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SMB ENVIRONMENTAL PROJECTS PVT. LTD.

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PROJECT REPORT
;6LL: INTE RATE8 10 MTP8 T:RE P:ROL:SIS PROJECT ;OR CONVERSION O; SCRAP T:RES INTO !I ! RA8E ;6RNACE OIL < LI !T SPEE8 8IESEL OIL

+,-./e Re010l"(2 Re(e#-3le E(e%21 P%o4e0/5

RE6SE 7 RE86CE 9 REC:CLE


1 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


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I=

INTRO86CTION

The present Project is centered on a Breakthrough Technology to turn a potentially hazardous waste product, namely, waste rubber and scrap tyres, into valuable I !"#T$I%& '"(&, called Pyro !iesel ) 'urnace *il, which is a high+grade substitute ,or 'urnace *il and &ight !iesel *il -&!*./ This is one o, the ,irst Integrated Plant 0on,igurations with an %uto+,eeder and a #emi+continuous Pyrolysis $eactor1 0arbon Black 'ine 2illing #tation and an %sh $emoval #ystem ,or the 0arbon Black/ This cutting edge Plant 2achinery &ine is available at a most reasonable price/ Problems associated with uncontrolled or illegal waste rubber dumping and scrap tyre disposal and burning are now a thing o, the past3 1.1 Raw Ma e!ial Availa"ili #$ The scrap tyre generation in industrialized countries is appro4imately, one Passenger+car Tyre (5uivalent -PT(., at the rate o, 67 lbs/, or 8 kg per person per year/ It is estimated that 6 to 9 billion scrap tyres are stockpiled in illegal or abandoned piles throughout orth %merica, (urope, and 2iddle (ast3 In India, with the e4ploding %utomobile industry dimensions, it is sa,e to assume scrap tyre piles are growing to the e4tent o, &akhs o, tons per annum/ #crap tyres are available in abundance in the 2iddle (astern countries, and their import as cut pieces is ,reely allowed by the :ovt/ o, India ,or certi,ied industrial end users/

% 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


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It is estimated that annually, about a 2illion Tons - about ;7 &akh Tons. o, scrap tyres are available in India, and this ,igure is increasing in leaps and bounds as the vehicle numbers in the passenger, commercial and industrial sectors in India too are catching up to the <estern levels3 (arlier there was one car ,or every =77 households -upper 2iddle 0lass./ the other generating scrap tyre waste/ ow, ,or every -above lower 2iddle 0lass. household, there is a vehicle o, one description or 'urther, the ,amous India Tyre $etreading Industry is virtually closed now, since the retreading is out o, the vehicle user>s ethos these days/ Thousands o, tons o, scrap tyres are available to be organized through a network o, scrap tyre pickers and scrap dealers in India at economically viable rates/

L"/e%-ll1 >o$(/-"(. o' .0%-& /1%e. -%e l1"(2 -%o$(* "( 6SA < E$%o&e < ME 0o$(/%"e.?

3 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


Cell No : +91 98602 40852, 96650 40852, 96650 40852, 96855 75970 PIONEERIN REEN TEC!NOLO IES V"e# o$% &%o'"le o( l"()e* "( : http://www.linkedin.com/profile/view?id=180359047&trk=ta !pro

1.% &'e ()!a* #!e 'ea* i( a +o(,ui o "!eeding g!ound$

The second problem o,ten caused by illegal tyre piles involves disease carrying mos5uitoes, which tend to breed in great numbers in the protected water puddles o, the tyres/ (specially in areas with warmer climates mos5uito+borne diseases like encephalitis and dengue ,ever have been reported around large tyre piles ???Gene!al -n.o )on inue( //

II= ;6LL: INTE RATE8 P:ROL:SIS TEC!NOLO ::


Pyrolysis o, waste tyre rubber consists o, controlled+temperature catalytic de+polymerization, in the absence o, o4ygen, that is, wi 'ou (+o0e and "u!ning, to obtain a valuable ,uel oil called Pyro !iesel *il -P!*./ The rubber char remaining as a residual byproduct is called carbon black, which is also a very use,ul industrial raw material in great demand, provided its 5uality parameters are properly upgraded, which is done in our technology/ Pyrolysis process is the thermal decomposition o, organic materials in an o4ygen+,ree environment and is an endothermic reaction/ It re5uires an input o, heat energy, pressure and pre+determined temperature depending
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on the organic material to be pyrolized/ Pyrolysis process has phases and in each phase di,,erent decompositions originate1 there,ore, di,,erent products -steam, gas, oil, etc/. are obtained/ Phases o, the process are determined by the process temperature1 pressure, duration, and the variety o, organic materials to be processed -scrap tyre, plastic bottles, medical waste, etc/./ %.1 Saleien 1ea u!e( o. 'e *!o)e(( and o*e!a ion($ ////////#alient 'eatures and other details continues//////

