What is tire pyrolysis: the essence of the operating method of a tire pyrolysis plant. Automobile Rubber Tire Recycling Equipment Tire Pyrolysis Technology

The idea of ​​recycling tires into fuel is dictated by the realities of our time. The car park is growing every year. Accordingly, the amount of consumables for their maintenance increases, and as a result, used spare parts also grow, falling into the category of waste. According to statistics, the volume of used tires per year is about a million tons.

Storage of old rubber requires large areas, so the issue of waste disposal is becoming increasingly important. The polymers from which tires are made do not decompose. The most obvious way to get rid of them is to burn them. Ecologists are sure that such a technology for processing rubber waste causes great harm to the environment. In the process of burning rubber, very toxic substances enter the air: benzapyrene, dioxins, PCBs, furan.

Each used tire can get a second life. When burning from one ton of waste, 700 kg of rubber and 720 kg of toxins and soot are obtained, unsuitable for anything. The polymers in older wheels remain virtually unchanged after several years of use. Therefore, simply burning tires is inefficient and not economically justified.

Recycling old tires is a fairly promising direction to open. The technology of the process does not require investment in the purchase of raw materials. Used car tires are thrown away, since the system for processing such waste in Russia is not established.

Owners of tire workshops are forced to pay money in order to organize the removal of rubber waste to a landfill. Therefore, there will definitely be those who want to provide the owners of such an enterprise with raw materials, as well as buyers for the finished product.

Types of rubber waste disposal

Depending on the method of exposure, the following methods of tire recycling are distinguished:

• Physical.
• Chemical.

Getting rubber crumb

Physical involves mechanical grinding of raw materials to the state of crumbs. The resulting powder is used in the production of new tires. This method is quite popular. In addition to rubber, chemical fibers and a small amount of steel are obtained from old tires.

The recycling process begins with cutting the feedstock into small pieces. With the help of a magnetic separator, the remnants of the metal cord are removed. The resulting mass is crushed to a state of crumbs.

pyrolysis method

This technology is based on the decomposition of raw materials into components under the action of temperatures without the participation of oxygen. The result of pyrolysis depends on the temperature at which waste is disposed of. There is low and high temperature pyrolysis. The method has become widespread in Europe. Tire pyrolysis is more environmentally friendly than incineration and economically interesting, as it allows you to get fuel from waste material.

As a result of pyrolysis recycling, the following products are obtained from old tires:

• Synthetic oil (the basis for the production of various petroleum products, including fuel).
• Technical carbon. It is used as a dye for concrete, for the manufacture of conveyor belts, the manufacture of paving slabs.
• Steel cord (secondarily used for the production of new tires or goes to scrap metal).
• Thermolysis gas (used for tire recycling plant or in mini-boilers to provide heat).

The most cost-effective way is the restoration of tires through vulcanization. This option is most relevant for large-sized wheels. The product obtained by this method is several times cheaper than a new tire. Passenger car tires are most advantageously recycled using pyrolysis.

How the process of recycling and processing by pyrolysis is built

Tire recycling chemically includes the following steps:

1. Tires to be recycled are collected at a recycling point.
2. With the help of a special machine, the tire is cut into pieces, separately the tread and beads.
3. The prepared raw material is loaded into the retort and heated to a temperature of 1000 - 1400°. The thermolysis gas released during waste processing is cooled and converted into pyrolysis oil.
4. The retort is replaced by another filled with the next batch of raw materials.
5. The cord remaining after the completion of the operation is screened out and sent for further processing.
6. The same thing happens with the carbon formed during pyrolysis.

It should be noted that the gas released during the pyrolysis process is used to maintain combustion in the installation. Part of the waste enters the atmosphere, therefore, when building a processing plant, the location relative to the nearest residential and other facilities is taken into account.

Tire Pyrolysis Equipment

Manufacturing process using high-temperature conditions has many advantages:

• Pyrolysis technology is practically waste-free. The resulting products are reused in any industry.
• Pyrolysis is the least environmentally harmful method of waste disposal.
• Recycling tires in a special reactor does not require huge energy costs.
• The possibility of using the resulting products to support the process itself.

The main component of the pyrolysis technology is the plant itself. Its cost ranges from one to ten million rubles. The reactor is a unit with dimensions of 10X5X3.5 m. The pyrolysis plant is mounted in an open space, not indoors. Power consumption - 6 kW per hour, productivity 5 tons per day. Of these, carbon-containing components account for 30%, fuel liquid - 40%, the rest - metal cord and gas.

For preparatory work you will need special scissors, which also consume electricity, and several crucibles to replace the retorts. The whole process must be carried out continuously. The fuel obtained during the pyrolysis process will require special containers for storage and transportation. Usually tanks are used for this.

Possible difficulties when opening a pyrolysis production

Despite the economic attractiveness, the organization of pyrolysis production can be fraught with some pitfalls. It is important to take into account some of the nuances before investing in equipment and people.

Features of the technology for working with any waste require the placement of equipment away from residential areas. The distance to the nearest houses should be at least 300 meters. But this does not guarantee you the absence of a negative reaction from the inhabitants. The perfect place may become an abandoned workshop of some enterprise. But its arrangement will require time and money.

