Republic of the Philippines

PALAWAN STATE UNIVERSITY

College of Engineering, Architecture, and Technology
Puerto Princesa City

Plant Design Optimization for a Continuous Waste Tire Pyrolysis Plant

in Laguna International Industrial Park (LIIP), Biñan, Laguna, Philippines

In partial fulfillment of the

Requirements for the course subject
of Pet41 DS5 Plant Design for PetE

Submitted by:
Lacsi, Vince Jerich S.
Paduga, Maria Nicole Beatriz A.
Sepida, Alliza Niña G.
Siozan, Dazyl Jhez

Submitted to:
Engr. Philip Ryan Maigue

November 2023
 Table of Contents
CHAPTER 1 ........................................................................................................................1
Introduction and Background of the Study ......................................................................3
1.1 Introduction ................................................................................................................3
1.2 Source of Raw Material .............................................................................................3
1.3 Process Plant Product .................................................................................................6
1.4 Demand and Supply Study .........................................................................................6
1.4.1 Demand Forecast ................................................................................................6
1.4.2 Supply Forecast ..................................................................................................7
1.4.3 Market Gap .........................................................................................................7
1.5 Design Objective ........................................................................................................6
1.6 Brief Discussion of the Plant Process ........................................................................6
1.7 Location ......................................................................................................................6
1.8 Definition of Terms ....................................................................................................6
CHAPTER 2 ........................................................................................................................1
Process Design Layout ........................................................................................................3
2.1 Block Diagram ...........................................................................................................6
2.2 Process Flow Diagram ...............................................................................................6
2.3 Pipping and Instrumentation Diagram .......................................................................6
2.4 Plant Layout ...............................................................................................................6
2.5 3D Plant Simulation ...................................................................................................6
CHAPTER 3 ........................................................................................................................1
Technical Aspects ................................................................................................................3
3.1 Raw Material Specification ........................................................................................6
3.2 Equipment Functions and Specification .....................................................................6
3.3 Material Balance ........................................................................................................6
CHAPTER 4 ........................................................................................................................1
Economic Study and Analysis ............................................................................................3
4.1 Direct Cost .................................................................................................................6
4.2 Indirect Cost ...............................................................................................................6
4.2.1 Fixed Cost ..........................................................................................................6
4.2.2 Variable Cost ......................................................................................................7
4.3 Cost Price and Selling Price .......................................................................................6
4.4 Cash Flow ...................................................................................................................6
CHAPTER 5 ........................................................................................................................1
Environmental and Safety Aspects ....................................................................................3
5.1 Environmental Consideration .....................................................................................6
5.1.1 Control Measures for Greenhouse Gases Emission ...........................................6
5.1.2 Water Pollutants Prevention and Control Measures ...........................................6
5.2 Health Consideration ..................................................................................................6
5.3 Safety Consideration ..................................................................................................6
5.4 Waste Management ....................................................................................................6
CHAPTER 6 ........................................................................................................................1
Project Execution Planning ................................................................................................3
6.1 Project Planning Flow ................................................................................................6
6.2 Construction Timetable ..............................................................................................6
 6.3 Critical Pathway Analysis ..........................................................................................6
6.4 Gantt Chart .................................................................................................................6
CHAPTER 7 ........................................................................................................................1
Summary of Findings, Conclusion, and Recommendation .............................................3
7.1 Summary of Findings .................................................................................................6
7.2 Conclusion ..................................................................................................................6
7.3 Recommendation ........................................................................................................6
References ............................................................................................................................3
Appendices ...........................................................................................................................3
Organizational Chart ..........................................................................................................3
 List of Figures

Figure 1. Satellite View of the Proposed Plant Location .......................................................3

Figure 2. A schematic block diagram of the Continuous Waste Tire Pyrolysis Process .......3
Figure 3. A process flow diagram of the Continuous Waste Tire Pyrolysis Process ............3
Figure 5. Pyrolysis Oil Supply Forecast in the Philippines from 2025-2040 ........................3
Figure 6. Market Gap from 2025-2040 ..................................................................................3

List of Tables

Table 1. Oil Product Demand Forecast from 2025 to 2040 ..................................................3

Table 2. Pyrolysis Oil Demand Forecast from 2025-2040 ....................................................3
Table 3. Oil Product Demand Forecast from 2025 to 2040 ...................................................3
Table 4. Pyrolysis Oil Supply Forecast in the Philippines from 2025-2040 .........................3
Table 5. Market Gap from 2025-2040 ...................................................................................3

List of Appendices
 CHAPTER 1

Introduction and Background of the Study

This chapter is crucial as it introduces the topic and the study's background. It delves into the
discussion of the reason for the selected plant design, offering a comprehensive exploration of
its intricacies to provide a foundational understanding of the areas essential to establishing a
good decision on the selection process.

