment and equipment and grounding; a suitable lightening conductor system will be established against lightening danger.


On and around of the tire batches will be disinfected regularly for the pests such as mosquito and mouse not reproducing. It will not be allowed that a fire is started in outdoors closer to the tire batches more than 100 meters and welding or other devices producing heat are operated closer than 20 meters. Wire Extraction: First the steel wire shall be separated from the stored tires mechanically and stored for putting up for sale. The wire extraction machine will provide that approximately 3.500 tons of steel wires are separated from the tire, which corresponds to the 15% and 25% part of the tires worn out, which is the raw material entering to the facility. The machine which will be placed in an area of maximum 50 m2 will separate the steel wire from the tire with a completely physical method and forms the starting point of the system. The engine power of the wire extraction machine is 30 KW. No waste production will be in question. Cutting Unit: The tires, cleared of steel wire, will be taken into the cutting unit to decrease the sizes and the cutting process will be made there. The machine will be in an average area of 100 m2. The engine power of the wire cutting machine is 25 KW. Crushing Unit (Shredding): The tires cleared of wire and cut will be taken into the shredding (crushing) unit and separated into the pieces in requested size and made ready for pyrolysis. It will be in an average area of 65 m2. The tires out of the cutting unit will be taken into the crushing unit by means of the conveyor band system. The engine power of the crushing (shredding) machine is 75 KW. There is no waste production in question in this unit too. Reactor Group: It shall be disintegrated as carbon black, pyrolytic oil vapor and gas under heat (650-‐720 °C), in an oxygen free environment in the pyrolysis reactor (rotating oven). There will be 2 reactors, 2 burning rooms and 2 burners in this part.


The first work, after the facility is established, will be with LPG or fuel-‐oil or diesel. The pyrolysis process will start within 3 hours and the separated gas will be returned to burners. External fuel usage will be stopped. During this time, pyrolysis oil will be started to be produced and stored too. Again the gas obtained in the works after that will be used. No external fuel will be needed. Gas and pyrolytic oil vapor will be transferred to the condensation part by means of heat exchanger; carbon black will be directed to the carbon black grinding group. The reactor is planned such that the approximate height is 11 meters and the area covered is 250 m2; the total engine power is 380 KW. Condensation Group: The gas released in the reactors will be passed through the heat exchangers and condensers and first gas and oil vapor will be separated. The gas to be purified (methane and butane mixture equivalent to natural gas) will be taken into recovery and used for meeting the heat energy needs of the reactor. By this way, the facility will be self-‐sufficient for the thermal energy needs. The oil vapor, after separated from the gas, will be condensed in the cooling towers included in the condensation group and it will be ensured that it turns into pyrolytic oil. The pyrolytic oil to be formed in the facility will be placed on an oil proof ground and stored in impermeable tanks, under which there are impermeable overflow pools. The product obtained, than, will be put up for sale by BGTI. Carbon Black Grinding Group: After pyrolysis, the carbon black will be taken from the reactor and grinded in the carbon black grinding group. Carbon Black Package Group: The pyrolytic carbon black (CBp) pulverized by passing through the grinder made granules and packed in the pelletizing group. The packing with the requested type (25 kg, 50 kg or big bags) is made. The area covered by the machines included in this part is approximately 50 m2. The total engine power will be 155 KW.


Steel Wire and Carbon Black Storage Area: The steel wire and carbon black, of the products obtained from the process will be stored on the impermeable ground as packed in an area of 350 m2 inside the factory area. Pyrolytic Oil Storage Area: Pyrolytic oil which is another product obtained from the process will be stored in the impermeable tanks which is closed and to be located on an impermeable concrete near the factory building, under which there is the overflow pool again ensured to be impermeable. The total storage capacity is planned as 500 m3. Recovery Efficiency: 100% recovery of the wastes is targeted by means of the waste tire recycling facility planned to be established. The steel wires, carbon black and pyrolytic oils which will be obtained from the facility will be separated and directly sold. By this way it will be ensured both that waste tires are recovered by the economy and that the creating environmental pollution will be prevented. The gas again released by the system will be included in the process in order to meet the energy needs of the facility. As it can be understood, the system will be obtained with zero waste principle and 100% recycling. This is also very important project which will be described to the public and required to be communicated. 8) Where, How and in which Way will the Products be Marketed? Scrap steel wire will be sold to melting and induction furnaces and steel industry facilities having activities in Sultanate of Oman or nearest GCC Countries’ market. Carbon black will be sold to rubber producers and paint industry. BGTI guarantees the marketing of this product. Steel wire shall be stacked in the trucks without packing as compressed state while carbon black is sold in trucks as packages. Pyrolytic oil will also be marketed by BGTI in the international markets. This also means the sales guarantee through exporting. BGTI will guarantee the purchasing 20% below the international market figures suitable for the type of the oil.