Ecologists are very wary of processing methods such as pyrolysis. It is absolutely certain that the owner of the installation will be obliged to purchase treatment equipment. Its cost is sometimes comparable to the investment in the main processes.

The entrepreneur must be prepared for questions and requirements from the regulatory services, the fire inspectorate and other authorities. Pyrolysis falls under the concept of "waste recycling". Such activities require a special license.

Given the above points, we can say that it is unprofitable to recycle only old car tires. Experts agree that the ideal option would be the production of some other raw material. An example of such a product would be glass or.

Video: Recycling tires into fuel

For a very long time, the governments of many developed countries have put the ecological situation in modern cities on the agenda. Hundreds of thousands of waste polymers end up in landfills every year, contaminating environment. But many organic substances, in particular - car tires that have become unusable, can be reused. By purchasing new or used equipment for the processing of rubber tires, everyone has the opportunity to build not only 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 the minimum of funds, while organizing an efficient workshop that brings a stable income.

Our business valuation:

Starting investments - from 6,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 7/10.

It is not very difficult to open a mini tire recycling plant in Russia, the main thing is to know from which side to approach the implementation of the planned project. As in any other market segment, there are some nuances here, which are extremely important to pay attention to. And the initial task of everyone who seriously decided to organize their own business is to draw up a business plan for the recycling of car tires, which would reflect the important stages of launching a manufacturing enterprise.

It is possible to single out 2 lines of business - processing of raw materials into crumbs and into liquid fuels. Each of these options is good and profitable in its own way. The difference here is only in the amount of initial investment and the technological process.

Why recycling old tires is 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 enter the workshop either at a very low price, or even completely free of charge.
• The simplicity of technology. Despite the fact that obtaining fuel from tires, from the point of view of physical and chemical processes, is a rather complicated process, modern equipment makes the technological scheme extremely simple.
• Huge market. With well-established sales channels, finished processed products will immediately be shipped to customers.
• Environmental friendliness. It would seem that the recycling of old car tires and tires should be a very dirty process, but no - as a result, only final products and some associated components that are not hazardous to human health are obtained. The only one harmful factor- increased noise level.
• Opportunity to obtain preferential conditions for doing business. The state today encourages innovators in every possible way and provides businessmen with subsidies and loans with "pleasant" interest.

But recycling used tires is not only characterized by 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, it is necessary to launch an advertising campaign at the stage of business planning and start producing products immediately “for a ready-made buyer”.

The business idea for recycling used tires is very promising, and all the difficulties that arise in preparing for the launch of the 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 task - to buy equipment for processing tires into crumbs. There are a lot of machines on the market that can perform the task - to grind tires to powder and crumbs of various sizes.

Such a business development scenario is especially good with simple technology and a huge sales market.

Tire recycling production line crumb rubber

Each line works on a specific technology:

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

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

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

• Ring cutter.
• Seat ring squeezer.
• Tire cutter for strips and blanks.
• Erasing machine.
• Vibrating sieve.
• Separators.
• Transporters.

It will be quite problematic to independently assemble such a line from separate machines, it is much more practical to buy a finished 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 apparatus with a minimum capacity (up to 100 kg / h) will cost the 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. Equipment of the following brands is 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 recycling machine. To start a business, an average capacity (200-500 kg / h) will be quite sufficient - so, the equipment will not stand idle in the absence of raw materials or customers.

When organizing a tire recycling business, 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 rather strict requirements for the location of the enterprise - away from residential areas.

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

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

• Sorting of incoming raw materials.
• "Cutting" tires.
• The crushed raw material decomposes in the reactor under the influence of high temperatures.

After all the technological stages, several semi-finished products are obtained at the output - gas, metal cord, liquid fuel.

Each product obtained in the process of processing finds its application. The gas is re-used during subsequent cycles, thereby saving on fuel. And the 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,
• pyrolytic unit,
• conveyors,
• separators for steel cord cleaning.

Pyrolysis line for the processing of tires and rubber goods

And the most expensive equipment of all pepper is a pyrolysis plant. It is for it that the entrepreneur pays, equipping a workshop for processing tires into diesel fuel.

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

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

The powerful tire pyrolysis plant can work continuously, showing the output of the following end products:

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

If the line is fully loaded, the output of liquid fuel will be 40% of the mass of the original rubber raw material.

Considering that the standard line is quite large in size, it may be difficult to choose a suitable room.

Where to get raw materials?

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

What are the possible options here?

• Buying tires in auto repair shops, services, from private traders.
• Collection of 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 recycling 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 from the city dump alone every day. But even this is not enough for the smooth operation of the equipment, so buying tires for recycling is also a place to be. Raw materials are inexpensive - many companies, realizing that a certain area of ​​\u200b\u200bthe enterprise is interested in worn tires today, began to ask for a certain amount, albeit purely symbolic. And the acceptance of used tires for recycling for a small compensation from the private population will allow not only stocking up on raw materials, but also drawing 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 here to establish distribution channels as soon as possible. And the priority, of course, are wholesale customers.

In fact, there are a lot of consumers of the products received. Rubber crumb is actively used in many industrial areas - construction, automotive and even textile. And the resulting fuel oil will be taken to production workshops, where secondary technical oil can be used as fuel.