1.1 Introduction

Every year, many tires are thrown away, making it increasingly unlikely that they will
be disposed of safely. In a journal article published by Scherer (2023), more than one billion
car tires reach the end of their life each year, and dealing with the resulting waste is an
escalating management headache worldwide. According to Kapilan et al. (2021), the purposes
of tires are to convey traction, bear the vehicle's weight, absorb imperfections in the road, and
offer stability and control. In 2013, around 16,037 discarded tires were directed towards
recycling, recovery, and reuse efforts. In the subsequent years, specifically 2014 and 2015, the
documented quantities of waste tires designated for recycling, energy recovery, and reuse
initiatives were 31,448 and 71,806, respectively, reflecting a notable increase in these numbers
over the years (Nkosi 2020). However, almost 1.5 billion tires are wasted annually after their
end-of-life, which tends to increase to 5 billion by the end of 2030. These would mainly be
disposed of in landfills, burned, or stockpiled, producing various environmental issues like soil
and air pollution and harmful substances (Moasas et al., 2022). Most countries already
established a concrete plan on tire waste management. For instance, South Africa has
established an effective system to repurpose waste tires across diverse markets. This includes
allocating 25% for reuse, 23% for cutting and shredding to create spongy mats or playground
materials, 18% for conversion to oil and carbon black via pyrolysis for various applications,
and 16% for incineration to produce energy in cement or brick manufacturing kilns. However,
approximately 18% of the waste tires are still directed to landfills, a significant percentage that
emphasizes the need for further efforts to repurpose these tires. Unfortunately, the Philippines
have not yet established a concrete plan. Waste tires are seen as an undervalued resource
worldwide, and their sheer bulk is used to dispose of them in landfills, posing a significant
problem. Utilization, rather than disposal of waste materials after recycling, can have a
considerable impact. In recent times, it has become more common to remove steel fibers from
used tires (Moasas et al., 2022).

Moreover, several authors have extensively examined the characteristics of tires, waste
tire pyrolysis, and the various primary and valuable secondary products associated with this
process. Muzenda (2014) provided a comprehensive account of the thermochemical processes,
such as pyrolysis, gasification, and liquefaction, that waste tires can undergo. Rodriguez
(2001), Islam (2010), and Williams (2013) elaborated on waste tire pyrolysis in detail,
exploring the diverse products resulting from this process. Parthasarathy et al. (2016) delved
into the impact of process conditions on waste tire pyrolysis product yield. Laresgoiti et al.
(2000) critically analyzed the gases obtained in tire pyrolysis; Cunliffe (1998) and Williams
(2013), as well as Islam et al. (2008), assessed the composition of oils from tire pyrolysis. Shah
et al. (2006) examined waste tire-derived black as an adsorbent. These referenced works have
significantly contributed to the proponents’ comprehension of the chemistry involved in waste
tire pyrolysis, the quantity and quality of final products, and potential markets and applications.
 The primary focus of this paper is to evaluate the economic feasibility of operating a
waste tire continuous pyrolysis plant, aiming to produce high-value primary and secondary
final products. Such an initiative holds the potential to effectively address the Philippines' waste
tire challenges and promote energy and material recovery, thus fostering socioeconomic
development.

1.1.1 Waste Tire Pyrolysis Product Compositions, Characteristics, and Application

During the process of waste tire pyrolysis, different components are obtained. This
includes gases that cannot be liquefied, an oily substance mainly containing organic materials,
and a solid part consisting largely of carbon, metal, and other inert elements. Several factors
influence the makeup of these primary pyrolysis products during the process, such as the feed
size, temperature, pressure, time inside the reactor, how fast it is heated, and the reactor's
design. The type of reactor used significantly affects the product output, the gas and oil
characteristics, and various process parameters.

Various types of reactors are used in this process, each with its specific characteristics.
For instance, fixed-bed reactors are commonly employed for slower pyrolysis, resulting in an
oil yield of around 35% to 50%. On the other hand, fluidized bed reactors, used for fast
pyrolysis, produce oil yields ranging from 65% to 70%. Each reactor type has advantages, such
as the inclined design of a rotary kiln reactor that optimizes the processing speed and particle
size. In contrast, a stirred tank reactor is designed to process whole tires, reducing energy costs
associated with size reduction.

The gas produced from waste tire pyrolysis amounts to about 10–30% of the total
weight and has a heating value of approximately 30–40 MJ/Nm3. This pyrolytic gas, mainly
composed of methane and ethane, is similar in composition to natural gas but contains
substantial amounts of carbon monoxide, which limits its blending capabilities. The oil derived
from tires, constituting around 40–50% of the output, contains several valuable compounds
such as aromatics and various chemicals like benzene, toluene, and xylenes, which have diverse
applications in industries like chemicals, plastics, and synthetic fibers.

Moreover, this tire-derived oil can potentially be used as automotive fuel after removing
metal contaminants. Its calorific value is relatively high, comparable to diesel oil. The solid
residue, char, holds substantial energy potential and can be used as a coal substitute in various
applications. Carbon black derived from this process also finds applications in wastewater
treatment, ink production, and as a filler in manufacturing tires and other products. The steel
wire obtained from pyrolysis can be commercially viable with minimal rubber contamination.

1.1.2 Waste Tire Pyrolysis in the Philippines

Similarly, the Philippine government passed the "Ecological Solid Waste Management
Act of the Philippines," or RA 9003, in 2001 to mandate local government entities to set
required goals for garbage recovery, recycling, reuse, and reducing waste at the source.
Moreover, in keeping with the same study by Kapilan et al., (2021), one of the best approaches
is to transform waste tires into fuel to boost their economic value. Thus, pyrolysis may be used
to turn waste tires into fuel. Furthermore, Olalo (2021) revealed that among several ways
(Oyedun et al., 2014; Idris et al., 2021), pyrolysis represents the most advantageous approach
for the direct recovery of energy from waste plastic, based on the techniques and methods
created from the energy recovery process. In addition, pyrolysis has emerged as a viable
solution to the waste and biomass management dilemma, one that may both provide economic
advantages and reduce the harmful consequences of waste on the environment (Afash et al.,
2023).