When marketing all products, printed media, internet (web introduction) services and various communication methods will be used. 9) Machinery and Equipment List* DEFINITION DESCRIPTION PIECE Tire Preparation Unit Wire Extraction Hydraulic double direction 1 Shredder Tire shredding, production with 3 tons/hour

capacity 1

Conveyor Conveyor with rubber band 1 Storage Tank -‐ Bunker Load cell cylinder with conical bottom (50-‐60

m3), 1

Conveyor Conveyor with rubber band, double direction 1 Pyrolysis Reactor Unit Reactor Universal pyrolysis reactor 2 De-‐dusting Unit Vertical dust collection system 280 m2 2 Condenser Horizantal 80m2 2 Flow Monitoring ∅ 200 glass monitoring production 2 Re-‐Separator Cylindrical level control 150 lt 2 Collection Tank Vertical cylindrical level with glass, manhole 4 Oil Pump 4 centrifuge mechanical packing power oil pump

10 m3 2

Steel Platform Console platforms system steel carriers 1 Carbon Processing Unit Carbon Discharge Closed conveyor with steel band 1 Magnetic Band Magnetic steel separation system 1 Grinder Preliminary Silo 1 cylindrical, bottom base conical 12 m3 1 Grinder Feeding System Grinder feeding unit with capacity control,

1

Grinder Carbon cooling production 1 Grinder Discharge Production carrier, spiral type, with screw 1 Sieve Unit Sieve unit with vibration, double product exits 1 Return Screw Oversize return screw 1 Sieve Product Exit Screw Undersize carbon discharge spiral screw 1 Carbon Silo Silo, cylindrical, with conical base 12 m3 1 Carbon Filling Carbon packing unit 1 Aspiration -‐ 1 Storage Unit Gas Tank Exiting gas compressor washing and storing set 1 Oil Tank Vertical, one side is curved, with a capacity of 60

m3

1


*Bridge Green Technologies and Investments and its manufacturing partners has the right to change the definitions, pieces and the core systems of this factory without changing the outputs, decreasing the quality levels and the capacity of the factory that is proposed in this feasibility.

Oil Transportation Pump Capacity of 30 m3/hour 2 General General Control Command All system control and command system

temperature vacuum set 1

PLC Tracking and Monitoring system 1 Management Software Production management and waste monitoring

software 1

Isolation Reactor + cold hot gas line isolation set 1 Static Electric Grounding Static and grounding works 1 Auxiliary Units Vacuum Pump 2 units, with a capacity of 450 m3/hour 2 Vacuum Safety Tank Pump system safety tank 1 Vacuum Water Cooling Tank

Vertical, cylindrical coolant gas safety system 2 m3

1

Laboratory Installment Laboratory equipment set 1 Water Cooling Tower 1.000.000 Kcal-‐chiller heat exchanger cooling 1 Circulation Pump Pump of the cooling tower water 70 m3/hour

capacity, centrifuge type pump

2

Chiller (cooling) Group

300.000 Kcal/hour capacity, 6 c group, imported

1

Brine Tank

Prismatic, isolated control systems and pumps 12-‐15 m3

1

Oven

Heating gas production system with a capacity of 3.000.000 kcal/hour

1

Reactor Cooling

Pyrolysis reactor air cooling system

2

Gasometer

Output gas compressor washing and storage set

1

Mechanical Installments

Vacuum product cooling, pressurize air and gas installments

1

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Documents

recycling of waste tires

waste tires of millions

tons of waste tire

waste tire scope

biggest waste items

coated tire usage

tire producers

industry tire oil