And if you have already found reliable distribution channels, know who is profitable to sell the resulting products, and have established your own stable enterprise, share your experience in tire recycling with newcomers who plan to develop in the same direction.

How much can a business afford to earn?

Practice has already shown that mechanical and pyrolysis processing of tires and rubber goods, with a competent approach, brings a stable profit.

When calculating the expected income, it is necessary to estimate how much initial investment will be required here. To organize a "middle" workshop, it is imperative to provide for:

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

The minimum money 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 distribution channels are found. The following figures are taken to calculate the profit: wholesale price for a crumb - from 15,000 rubles / t, wholesale price of processed diesel - from 6,000 rubles / t.

Worn-out tires are almost not subject to natural decomposition, which means that sooner or later they should be disposed of. Tires cannot simply be burned - such a “disposal” of even one ton of products is fraught with “enrichment” of the atmosphere with centners of soot and toxic gases. In addition, this is simply a senseless waste of resources, because thanks to modern technologies waste tires can be profitably recycled, for example, into fuel. Consider the case of opening a company specializing in the processing of tires into fuel oil.

Tire recycling as a business is a unique activity, as there are practically no costs for raw materials. Moreover, in many cities, municipal authorities even pay for the disposal of tires. As for the resulting fuel oil, this is a product that is constantly in demand.

As a result of the tire recycling process, a dark oily liquid is released (30-40% of the total mass of raw materials). This so-called pyrolysis oil, its chemical properties are similar to those of fuel oil and heating oil. It can be used in industrial furnaces, heat generators, boiler houses. In addition, the pyrolysis liquid is processed to produce higher quality fuel oil, diesel fuel or gasoline.

Potential Buyers

• boiler rooms;
• industrial enterprises;
• owners of private houses.

Equipment

To open this business, you will need the following tire recycling equipment (basic):

Almost all pyrolysis plants present on the domestic market are of Russian or "post-Soviet" origin. Their cost varies from one million to ten million rubles.

For example, the mini tire processing plant "Consum-Avtotyres-Classic", which not only cuts and processes car tires into pyrolysis oil, but also turns it into diesel and gasoline distillates, will cost from 7,500,000 rubles. This plant is capable of processing 15-20 tons of raw materials per day.

From the same manufacturer, you can also purchase a conventional installation for the production of pyrolysis fuel SHAH (from 2,000,000 rubles), with a capacity of 5 tons of raw materials per day.

The cost of hydraulic scissors NS-400 capable of cutting both passenger and truck tires is 300,000 rubles.

A fuel storage tank with a capacity of 10,000 liters will cost 220,000 rubles.

Example of production organization

Consider an enterprise that processes tires into fuel (fuel oil) using a SHAH pyrolysis plant with a capacity of 5 tons. According to its technical characteristics, up to 400 kg of pyrolysis liquid should be obtained from one ton of raw materials.

To start a business, an investment of 4.6 million rubles will be required:

• Purchase of the SHAH pyrolysis plant - 3,000 thousand rubles

  Utilization and recycling of car tires

• Hydraulic shears - 300 thousand rubles.
• A tank with a capacity of 10 thousand liters - 220 thousand rubles.
• Tools, consumables - 280 thousand rubles.
• Delivery, installation, commissioning - 300 thousand rubles.
• Other expenses (coordination, connection to power grids) - 500 thousand rubles.

With an operating mode of 30 shifts per month and 100% equipment loading, the plant produces 60 tons of products.

By its properties, the resulting pyrolysis oil corresponds to heating oil. The average wholesale cost of this fuel is 9,500 rubles per ton (the price is current as of February 12, 2013).

With this option, the monthly revenue will be 570,000 rubles, the net profitability of the activity is 50%. The return on investment, at 100% load of the line will be 16 months, and at 50% load 32 months.

Equipment | for cleaning and regeneration | Vacuum regeneration plant UVR

Designed

for regeneration (restoration of working condition), primarily mineral oils, hydraulic oils, compressor oils, industrial oils, as well as lighter electrically insulating transformer and turbine oils;

for purification, clarification, regeneration, removal of paraffins, removal of sulfur (desulfurization) - furnace, diesel and pyrolysis fuels, as well as other fuel liquids.

Business Idea #102: How profitable is tire recycling?

Vacuum regeneration plant UVR

regenerates, clarifies, removes aging processes, filters and purifies: mineral oils, diesel fuel, heating oil, petroleum products, pyrolysis liquid, the unit removes paraffins and sulfur from diesel and heating oil.

The cost of regeneration of the 1st ton (depending on the regenerated liquid) ranges from $6.5 to $35.

Regenerated, clarified and filtered this or that liquid, after the processing process, also corresponds to GOST.

This equipment will not solve the issue of oil disposal, but will give and gives oils a second life.

Installation universal and works on any liquids without any reconfiguration, the only changeable parameter will be the performance of the unit, it will depend on the type and viscosity of the liquid being cleaned.

The equipment is certified and complies with all GOSTs and standards.