From an economic perspective, the pyrolysis procedure's end-products are

substantially less expensive than their market value. While, in terms of the energy recovery
method, the benefits of the pyrolysis process include lower maintenance and operating
costs (Ayanoglu and Yumrutas, 2016; Olalo, 2021; Huijbregts et al., 2008). Ultimately,
pyrolysis is considered as an environmentally beneficial waste processing method (Pyrolysis
Plant in the Philippines - Recycling Tire/Rubber/Plastic/Oil Sludge, 2022).

1.2 Source of Raw Material

Waste Tire

Tires are complicated constructions that need precise manufacturing methods in order
to produce compounds that are durable enough for regular usage on various road conditions.
Furthermore, it is frequently utilized in a variety of applications, such as automobiles,
motorcycles, bicycles, and aircraft. Tires have several purposes, including carrying the weight
of the vehicle, absorbing imperfections in the road, supplying stability and control, and
transferring traction (Kapilan et al., 2021). Similarly, according to Kapilan et al. (2021), tires
are made up of around 45% rubber or elastomer, 22% carbon black, 18% metal, 7% additives,
7% textile material, 2% zinc oxide, 1% sulfur, and other materials.

The compound is composed of several elements; thus, a typical car tire contains about
60 raw materials (Lindenmuth, 2006). The following are the composition of the compound:

Elastomers: These are materials that, once under stress, may regain their previous size and
shape, even if they have been severely distorted (Campbell, 1963; Mark, 1943). They are
distinguished by having a low elastic modulus and mostly amorphous structure. Lastly, they
can endure significant deformations before breaking.

Carbon black: A product of incomplete combustion of heavy oil, such as tar or fossil tar, from
ethylene cracking (Clarke, 2014a). It has a high surface/volume ratio and includes a low
amount of PAH (polycyclic aromatic hydrocarbons). It is used both as a pigment and as a filler
for reinforcement. It assists to heat dissipation, therefore improving the life of the tire.

Silica: In the form of fumed silica. When used as a filler, it raises the viscosity. Additionally,
it ensures less rolling friction than carbon black (Clarke, 2014a). This guarantees improved
wet grip and reduced usage.

Antiozonants: These chemicals are designed to prevent or reduce the degradation and cracking
produced by ozone, an allotropic form of oxygen found in the environment (Ozone damage
tests, 2010).
Antioxidants: Materials with wax. They stop oxidation, which stops the tire from
deteriorating from exposure to oxygen and UV light.

Plasticizers: These are substances that alter the compound's inherent characteristics, such as
its malleability, flexibility, density, tensile strength, or adhesiveness.

Vulcanizing agents: these substances change rubber from an elastic substance to a plastic one
during the vulcanization process. For both natural and many manufactured forms of rubber,
sulfur is the most often utilized chemical (Niyogi, 2007b). When it comes to some elastomers,
agents other than sulfur are combined, such as metal oxides, difunctional compounds, or
peroxides (Niyogi, 2007b).

Accelerators: They quicken the process of vulcanization. If they were not there, the procedure
would take five hours at 140 °C to finish (Niyogi, 2007b). Aldehyde-amines (also used as a
secondary plasticizer), guanidines, benzothiazoles, sulfenamides, dithocarbamates, thiurams,
xanthates, and morpholins are the main accelerators utilized in the vulcanization process with
sulfur (Niyogi, 2007b).

Activators: They speed up the vulcanization process by activating accelerators. There are two
categories of activators: inorganic and organic. Zinc oxide, hydrated lime, litharge, red lead,
white lead, and magnesium oxide are examples of inorganic activators. Usually, inorganic and
organic are utilized in tandem. According to Niyogi (2007b), they are mostly monobasic fatty
acids or mixes of the following: hydrogeneated oils from palm, castor, fish, and linseed oils;
and stearic, oleic, lauric, palmitic, and myristic acids.

Retarders: They keep the product from scorching during manufacturing and from pre
vulcanizing during storage. They function by bringing the compound's pH down, and they are
ineffective at vulcanization temperatures.

1.2 Process Plant Product

Pyrolysis is a thermochemical technique that can help with material recovery, energy
shortfalls, and the rising waste tire issue by turning waste tires into fuel-grade pyrolysis oil
(Nkosi et al., 2020). Chang (1996) further regarded pyrolysis as an energy and resource
technique that may be used to recover fuel or usable chemical material from solid waste, with
the primary goal being energy conservation. At normal temperatures, the primary byproducts
of the pyrolysis process may be loosely divided into three phases: gas product, liquid oil, solid
residue, or char. In addition, pyrolysis is the process by which big complex molecules are
broken down into smaller ones. Its product has three main categories: 1. Liquid (water, tars,
and heavier hydrocarbons) 2. Solid (mostly carbon or char) 3. Gas (e.g., CO2, H2O, CO, C2H2,
C2H4, C2H6, C6H6).

Steel Wires

According to Britannica, steel is an alloy composed of iron and carbon, typically

containing less than 2% carbon and 1% manganese, as well as small amounts of silicon,
phosphorus, sulfur, and oxygen. Steel is a versatile and highly valuable material used in
various applications, such as engineering, construction, transportation, and medical equipment,
as reported by the World Steel Association.

According to a study published in Waste Management titled “Pyrolysis of waste tires:

A review,” waste tire pyrolysis is a process that mainly produces valuable products like
pyrolysis oil and carbon black. Although steel wires are not a direct end product of this process,
they are usually extracted from the tires during pre-processing stages and recycled separately.
Recycled steel wires are highly valuable due to their versatile applications across various
industries, including construction, manufacturing, and other essential sectors. This contributes
to the production of sustainable construction materials and enhances resource efficiency (Habib
et al., 2017).