%.%.1

2uali # o. 1u!na)e 3il *!odu)ed .!o+ 'e *#!ol#(i( *!o)e(($

4 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


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C5ARAC&6R-S&-CS 31 3-7 PR38UC68 P!o*e! ie( !ensity, gm ) cc 'lash Point, deg 0 A P200, min Pour Point/ !eg 0, ma4 Din Eiscosity 0# F G7 deg/ 2a4 #ul,ur, Total/ H by weight, 2a4 #ediment, H by weight, ma4 :ross 0al Ealue, D 0al ) Dg %sh content, H by weight, ma4 <ater content, H by Eol, 2a4 9alue 7/8@;6 B7 C9 9@ ;/;B 7/76 ;7;7; 7/7; I 7/7=

The ,urnace oil meets all the speci,ications as per I#I ) B# and is a valuable ,uel readily saleable in the industrial market at prices ranging between $s/ G=,777 to =7,777 per tonne/ %.%.% 2uali # o. Ca!"on Bla)0 *!odu)ed .!o+ P#!o *!o)e(($

: 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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P!o*e! ie( %bsorption, cc ) ;77 gms #ur,ace %rea, 26 ) gm PK value Keating &oss, H ma4 %sh 0ontent, H ma4 %vg Particle size, micron

9alue BJ @J 8 ;/= ;7 677 A G77 mesh

This is also a valuable industrial intermediate product, used in the ,ollowing industriesL 0able Macketing 0onveyor N 0areer bands Black ylon bags

Kose and !oormats


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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


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$ubber %dditive %utomobile #pare parts Black colorant in rubber Plastic pipes 'ire 'ighting

//..P!o)e(( de ail( and 'e .a)ili ie( )on inue/.. P'o og!a*'( o. a .ew i+*o! an e,ui*+en o. 'e (#( e+$ REACTOR 6NIT

8 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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OIL CON8ENSATION < SEPARATION

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SMB ENVIRONMENTAL PROJECTS PVT. LTD.


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CARBON BLAC@ EATRACTION < CONVE:OR S:STEM

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---. PR3=6C& -MP76M6N&A&-3N SC568U76$ BAR C5AR& >AS&6 &?R6 @ 3-7 PR3=6C& -MP76M6N&A&-3N

*+, -.+,/ 01, /.2 P31 P,142-/ 5MP62M27/+/517


Mon h 8 +c ivi % 1 Prelimin#r% #c ivi ies #$ -omp#n% 0orm# ion b$ 9i"nin" o: pl#n m#chiner% s)ppl% con r#c c$ Prep#r# ion o: 3P, ;$ 9)bmission o: lo#n ;oc)men # ion o *#n<s 2 6#n; p)rch#se or le#se 3 6#n; ;evelopmen = in:r#s r)c )re >po'er = '# er? 4 Projec #ppr#is#l = lo#n s#nc ion 5 *)il;in" cons r)c ion 6 Pl#cin" o: or;ers :or #)@$eA)ipmen = :#bric# ion 'or< 7 ,eceivin" o: Pl#n m#chiner% # si e 8 ,ecr)i men o: projec personnel 9 2rec ion = commissionin" 10 -ommerci#l Pro;)c ion 1 2 3 4 5 6 7

11 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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-9.

MANP3>6R A 3RGAN-BA&-3N C5AR&$

OR GAN IZATION CHAR T M AN AGIN G D IR ECTOR P LAN T M AN AGER /EN GIN EER SHIFT SUP ER VISOR S SKILLED ELECTR ICIAN S SKILLED FITTER S SEM I- SKILLED W OR KER S W ATCH & W AR D

It is estimated that a total o, ;7 persons are re5uired to run this plant based on 6 shi,t semi+continuous operations/ %lso an e4perienced gang o, operating personnel is being pre,erred nowadays, which is taking up the operating contract F $s/ B to J,777 per batch and can give as many as 6= batches in a month/ #o the manpower cost e4cluding the company supervisor and
1% 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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accountant shall be app4/ $s/ 6G &akh per year/ %dd $s/ @ &akhs ,or company manpower/ #o the yearly e4penses will be $s/ 97 lakhs/

9.

6nvi!on+en al A So)io@6)ono+i) Bene.i ($

4.1 P!even ion o. MaCo! 6nvi!on+en al Pollu ion The details will be covered in a !P$/ 4.% Advan age( o. 'i( *!oCe) .o! 'e envi!on+en $ The present project has a major advantage above any other technology in protecting the environment as described herein/ 4.%.1 No 6D'au( ga( i( le ou o *ollu e 'e ai!