Engine oil samples before and after the regeneration process,
as well as other samples of purified and clarified liquids

Pyrolysis plant for tire recycling. Pyrolysis is a waste-free waste disposal technology.

Pyrolysis of tires, tires, plastics and other waste allows you to recycle and recycle toxic waste into fuel, carbon and steel cord. The pyrolysis plant is simple and efficient. Investments in pyrolysis equipment pay off in less than a year; when acquiring equipment on lease, the payback period is reduced to several months. The pyrolysis plant does not require numerous personnel. To service a horizontal pyrolysis plant, 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. Delivery of the reactor from heat-resistant stainless steel is possible. After 7-8 years of operation, the reactor is replaced with a new one. The remaining components of the installation do not require replacement. The installation used automation Siemens.

Leasing of equipment for 2 - 5 years is possible, the down payment is 10 -15%, the rise in price is 5 -12% per year, the currency is rubles.

Waste pyrolysis. Depending on temperatures and materials, installations for low-temperature pyrolysis and high-temperature pyrolysis of waste 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. In the process of pyrolysis, we get fuel and other valuable waste. In our installations, the catalytic pyrolysis process is used to increase the efficiency and speed of the process.

Tire recycling as a business

In the output units, we get heavy and light fractions of fuel, non-condensable fractions - gas is used to heat the pyrolysis furnace, therefore, only initial heating is necessary for the operation of the pyrolysis furnace. After the start of the pyrolysis process, 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 type of fuel at all. The pyrolysis unit is equipped with a 4-stage gas purification system. Price list for pyrolysis plants.

High-temperature pyrolysis proceeds at temperatures of about 1000-1400 degrees and is characterized by a maximum gas yield. High temperature pyrolysis is one better ways processing of municipal solid waste, MSW, both from the point of view of both environmental safety and the production of synthesis gas, slag, metals and other materials that can be widely used in the national economy. High-temperature gasification makes it possible technically simply to process municipal solid waste without their preliminary preparation, sorting, drying, etc.

Waste equipment - advantage of pyrolysis:

• Pyrolysis equipment is the optimal solution for waste processing. Pyrolysis is not very sensitive to the type of raw materials and is able to process unsorted municipal solid waste, sewage sludge, oil residues, paper pulp, mixed plastics and shredded car residues, rubber and tires, woodworking waste, hospital waste, etc. Plant automation adapts to changes in waste composition .
• There is no combustion waste, the pyrolysis plant has excellent performance in terms of emissions of harmful substances such as dioxins, the level of which is lower than that required by the relevant legislation.
• The plant does not produce waste water.
• Highly qualified personnel is not required, the installation works automatically.
• There is a large decrease in the amount of waste for disposal.
• Harmless production residues can be used in the future, in the production of tires, road construction, etc.
• The pyrolysis plant is easy to operate and maintain, and 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. You can purchase horizontal pyrolysis machines from us for processing tire waste, etc. and vertical machines for processing of waste oil and oil products.

Advantages of horizontal pyrolysis plants:

• The material is mixed in the reactor, which accelerates the pyrolysis process.
• There is no need for overhead cranes to unload the retorts.
• The shop may have a lower height.
• The big sizes of loading doors of installation.
• Possibility of automating the loading, the loading device can have a diameter equal to the machine door.
• Fully automatic carbon unloading, steel cord unloading device, Small number of staff 3-4 people, especially high savings are obtained when the plant capacity is large or when 2 or more units are purchased.

Pyrolysis of rubber and tires.

Rubber pyrolysis and disposal car tires— the most demanded direction, where horizontal pyrolysis plants are widely used. The large volume of the reactor from 12 m3 to 50 m3, large loading doors from 2.2 to 2.8 meters in diameter, automatic unloading of the plant, and a small number of maintenance personnel make horizontal plants the most advantageous to use for these purposes.

Pyrolysis of plastic.

• Pyrolysis of plastic, one more popular destination use of pyrolysis machines. What is especially important is that the plastic decomposes in the pyrolysis machine without the formation of dioxins. In this case, the yield of pyrolysis fuel is about 65% of the weight of the plastic. Upon delivery of the dechlorination unit, it is possible to process plastics with PVC impurities.

• Waste pyrolysis

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

• Pyrolysis of waste oil and petroleum products

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

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

Installations for the regeneration of oil properties with a capacity of 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 feed inlet, depending on the volumes and material, a loading conveyor can be supplied. Then, the reactor of the pyrolysis machine is heated by a gas or diesel burner, at the choice of the customer. When the temperature reaches up to 350°C-400°C, the pyrolysis reaction starts in the reactor. Light and heavy components will be separated from the formed petroleum gas. The light component is cooled in the condenser and accumulated in the fuel tank, and combustible gases remain in the system, which cannot be liquefied, they are returned to the heat supply 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 range of Pyrolysis machines with different capacities:

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

№	Name	Power kW.	Volume reactor m3/hour	Volume downloads tons.	Volume per day tons.	Quantity downloads in a 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

* - the price of a pyrolysis plant without adaptation to a cold climate. Heating installation with coal, firewood.

** - price of pyrolysis plant without adaptation to cold climate. Heating of the installation with multi-fuel burners operating on diesel fuel, pyrolysis oil, 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, fuel oil.