Pyrolysis Oil: Light and Heavy Oil

Another end-product of pyrolysis is liquid which includes bio-oil, tar, or biocrude,

which is a black tarry fluid containing up to 20% water that consists mainly of homologous
phenolic compounds (Basu, 2018).

Oil is a general term that describes a wide variety of natural substances of plant, animal,
or mineral origin, as well as a range of synthetic compounds (Fingas, 2011). According to a
research article published in the Journal of Oleo Science titled “Characterization of Heavy Oils
and Asphaltene Precipitates by High-Resolution Mass Spectrometry,” oils typically contain
varying amounts of sulfur, nitrogen, oxygen, and sometimes mineral salts, as well as trace
metals such as nickel, vanadium, and chromium (Nakashima et al., 2016). However, its
properties include viscosity, density, specific gravity, solubility, flash point, pour point,
distillation fractions, interfacial tension, and vapor pressure.

Meanwhile, the intended outcome of waste tire pyrolysis is tire pyrolysis oil, or TPO,
in brief. It is a product formed by condensing the oil gas degraded by the high-temperature
method. The oil is commonly used as an industrial fuel to replace furnace oil or industrial
diesel. The process of converting waste tires and rubber into oil can yield anywhere between
35% to 50% of pyrolysis fuel oil, meaning that 10 tons of waste tires can produce
approximately 3.5 to 5 tons of fuel oil. However, the yield of waste tire pyrolysis oil can vary
depending on the type of tire being used. For instance, the oil yield from big car tires, truck
tires, and OTR tires ranges between 45% to 52%. On the other hand, the yield from small car
tires, motorcycle tires, and bicycle tires is around 35% to 40%. Rubber cable sheaths and soles
have an oil yield of about 35%, while all kinds of rubber sheets or carpets have a yield of 30%.
Unclassified rubbers generally have an oil yield of approximately 35% (Arnion, 2022).

Light oil, also known as distillate fuel, is a type of petroleum product that has a
relatively low molecular weight and a lower boiling point compared to heavier oils. It is a
clean-burning fuel that does not produce smoke when used in properly maintained appliances
(Bachu, 2013). According to Zhang et al. (2017), light oil is one of the major products obtained
from waste tire pyrolysis. The process involves the thermal decomposition of tires in an
oxygen-free environment, leading to the breakdown of complex hydrocarbons to simpler
compounds, resulting in the formation of gases and liquid fractions. The light oil fraction,
which contains lower molecular weight hydrocarbons, is then separated and collected through
fractionation. This fraction has a wide range of applications in various industries, including as
fuel for diesel engines, as a feedstock for the production of chemicals, and as a source of energy
(Zhang et al., 2017). This process helps in reducing waste generated by tire disposal and
contributes to resource recovery. Light oil derived from waste tire pyrolysis is a versatile
resource, serving as a valuable fuel for heating, power generation, and as a feedstock for
chemicals. Its use in energy production helps in diversifying energy sources, reducing reliance
on traditional fuels, and promoting resource efficiency by repurposing waste tires. Embracing
light oil contributes to waste reduction and aligns with sustainability goals, creating
opportunities in the growing market for recycled products.

According to Speight (2007), heavy oil is a general term used to describe hydrocarbons
with higher molecular weights. These types of oils are typically more viscous and denser than
lighter oils, such as crude oil or lighter fractions produced through refining processes. In
general, heavy oil contains moderate-to-high levels of asphaltene constituents and low levels,
if any, of paraffin constituents (straight-chain alkanes). Similarly, in waste tire pyrolysis, heavy
oil is created by the heat degradation of tires in the absence of oxygen. Tires are heated, organic
materials are broken down into a mixture of hydrocarbons, and heavier oil fractions are
condensed throughout this process (Banar et al., 2020). The potential of heavy oil as a fuel
source for industrial uses is what makes it significant. Pyrolysis-derived heavy fuel oil may be
utilized in power generation, heating systems, and other industrial operations, therefore
promoting resource efficiency and energy output. Adopting heavy oil from waste tire pyrolysis
corresponds with sustainability goals since it converts a waste stream into a useful resource,
decreasing environmental impact and promoting a circular economy.

Carbon Black

According to Han et al. (2023), carbon black is an ultralight, fine black powder with a
density of 1.79 g/cm3, which is formed through the incomplete combustion or thermal
decomposition of carbon-containing substances such as coal, natural gas, heavy oil, and fuel
oil. The structure of carbon black is paracrystalline. The short-range and medium-range
ordering of a paracrystalline structure is similar to that of a liquid crystal. However, there is no
such thing as long-range ordering. As a result, the substance is neither entirely crystalline nor
entirely amorphous.

With its qualities and attributes, carbon black finds significant use in a wide range of
applications. The primary uses of carbon black are in the rubber manufacturing sector as well
as in non-rubber sectors such as coatings, inks, and plastics. One may argue that the
manufacture of rubber uses roughly 90% of carbon black, primarily for tires and mechanical
rubbers like hoses and automobile belts. The rubber material’s performance and longevity are
enhanced by the reinforcing qualities of carbon black (Carbon Black Properties and
Applications, n.d.).