'ull combustion in water seal and gas burner with sa,ety devices, the pollution to e4haust gas is eliminated and a large amount o, ,uel shall be saved/ The gases shall be either stored ,or ,urther use in process or shall be burnt in a incinerator cum scrubber, pre treated in wet scrubber be,ore discharging to atmosphere/ 4.%.% No >a( e li,uid e..luen i( le ou o *ollu e wa e! A (oil

'aint acidic waste water will be produced in the course o, treatment o, oil products -about =7 kg o, waste water per ton o, oil./ This water is neutralized by passing through a wet scrubber and evaporated in a specially designed evaporatoer cum gas burner system/ 4.%.3 No >a( e (olid( a!e du+*ed a( land.ill
13 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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The residue le,t ,rom catalysis and split o, waste tires is only carbon black, which is a use,ul industrial raw material and saleable product/ 4.3 Con(e!va ion o. 9alua"le 1o!eign 6D)'ange &ight #peed !iesel *il - &!* . and Industrial 'urnace *il -I'*. is mostly an imported commodity or imported crude based derivative/ Kence, the production o, P!* will save ,oreign e4change out,low/ 4.4 Ru!al 8evelo*+en S i+ula o! $ecovered &!* N I'* being suitable ,uel oils ,or rural pump sets and gen+sets, will help in mitigation o, the su,,erings o, the ,armers, who su,,er heavy power cuts throughout the year/ 5.4 #pecial 'eatures o, this project vis a vis (nvironmental ProtectionL

????/#pecial ,eature continues??/

VI= PROJECT PRO;IABILIT: < ;INANCIAL ASPECTS


:.1 -n( alled )a*a)i # o. 'e P#!ol#(i( Plan $ 10 M&P8 E 8 &onne( *e! Ba )' F :.% P!odu) ?ield a/ &ight !iesel *il ) 'urnace *il F G7 H o, 6G77 Tonnes o, tyres -#p :ravoty o, *il is taken as 7/8@. b/ 0arbon black+ Ki+:radeL L 8@7 D& p/a/

F 97H o, ,eed L B67 2T p/ a/

-slightly variable, subject to ,raction o, carbon black puri,ied. c/ #teel scrap F ;6 H L 6JJ 2T p/ a/

14 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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Cell No : +91 98602 40852, 96650 40852, 96650 40852, 96855 75970 PIONEERIN REEN TEC!NOLO IES V"e# o$% &%o'"le o( l"()e* "( : http://www.linkedin.com/profile/view?id=180359047&trk=ta !pro

-variable, subject to ,raction o, radial tyres in the scrap. :.3 P!odu) (elling *!i)e($ a/ Industrial 'urnace oilL b/ 0arbon blackL $s/ G7 per liter $s/ = per kg -could be much higher, i, pelletized as ,uel . c/ #teel scrapL d/ $aw material costL :.4. ?ea!l# !evenue( $s/ ;= per kg -variable. $s/ ;7,777 per 2T $ <:0 D 40,000 G ;%0 D 4000 G %88 D 14000 H R(. 4,:3,%0,000 // A

:.4.

6( i+a ed

6D*endi u!e *e! #ea!$ O O O $s/ ;=,77,777 $s/ 97,77,777 $s/ 6,G7,77,777

@/=/; L 0ost o, PowerL G7 KP N utilites like ,uel etc/ @/=/6 L 0ost o, 2anpower @/=/9 L 0ost o, $aw 2aterials @/=/G @/=/=

$ent ,or the land and shed F $s/ 6=,777 per month O $s/ 9,77,777 :en (4penses like phone, courier, travelling, postage, pollution control testing etc/ O $s/ @,77,777

14 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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Cell No : +91 98602 40852, 96650 40852, 96650 40852, 96855 75970 PIONEERIN REEN TEC!NOLO IES V"e# o$% &%o'"le o( l"()e* "( : http://www.linkedin.com/profile/view?id=180359047&trk=ta !pro

&o al 6D*endi u!e E 3*e!a ing 6D*en(e(F @/@ 6( i+a ed P!o.i Ma!gin *e! #ea! E "e.o!e aDe(, du ie( A de*!e)ia ion F

R(. %,<4,00,000 ..B

AB

R(. 1.4% )!o!e( :.: C3S& 31 PR3=6C&$ :.:.1$ Ca*i al Co( E >ill >o!0 ou in 'e 8PR F a( i de*end( on 'e

.a)ili ie( o "e in)luded in 'e *!oCe) . + + 0ost o, &and - Taken on a &ease. 0ost o, Plant N 2achineries O il

O $s/ PPPPPP lakhs O $s/ PPPPPP &akhs +++++++++++++++++++++++++++++++++++++++++

+ 0ost ,or Pre+project activities

&o al Ca*i al Co(

H +++++++++++++++++++++++++++++++++++++++++++

+@/@/6L <orking 0apitalL + + + Investment in B days raw materialsL B 4 J 4 ;7,777 O O =,@7,777 =,77,777

#alary N <ages ,or 6 monthsL 97 4 6 ) ;6

'uel, utilities N other running e4penses A ; month O 6G);6 O 6,77,777 &o al >o!0ing Ca*i al !e,ui!e+en H R(. 1%,:0,000

1: 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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;.0

Ma!0e ing Po en ial$

'urnace *il is in short supply/ It is a commodity o, daily consumption ,or a large number o, industries and hence, very easy to sell/ 2oreover, it is a cash N carry business/ Ki+grade re,ined 0arbon black produced in our plant ,etches good price even without re,ining and also easy to sell at ,actory doorstep/

1; 13 / 14, Seva Sadan Building, CA Road, NAGPUR 440 018 ,

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