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

The standard cycle of the pyrolysis machine.

We give a guarantee for the machine for 1 year, a period for a stainless steel reactor with a thickness of 14 mm. 3 years, other parts of the machine do not need to be changed during its entire period of operation, except for wear parts and components.

The composition of the pyrolysis machine includes

1. Reactor heating system
2. Thermally insulated body of the pyrolysis machine
3. The pyrolysis reactor is made of stainless steel 14 mm thick.
4. Machine control panel.
5. catalytic column
6. Tank for heavy fraction of pyrolysis oil
7. Pyrolysis gas cooling system
8. Container for 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 cleaning system
15. Burner for afterburning gas
16. speed reducer
17. Automatic Soot Removal Conveyor
18. Service platforms
19. Roller for steel unloading (cord)

Pyrolysis is the process of decomposition by fire in a literal translation. The material of used tires under the influence of heat in an oxygen-free environment is divided into solid, liquid and gaseous substances.

Business for the processing of automobile tires and tires into fuel oil

In this case, long polymer chains are converted into liquid components with a significantly lower molecular weight.
The raw material for pyrolysis technology can be not only car tires that have lost their properties,
but also used polypropylene, polyethylene, used motor oil and other carbon waste.

In its apparent simplicity of implementation, pyrolysis has a number of pitfalls. Heat process (above 500C) requires no moving parts in the reaction zone or expensive construction materials.

The periodic process, apart from a long production period, has an unreasonably high fuel consumption (up to 15% versus 6% continuous), due to the need to heat the cooled retort.

The primary product - pyrolysis oil has not just unacceptable quality indicators. It has a disgusting smell, a very high content of unacceptable products in fuels, is not stable and does not change during distillation.

The rest of the products obtained from tires by pyrolysis (carbon and steel) require additional costs to bring them to marketable condition.

Due to its low quality and organoleptic characteristics, pyrolysis oil cannot be used as a competitive product - a substitute for fuel.

We offer a modern high-quality technological system of environmentally friendly
highly profitable, waste-free production of recycling tires and other carbon-forming wastes with the production of highly competitive marketable products.

The technological process has two stages.

1. pyrolysis stage. But this is a "light" version - a low-temperature analogue of pyrolysis. Our specialists have developed promoters that allow the pyrolysis process to take place at low temperatures, while the output of pyrolysis oil occurs with better characteristics.
2. Reactive distillation taking place in the presence of catalyst systems of a unique structure, which makes it possible to obtain a commercial product from the product of low-temperature pyrolysis.

To date, the technological process has passed the stage of laboratory testing, pilot plant and industrial prototype. V this moment an industrial design is being installed in the Krasnodar Territory.

A number of tests (carried out in the ROSNEFT laboratories) of products manufactured according to new technology showed both the high quality of the product itself and the high efficiency of the catalyst.

The results were highly appreciated by the oil refining industry specialists.

The essence of the technology lies in the use of an unparalleled field-promoted catalyst system. The use of field promotion makes it possible to reduce the energy costs for carrying out the pyrolysis process and reactions on a catalyst. As well as a product of commercial quality, corresponding to the 4-5 ecological class of motor fuels of the Russian Federation, and as a result, an increase in the cost of selling one kg up to 30 rubles, while the cost of raw materials (tires) at a landfill is 0 rubles.

A new technological approach will make this production highly profitable due to the following factors that are inherent ONLY in our technology:

1. The area of ​​the occupied site is very compact, which makes it possible to locate production at the waste tire collection site or in its immediate vicinity.
2. The required electricity to put production into operation is minimal. Energy costs for the technological process itself are covered by the use of hydrocarbon gas generated during production.
3. The quality of the resulting finished product makes it in demand on the market of high-octane motor fuels (EURO-4 and EURO-5), with a selling price of over 30 rubles per kg.
4. Waste-free production, which allows us to talk about its environmental safety.

Pyrolysis of tires and tires

The problem of disposal of household waste is quite acute today all over the world. Moreover, if with household waste organic origin, you can rely on nature itself, then it is necessary to worry about the disposal of polymers for the person himself. 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 dump.

Disposal of car tires at this point in time is done in several different ways.

Processing into crumbs. Recycling tires by shredding is the simplest and most common method in our country. It allows you to save the chemical and physical-mechanical characteristics of rubber. After crushing, rubber can be used in the construction of roads and structures. Also, rubber grinding allows compact storage and transportation of rubber before further processing by pyrolysis.

Tire recycling by incineration. This recycling method was invented back in the days when mankind did not invent any alternatives to the destruction of rubber. Tires were burned mainly in the cement industry, where they partially replaced fuels such as fuel oil and coal. Burning tires looks like a real barbarism from the point of view of ecology, since many harmful substances do not break down during the combustion of rubber, but enter the atmosphere. Among these substances, the most harmful:

• 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. More correct is the method of recycling tires using pyrolysis. How does it happen?

Tire recycling by pyrolysis

Pyrolysis is used today 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, but also allows you to get fuel literally from garbage.

Low-temperature pyrolysis breaks tires down into their constituent components, each of which can be used for specific purposes.