On the other hand, waste tire pyrolysis is a process that involves heating tires in the
absence of oxygen, resulting in the production of carbon black as a solid byproduct. According
to Rahimi and Omidvarborna (2021), this process typically converts approximately 20-35% of
the tire weight into carbon black. Carbon black is an essential component in the rubber industry,
playing a crucial role in enhancing the mechanical properties of rubber. It constitutes a
significant portion of the global carbon black market, which was valued at over $17 billion in
2020 and is expected to reach around $22 billion by 2026 (Grand View Research, 2021). The
significance of carbon black in tire manufacturing is undeniable, as it is used in the production
of tires, conveyor belts, and various molded and extruded rubber products. Moreover, carbon
black has various applications in the manufacturing of inks, coatings, and pigments,
contributing to its widespread demand and economic significance in multiple industries. The
recycling of waste tires through pyrolysis not only addresses environmental concerns but also
provides a sustainable source of carbon black for these applications.

1.4 Demand and Supply Study

1.4.1 Demand Forecast

The Philippines has been experiencing a series of oil price hikes from the start of 2022
until the beginning of the early month of 2023, with seven consecutive weeks of increases
recorded. This uptrend is attributed to factors, including inflation, rising oil demand, the
previous conflict between Russia and Ukraine, and the COVID-19 pandemic. The successive
oil price increases indicate a strong demand for certain supplies among the public, as the prices
of essential goods are also expected to rise due to inflation.
The Philippines is projected to face a significant surge in fuel demand in the coming
years. The Department of Energy (DOE) forecasts that fuel product demand will reach
approximately 56 million tons of oil equivalent by 2040. This growth is driven by population
expansion, economic progress, urbanization, and increasing vehicle ownership.

Table 1. Oil Product Demand Forecast from 2025 to 2040 (Philippine Energy Plan 2025-2040)

The table shows the numerical data of demand forecast for the Philippines from 2025
to 2040. It presents the demand gap and its increment per interval. This means the country will
need to import a significant amount of fuel to meet its demand.

According to the Department of Energy, pyrolysis oil is projected to account for

approximately 7% of the country's targeted demand for oil products from 2025 to 2040. This
growth is driven by increasing demand for transportation fuel and growing awareness of the
environmental benefits of pyrolysis oil.
 Table 2. Pyrolysis Oil Demand Forecast from 2025-2040 (Department of Energy- Philippines)

The table shows the projected demand for pyrolysis oil in the Philippines in million
barrels of oil equivalent (MBOE) from 2025 to 2040. The data shows that the demand for
pyrolysis oil is expected to grow significantly over this period, from 1.61 MBOE in 2025 to
3.31 MTOE in 2040. This represents a compound annual growth rate (CAGR) of 7.1%.

1.4.2 Supply Forecast

In light of the anticipated surge in fuel demand, it is imperative for the country to
proactively enhance its fuel production capacity to ensure that the forecasted demand is
adequately met. This proactive approach will safeguard the country's energy security and
prevent potential fuel shortages that could hinder economic growth and disrupt essential
services.

Several factors, including population growth, economic progress, urbanization, and

rising vehicle ownership, drive the increasing fuel supply. These trends strain the country's
energy resources, making it more vulnerable to global oil price fluctuations.

Table 3. Oil Product Demand Forecast from 2025 to 2040 (Philippine Energy Plan 2025-2040)

The table shows the number of supply forecasts for the Philippines from the year 2025
to 2040 to be able to suffice the significant number of demand forecasts. This means the country
will need to import a substantial amount of fuel to meet its demand.

Table 4. Pyrolysis Oil Supply Forecast in the Philippines from 2025-2040 (Department of Energy-
Philippines)
 The table shows the projected demand for pyrolysis oil in the Philippines from 2025 to
2040 in millions of tons of oil equivalent (MTOE). The data shows that the demand for
pyrolysis oil is expected to grow significantly over this period, from 1.43 MTOE in 2025 to
2.52 MTOE in 2040.

1.4.3 Market Gap

Despite the Philippines' adequate supply of oil products, there is still a need for
increased production to meet future demand and strengthen the country's import and export
capabilities, bolstering its economic standing and foreign exchange reserves in the global
market.

Oil products are crucial in various industries, particularly powering engines. As the
global economy expands and the use of fueling engines intensifies, the industrial sector is
expected to witness significant growth in the coming years, leading to a surge in global demand
for oil products.

Market growth is anticipated to be fueled by rising disposable incomes, increasing

travel preferences, and heightened product consumption. However, global market growth may
be hampered by fluctuating costs, competitive pricing of services across various products, and
intensifying industry rivalry.

Table 5. Market Gap from 2025-2040 (Department of Energy- Philippines)

The table shows a table of the projected demand and supply of oil equivalent in million
barrels of oil equivalent (MBOE) from 2025 to 2040, as well as the resulting market gap and
percentage market gap. The data shows that demand for oil equivalent is projected to increase
from 1.61 MBOE in 2025 to 3.31 MBOE in 2040, while supply is projected to increase from
1.43 MBOE to 2.52 MBOE over the same period. This results in a growing market gap, from
0.18 MBOE in 2025 to 0.79 MBOE in 2040. The percentage market gap is also projected to
increase from 11.18% in 2025 to 23.87% in 2040.