Tire recycling business pays off in 6 months

Tire recycling by pyrolysis has long been used in European countries, since in addition to environmentally friendly recycling, this type of recycling can bring very good profits. So, what kind of products can an ordinary tire recycling plant produce:

1. Carbon black, which is used as a filler in the production of non-critical rubbers, conveyor belts, technical plates, and much more. It is also a pigment for the production of paints. Lower quality carbon black is widely used in construction (paving slabs, concrete products and bricks are made from it).
2. Thermolysis gas, which is analogous to natural gas. This gas is quite pure and can be freely used in mini-boilers to produce heat and electricity.
3. Pressed steel cord used for the needs of the metallurgical industry. It can be sold both as scrap metal and as knitting wire (subject to its additional firing)
4. Synthetic oil, which in its composition is almost identical to natural. Under the condition of its purification, it is able to replace many petroleum products.

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

Tire pyrolysis.

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

1. Car tires intended for recycling are sent to the raw materials warehouse.
2. With the help of a bead cutter, the tires are cut into the tread part and the sides (for the most dense 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 support the pyrolysis process, part of the resulting gas is fed into 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 into its place.
5. After cooling, the retort is unloaded and the metal cord is separated from the pyrocarbon.
6. Finished pyrolysis products are sent to a warehouse, where they are stored until they are shipped directly to the final consumer.

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

• This recycling process is safe from an environmental point of view, and there are no highly toxic substances in the processed products.
• No waste in production - absolutely everything that is generated during the processing of tires is a liquid product.
• This processing of MSW does not require serious 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 right solution for rubber recycling 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 way recycling old car tires.

accept 4 station wagon

Each of us knows that a vehicle cannot do without tires. However, not everyone thinks about where the worn rubber goes. There are two ways: either the tire is sent to a landfill and thereby pollutes the environment, or it is recycled. It's safe to say that rubber is a dangerous pollutant, so they always try to dispose of it. For this simple reason, there are all the prerequisites for creating your own small plant, where tires will be processed.

What everyone should know

Every year the number of cars on the roads increases by about 5-10%. Based on this, the amount of worn rubber increases by about 1 million tons. In many countries, the issue of recycling is very acute. partly solve this problem You can, if you set up your own small production. You have several business development options. For example, it can be the processing of car tires into fuel oil or crumbs. If you want to get fuel, you will have to spend a little more money, since the production line is quite serious. Pay attention also to the fact that you can work not only with tires, but also with plastic products, which will slightly increase the profitability of the enterprise. This business has several undeniable advantages, now we will consider each of them.

Firstly, you do not need to inject a lot of money into the purchase of raw materials. This is due to the fact that worn rubber is thrown away. Local authorities, if they, of course, are worried about the ecology of their city, will deliver everything to you. But that's not all, as the municipality is ready to pay for the fact that your company will process car tires. Agree, getting almost free raw materials, and even making a profit from the fact that you are doing this business, is not bad at all. Of course, everything does not end there, since our main goal is not only to save the environment, but also to make a net profit. Fixed assets will come from the sale of the same fuel oil, which is an extremely popular type of fuel in agriculture. By the way, you can also get free raw materials at tire fitting points, which are more than enough in big cities. The thing is that service station employees, etc. pay additional funds for the removal of old tires and their disposal.

Recycling rubber tires: pros and cons

It is impossible not to say a few words about the fact that this niche has not yet been fully filled. The number of entrepreneurs in this area is relatively small, about 20% of the optimal figure. This means that only a fifth of the worn rubber is disposed of and recycled, the rest goes to landfill. You must understand that 1,000 kilograms of burned tires is 450 kg of various toxic gases, as well as 250-270 kilograms of soot. But if the same amount of rubber is properly disposed of, then about 700 kilograms of full-fledged rubber can be obtained from mining, which can be used to make fuel and rubber products. It hardly makes sense to talk about the industrial scale of the enterprise, but it is very possible to establish a small tire processing plant.

The complex itself is relatively small, but its size directly depends on production volumes. So, for processing 5 tons per day, you need a room of 18 squares and 10 meters in height. There must be a warehouse on the site where you will store tires, plastic, etc. There must be a site for the preliminary preparation of raw materials (cleaning, cutting rubber). You can not do without a room for storing finished products. In this case, it all depends on what exactly you get. It could be fuel and so on. For example, for fuel oil, you will need to purchase several large-capacity tanks. They don't have to be new, it's even better to buy used, it's much cheaper. Please note that recycling rubber tires is a difficult and dangerous business. Therefore, technology must be carefully observed. Let's talk about this in more detail.

Technological process

In fact, there is nothing complicated here, but it is necessary to control the process at all stages of production. At the very beginning, you have to start collecting tires. Then you must take them to the warehouse of your enterprise for further processing. In order not to damage the scissors, which, by the way, are not cheap, it is necessary to inspect all raw materials for the presence of metal objects, such as discs or rings. As for the cutting tool, ideally it should be hydraulic shears, but this is not at all necessary, we will talk about this a little later. Next, the crushed rubber is sent to the reactor - a special tire recycling plant that operates at a given temperature, most often 450 degrees Celsius. Decomposition leads to the fact that we get several semi-finished products, such as gas, metal cord, fuel fraction.