Through the data presented, Wire pyrolysis technology has the potential to play
a significant role in bridging the gap between oil product supply and demand in the Philippines.
This innovative technology can convert waste plastics into valuable products, including
synthetic oil, which can be used as a substitute for traditional petroleum-based oil products. By
utilizing wire pyrolysis, the Philippines can effectively reduce its reliance on imported oil,
enhance its energy security, and promote a more sustainable circular economy.
1.5 Design Objective

The proposed plant design aims to design and model a continuous waste tire pyrolysis
plant. It also aims to illustrate the production process of waste tire pyrolysis through a
comprehensive process flow diagram.

Specifically, the proposed continuous waste tire pyrolysis plant is intended to produce
the following end-products:

1. Steel Wire

2. Pyrolysis Oil:

• Light Oil

• Heavy Oil

3. Carbon Black

This design emphasizes the efficient production of these end-products through the
waste tire pyrolysis process, showcasing the diverse outputs that can be obtained.

However, this plant design holds significant merit for several reasons:

1. Resource Utilization: The process of waste tire pyrolysis is an eco-friendly

technique that converts discarded tires into useful products. This method helps in reducing
waste and optimizing the use of resources by repurposing an otherwise useless material into
something valuable.
2. Economic Viability: The waste tire pyrolysis process has economic benefits as
it produces Steel Wire, Pyrolysis Oil (Light and Heavy Oil), and Carbon Black, which have
multiple industrial uses in construction, energy production, and manufacturing. Due to this, the
plant becomes financially feasible as it can generate revenue from the sale of these valuable
end-products.
3. Environmental Impact: The waste tire pyrolysis plant plays a crucial role in
mitigating environmental pollution by recycling waste tires. This process helps to avoid the
disposal of tires in landfills, which can harm the environment due to slow decomposition and
possible leaching of harmful substances. Therefore, the plant significantly contributes to
reducing environmental pollution.

1.6 Brief Discussion of Plant Process

The tire waste pyrolysis process represents a thermal degradation method wherein
discarded tires undergo decomposition in a controlled, oxygen-deprived environment at
elevated temperatures. This process aims to break down the complex hydrocarbons in tires into
valuable by-products, including liquid fuel, gases, and solid residues, notably carbon black.
 Within a specialized reactor, the tire waste is subjected to high temperatures, prompting
the disintegration of its constituent compounds. The absence of oxygen in the reactor prevents
combustion and facilitates the production of three primary products.

The pyrolysis process generates a liquid product comprising a mixture of hydrocarbons,

the quality and composition of which are contingent upon factors such as temperature and
pressure. This liquid fuel has the potential for further refinement and application in diverse
industries.

Concurrently, the pyrolysis process yields gaseous by-products encompassing

hydrocarbon gases and steam. These gases have utility as sources of energy or can be channeled
back to fuel the pyrolysis process itself.

Following the pyrolysis, a solid residue known as carbon black remains. Carbon black
holds multifaceted applications, particularly in rubber manufacturing and as an additive in
producing new tires or other rubber-based commodities.

Tire waste pyrolysis is a promising approach in the recycling paradigm, offering a

means to alleviate environmental impact by repurposing discarded tires. However, successful
implementation necessitates stringent control and monitoring to ensure both the efficiency of
the process and its environmental sustainability.

1.7 Location

Plant location involves choosing the geographical area where people, resources, capital,
machinery, and equipment are brought together to establish a business or factory. The selection
of the plant's location is a critical decision influenced by economic factors and must consider
the desired production capacity. A plant serves as a hub where production costs are strategically
minimized to maximize profits. The ideal location should always optimize the net advantage
while minimizing unit production and distribution costs. The overall size of the plant includes
the land for production, employee housing, product storage, and the entire industrial site. Once
a plant is established at a specific site, it must carefully evaluate the advantages and
disadvantages of that initial decision, emphasizing the significance of plant location decisions.

The satellite image below provides an overview of the designated plant site, situated
within the Laguna International Industrial Park in Binan, Laguna, Philippines. The proposed
industrial lot spans 5,000 square meters. Notably, the CALABARZON region is identified as
a significant producer of waste tires, presenting an opportunity for sustainable waste
management solutions.

In both commercial and industrial sectors, there exists a considerable volume of

discarded tires. This waste material has prompted a noteworthy demand within the
CALABARZON Region. This proposal strategically aims to establish an economically viable
waste tire-to-fuel pyrolysis plant in Laguna. By converting waste tires into usable fuel through
the pyrolysis process, the initiative not only addresses environmental concerns associated with
tire disposal but also aligns with the growing demand for alternative fuel sources.
 Positioning the plant in the Laguna International Industrial Park offers logistical
advantages, leveraging existing infrastructure and contributing to the economic development
of the region. The 5,000-square-meter industrial lot provides a suitable footprint for the
proposed facility.

This endeavor is poised to be highly advantageous for the company, positioning itself
as a pivotal player in addressing the continuous demand for locally produced fuel in Laguna
and the broader CALABARZON Region. Beyond the economic benefits, the project holds the
potential to make a positive environmental impact by contributing to the reduction of waste tire
accumulation in the region while simultaneously meeting the energy needs of the local
community. As regulatory compliance, community engagement, and sustainable practices are
integral components of such initiatives, a comprehensive approach will be taken to ensure the
success and responsible operation of the waste tire-to-fuel pyrolysis plant in this strategic
location.

Figure 1. Satellite View of the Proposed Plant Location

1.8 Definition of Terms

These terms are integral in understanding the various processes and products involved
in waste tire pyrolysis and its applications in recycling and resource recovery.

Pyrolysis: This is a chemical process that involves the thermal decomposition of

materials at high temperatures in an oxygen-deprived environment. In the context of waste tire
pyrolysis, this process is used to break down tires into smaller molecules, resulting in the
production of various by-products like liquid fuel, gases, and solid residues.