The same gas is used to support combustion in the furnace as a by-product fuel. Its waste is released into the environment. You can’t call it a good solution, but the emission resembles exhaust gases truck. As for the remaining mass, it passes through the magnetic separator, speaking in simple terms then sifted through a sieve. Metal elements are screened out and sent to the warehouse. Fuel oil is transported by a conveyor to tanks, in which the fuel will be stored until shipment. It should be noted that the plant for the processing of tires, which allows you to get pyrolysis fuel, is quite expensive - about 2 million rubles. Its productivity is about 5 thousand tons of raw materials per day, which is quite a lot.

Production of crumb rubber

And here's one more enough interesting idea, which has not received due distribution to date. The essence of such a business is that you will sell shredded and processed rubber, which can be used for different purposes. In order for you to roughly understand what we are talking about, it is necessary to give general indicators in numbers. So, a ton of crumb rubber on Russian market will cost no more than 20,000 rubles. As for the main consumers, these are construction companies, manufacturers of rubber products, roofing materials, coatings for building and sports tools, etc. In principle, it is quite easy to find a point of sale.

It is also necessary to take into account the fact that approximately 700-800 thousand tons of worn tires are thrown away on the territory of the Russian Federation every year. Approximately 20-25% is disposed of properly, everything else is either simply lying in landfills or burned. So, the processing of tires into crumbs can bring 5-8 billion, but this is already an industrial scale. If you are going to be doing this kind of recycling at your plant, then you will need a mechanical crusher. will have to be changed very often, which leads to high costs. Another disadvantage of this idea is that a lot of electricity is consumed, about 500 kilowatts per ton of finished products. Nevertheless, recycling auto tires in this way will be beneficial. But only if you receive appropriate support from the state.

Tire recycling equipment

Separately, we need to talk about what our production line will consist of. In principle, there is not so much equipment, and it is not difficult at all. Nevertheless, the price "bites". The main unit is a tire recycling plant (reactor), 10 meters high, 3.5 meters wide, 5 m long. This unit must be installed only in an open area, that is, under the open sky. You, as a future entrepreneur, must understand that you will have to pay quite a lot of money for electricity. The reactor itself consumes about 6 kW per hour. In addition, there are also scissors - 7-8 kW / h. In principle, this is practically all the equipment that is necessary to start production. What else is needed is a few crucibles to unload the resulting material.

As noted above, the reactor has a capacity of about 5 tons per day. But of this mass, approximately 40% will be liquid fuel. The fact is that as a result of decomposition, you will get gas (about a ton) and somewhere around 0.5 tons of steel cord. We should not forget about the solid residue (carbon-containing materials), which is approximately 30% of the total output. It is worth paying your attention to the fact that the processing of old tires in the reactor is carried out continuously. All you have to do is add tires. Combustion is supported by the gas produced inside the furnace. The reactor should be operated by two specially trained specialists. In principle, training courses can be completed fairly quickly. Now let's go ahead and look at a few more important points.

How much money do you need to get started?

This is one of the main aspects that interests absolutely all beginners. You don't need to spend a lot here. If you are going to purchase used equipment (reactor, shears), you can save up to 20% of the total amount. It is worth taking such a step or not, it's up to you. There is no guarantee that a used reactor will not fail after the first heat. In this case, no one will compensate you for the damage. One million rubles should be enough for everything about everything. This includes the cost of a reactor with a capacity of 5 tons / day, as well as shears. In addition, you will need to purchase several tanks (60 tons). If these are used containers, then you will have to pay about 25,000 rubles apiece. How many pieces you need, think for yourself, but you do not need to be limited to one or two tanks. The fact is that the processing of tires into fuel is a seasonal business.

During the period of a decline in fuel prices, it is better not to sell it, but only to accumulate it. When the period of increase comes, and this will happen for sure, you can get a good income by selling all the fuel oil at once. This tactic works and is considered quite effective. But this does not mean at all that you should completely freeze sales, it is enough to reduce them by 50-75%. You still have to pay employees. Four specialists will cost about 60,000 rubles a month, and tools and overalls - another 50,000. There are also regular monthly costs: electricity, taxes, rent, etc.

About the income of the enterprise

As you can see, tire recycling technology is quite simple. There are no additives to the fuel, complex chemical reactions and other points. Moreover, as noted above, the raw materials are completely free. Sometimes even collecting tires can make some money, which will pay off the monthly electricity costs. If you live in the outback, then it is unlikely that you will be paid for disposal, but in big cities the situation is completely different. There are many industrial enterprises who pay good money for rubber recycling. This is due to the fact that many city dumps refuse to accept such waste. For the processing of a ton of tires, you can get a different amount, from 2 to 5 thousand rubles.

It is safe to say that even recycling tires at home will bring a good income. Thus, consumers are ready to pay 3,000 rubles for a ton of low-quality carbon. Scrap metal is accepted at the rate of 4 thousand rubles per ton, and fuel oil - 3-4 thousand rubles per ton, depending on the period. By simple calculations, you can come to the conclusion that in a month you will earn about 350,000-400,000 rubles. Approximately 50% must be paid for electricity, workers, etc. With such an intensity, the tire recycling line will pay off in six months, which is quite fast. As you can see, the idea is very interesting and promising, but not everything is so simple. In such a business, as, in fact, in any other, there are a lot of pitfalls. Let's see how not to make a mistake.

Problems when starting a business

It happens that it is simply not possible to find a free piece of land. This is due to the fact that it is necessary to maintain a safe distance to residential buildings, which is 300 meters. The farther the plant is from the city, the greater the cost of delivering raw materials, we should not forget about this. Remember that not everyone wants tires to be recycled under their windows. Feedback from ordinary residents will be negative, even if the reactor is located at a distance of 400 meters from residential areas. For this simple reason, look for a place on the production site. Most likely, you will find it, since quite a few sites are empty. All that is required of you is to negotiate directly with the company, as a rule, this is not so difficult to do. At least, it is much easier than to conclude an agreement with firefighters and a sanitary and epidemiological station.

Do not forget that you need a license to get a permit is not difficult, since tires are non-hazardous materials (4th group). But the catch is that your production officially pollutes the atmosphere. Most likely, you will be asked (forcibly) to buy a treatment plant. Its price is usually several times higher than the entire plant. But there are several ways that will help you delay the purchase for a certain time. Experts say that it is not advisable to open an enterprise for the processing of any one material. Like it or not, decide for yourself. In any case, you can always expand your workshop and melt glass, plastic or metal there. According to statistics, 75% of entrepreneurs encounter environmentalists who are wary of this kind of production.

A few important details

As noted a little above, you will encounter the fact that the item "contingencies" will appear in your business plan. This is due to the fact that it will be necessary to resolve issues with environmentalists and firefighters. For example, to store fuel oil in new tanks, only a protective shield is needed, but used tanks require additional protection. There are special lines for fuel and gas, and fire safety instructions for personnel, and much more. In any case, you need to have a reserve in your budget of several hundred thousand rubles. This will save you a lot of trouble. The expense items are quite large, but we have already considered them, and you probably know what you will be dealing with.

Do not forget that you, as a manager, must not only observe how your employees work, but also perform a number of other equally important tasks. Among these: the constant development and growth of the boundaries of the enterprise, accounting and tax accounting, as well as the adjustment of goals and plans for the near future. In this article, one important point was not mentioned - advertising your product. There are several options here. One of them is to create your own thematic site where you can offer fuel oil, etc. Nobody has canceled ads on poles, stops and stands. Until now, this is a good and effective method to loudly declare yourself. In addition, for a nominal fee, you can rent a billboard and place your advertisement there. By the way, you need to do it wisely. It is important not to overload with unnecessary information, but also to attract the attention of a potential audience.

Conclusion

So we talked with you about what tire recycling is and how to open such a business. As you can see, everything is quite simple, but there are a lot of important points. Sometimes it happens that it is difficult to find a supplier, or the latter refuses to just give away old tires and demands money for them. In principle, you can find another, more acceptable enterprise, where they will only be happy to get rid of excess garbage, and they will even give you money for the road. Sometimes it makes sense to conclude a full-fledged long-term supply contract. So you can eliminate downtime for your business and increase income. But all these points should be discussed directly with the supplier. Remember that it is much more difficult to find a point of sale for tires than a businessman who is ready to buy this garbage. This is due to the fact that in some cities there are no tire recycling reactors at all.

If you get good fuel oil, then aim at city or private boiler houses. There you will be happy to purchase fuel, which is vital for heating water. If you are going to get crumb rubber, then you will need a machine that costs about 500,000 rubles. The cost of electricity per 1 ton of products - 90 kW. The disadvantage of this approach is that a group of knives (40 pieces) wears out after processing hundreds of tires, so they often need to be changed. In principle, for one knife you need to pay only 30 rubles, which is relatively little. So, a unit with a capacity of 20 tires per hour pays off in about six months. The results are the same as in the production of fuel oil. But in the first case, there are fewer problems with environmentalists and firefighters, since we are not dealing with either waste into the atmosphere or liquid fuel. Well, in principle, and all on this topic. The most difficult thing is to start, and then it will be much easier.

It is hard to imagine modern world without 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, as they are highly flammable and do not naturally decompose. Currently, only 20% of old tires are recycled. Therefore, this type of activity is very relevant, especially for large cities, so this is a good and modern business idea.

Why recycle old tires? In addition to the disposal of environmentally hazardous human waste products, 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, 400 kg of finished raw materials can be produced. During processing, about 30-40% of raw materials give pyrolysis oil, which is used in boiler houses. Having processed pyrolysis oil, we get high-quality fuel oil, diesel fuel, gasoline.

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

To organize this activity, it is necessary to find a suitable area 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, a warehouse for finished products.

Of the equipment, it will be necessary to purchase a plant for grinding tires (hydraulic shears), a reactor - a pyrolysis plant, and tanks for the resulting products. The reactor is installed in an open area. It is possible to process 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 specifications and varies from 1 to 10 million rubles. More expensive installations allow not only to obtain pyrolysis oil from recycled tires, but also process it further into diesel or gasoline distillate. Also, the plants are distinguished by their processing capacity - 5-20 tons per day.

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

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