Thermal decomposition: This refers to the breakdown of organic materials by

applying heat in the absence of oxygen. In waste tire pyrolysis, thermal decomposition is the
fundamental mechanism that causes tires to disintegrate into constituent components, resulting
in the production of different substances.
 By-products: In waste tire pyrolysis, it includes the various substances generated
during the process, such as liquid fuel, gases (like hydrocarbon gases and steam), and solid
residues like carbon black. These by-products have various potential applications, making the
pyrolysis process economically viable.

Carbon Black: A solid residue from the waste tire pyrolysis process, carbon black is a
fine black powder consisting primarily of carbon. It finds applications in industries such as
rubber manufacturing and can be utilized as an additive in the production of new tires or other
rubber-based products.

Hydrocarbons: Hydrocarbons are organic compounds consisting primarily of

hydrogen and carbon. In waste tire pyrolysis, they are among the components found in the
liquid fuel produced by the process and hold potential for various applications or further
refinement.
 CHAPTER 2

Process Design Layout

This describes the layout of this plant design. It contains various diagrams, such as a
block diagram, process flow diagram, piping and instrumentation diagram, plant layout, and
the plant simulation as a whole, along with additional discussions and explanations to aid
comprehension of this paper.

2.1 Block Diagram

Figure 2. A schematic block diagram of the Continuous Waste Tire Pyrolysis Process
 Waste tire pyrolysis involves a thermal decomposition process of used tires to produce
valuable products such as pyrolysis oil, carbon black, and steel. A block diagram of this process
outlines the key components and steps involved in breaking down the tires to obtain these
products. The objective of this section is to explain the importance of each block in the process
and how they work together to ensure the smooth operation of the entire plant. Furthermore,
waste tire pyrolysis is the process of breaking down the main rubber chain of tires into
monomers, biopolymers, and fragments under a sealed pyrolysis reactor with the right amount
of heat. These fragments are then polymerized into various types of olefins, which allows the
volatile substances to be converted to solid carbon (Ltd, n.d.).

Feed System

• At this stage, waste tires are first shredded and then fed into the pyrolysis system
through the feeding mechanism. The shredding of tires serves as a preliminary step
before they are introduced into the feeding system
• The pyrolysis reactor receives waste tires through the feeding mechanism. Using an
automatic feeding machine reduces labor, time, and effort as compared to manual
feeding (Plant, 2023).

Reactor

• The pyrolysis reactor is made in full compliance with pressure vessel standards that can
withstand heating to high temperatures. The reactor head is made of one piece and has
a rounded shape to withstand pressure. Additionally, at high pressure and high
temperature, the round-shaped reactor head's excellent connection and extremely strong
tension prevented it from cracking (What Is the Function of Pyrolysis Reactor in Waste
Tire Pyrolysis Plant? How Does It Work?_Pyrolysis Machine FAQ, n.d.).
• In order to enable pyrolysis, a high-temperature, oxygen-free atmosphere is often
maintained.

Separation System

• The separation system in a waste tire pyrolysis factory is critical for separating and
isolating rubber, steel, and fibers from shredded tires. It maximizes the quality of the
final products, such as pyrolysis oil and gas, by guaranteeing exact control and
preventing contamination throughout the pyrolysis process. This technique effectively
recovers valuable materials for recycling, such as steel wires, improving both the
sustainability of the environment and financial feasibility.

Condensation System

• In a waste tire pyrolysis plant, the condensing system changes the pyrolysis gases into
useful liquid products such as pyrolysis oil. This process optimizes efficiency and
resource recovery, which is crucial for economic viability.
 • The unstable gases produced by the pyrolysis reactor move through the char separators
and are directed to the condensing system or volatile vapor recovery unit. The
condensable gases are separated from the non-condensable ones. To prevent the
conversion of condensable vapors into non-condensable or permanent gases, the
volatile vapors are quickly cooled down to avoid any secondary reactions (Papari &
Hawboldt, 2018).

Distillation System

• The distillation system in a waste tire pyrolysis plant is in charge of further purifying
the liquid products acquired from the condensation process, mainly the pyrolysis oil.
Distillation separates and collects distinct liquid components, such as hydrocarbons
with variable boiling points.
• Through the removal of contaminants and the extraction of fractions with particular
qualities, this procedure raises the quality of the end product. The distillation system
enhances overall efficiency and the financial sustainability of the waste tire-to-energy
conversion process by helping to produce higher-grade fuels or chemicals from the
pyrolysis oil.

Desulfurization System

• Desulfurization can be stated as the process in which the amount of sulfur reduced from
the oil obtained after the pyrolysis of the waste tire (Aydın & İlkılıç, 2012; Toteva and
Stanulov, 2019; Tabinda et al. 2023).
• The desulfurization system in a waste tire pyrolysis plant removes sulfur compounds
from pyrolysis oil, increasing environmental compliance and the quality of final
products for market acceptance.
 2.2 Process Flow Diagram

Figure 3. A process flow diagram of the Continuous Waste Tire Pyrolysis

Process in LIIP
 The process flow diagram is a crucial tool that serves as the foundation for this project.
It gives a clear representation of the inputs, outputs, as well as the steps in between. The PFD
enables the team to understand the process and identify areas that are critical to the project's
success. It helps to identify any potential bottlenecks and inefficiencies that could be improved
upon. By creating a visual representation of the process, the PFD enables the team members to
communicate and collaborate more effectively, resulting in a more streamlined and efficient
project.

Figure 12. illustrates the Process Flow Diagram of the Continuous Waste Tire Pyrolysis
Plant. This process flow diagram depicts a form of waste tire recycling to a fuel oil plant. Its
basic mechanism is to feed and discharge continuously to create a continuous pyrolysis
manufacturing line. The tire pre-treatment, continuous pyrolysis, cooling, tail gas purification,
discharge carbon black, and fume treatment are the precise procedures.

The continuous waste tire pyrolysis plant comprises a sequence of steps that
systematically transform used tires into valuable products. Initially, the used tires undergo
preparation and processing to remove non-tire components. The most vital component of this
plant is the pyrolysis reactor, where thermal decomposition occurs in an oxygen-controlled
environment and produces pyrolysis gas, liquid pyrolysis oil, and solid carbon black. Further
processes include cooling and cleaning of the gas, solid separation to isolate carbon black, and
oil storage, which involves additional filtration to maintain product purity. The pyrolysis gas
that undergoes cleaning is often used as a supplementary fuel source, making the plant self-
sufficient in energy. Steel recovery is facilitated through magnetic separation for recycling
purposes. Advanced control and instrumentation systems are in place to oversee the entire
process, ensuring efficiency and safety. The integration of these processes creates an
uninterrupted and streamlined waste tire pyrolysis plant that is efficient, safe, and produces
valuable products.
 2.3 Pipping and Instrumentation Diagram

Figure 4. Pipping and Instrumentation Diagram of the Continuous Waste Tire Pyrolysis
Process in LIIP
 The Piping and Instrumentation Diagram (P&ID) is an advanced version of the Process
Flow Diagram (PFD) that provides more details about the process. It includes all the
information contained in the PFD, along with additional details about the instruments, pipe
sizing, and other components, which makes it a more comprehensive and detailed diagram.
The P&ID is typically used in the design and operation of chemical and process plants to help
engineers and operators understand the process flow and equipment involved in the process.
By providing a more detailed representation of the process, the P&ID helps to ensure that the
plant operates safely and efficiently.

2.4 Plant Layout

The waste tire pyrolysis plant is set up in a way that efficiently processes used tires. It
starts with a feeding system, which includes a conveyor belt and possibly a shredder for pre-
processing. The central component of the plant is the continuous pyrolysis reactor, which uses
an external heating system to thermally decompose the tires. The gases produced during the
process are condensed into liquid products, which are then separated into oil and water. The
solid residue, such as carbon black and steel wires, are handled separately. The gas released
during pyrolysis is used to generate energy. The separated components are stored in product
storage tanks, and the plant's operations are managed from a centralized control room. The
plant is designed to minimize emissions and comply with environmental standards, with
utilities and support systems ensuring the overall efficiency and safety of the process. The
layout is designed for continuous operation with a focus on optimizing resources.
 Plant Layout

Figure 5. Plant Layout of the Continuous Waste Tire Pyrolysis Process in LIIP
2.5 Plant Simulation

Figure 6. 3D Plant Simulation: Top View of Continuous Waste Tire Pyrolysis.

Figure 7. 3D Plant Simulation: Top Iso View of Continuous Waste Tire Pyrolysis.
Figure 8. 3D Plant Simulation: Front View Perspective of the Pyrolysis Plant

Figure 9. 3D Plant Simulation: Left View Perspective of the Main Office

Figure 10. 3D Plant Simulation: Front Parallel Projection Perspective of the Main
Office
 CHAPTER 3

Technical Aspects

This chapter examines the characteristics of waste tires, the raw material for this
proposed waste tire pyrolysis plant. It thoroughly outlines the machinery employed in crafting
the design of this facility, offering intricate insights into their functions, specifications, and
tailored configurations specifically engineered for waste tire pyrolysis. Chapter 3 is dedicated
to conducting material balance computations, an essential process that contributes to a thorough
comprehension of the intricate operations integral to our waste tires pyrolysis plant's
functionality and efficiency.

3.1 Raw Material Specification

Waste tire pyrolysis is a promising approach for converting discarded tires into valuable
resources, presenting a sustainable solution for waste management while yielding valuable
products. The raw material, waste tires, comprises a mix of rubber, steel, and fabric, with rubber
constituting approximately 40% to 60% of the tire's weight.

Preparing waste tires for pyrolysis involves several essential steps. Shredding or cutting
tires into smaller, uniform pieces enhances the efficiency of the pyrolysis process and facilitates
handling. Concurrently, removing steel wires, commonly achieved through de-beading, is
crucial to prevent damage to the pyrolysis reactor and downstream equipment, ensuring a
smooth process.

The quality of the feedstock significantly shapes the success of the pyrolysis endeavor.
Maintaining minimal moisture levels within the tires stands as a critical prerequisite, aiming to
avert adverse reactions and foster efficient conversion. Moreover, the reduction of
contaminants like dirt or stones assumes pivotal importance, upholding the sanctity of the
pyrolysis process and guaranteeing the production of high-caliber end products.

3.1.1 Composition of Waste Tires that are Important for Waste Tires Pyrolysis

In tire pyrolysis, various components within tires play essential roles in the conversion process:

• Rubber: The rubber in tires is the primary component subjected to pyrolysis. It breaks
down into pyrolysis oil, gas, and char (carbon black) during the process. Both natural
and synthetic rubbers are crucial for producing valuable pyrolysis products.
• Carbon Black: This is a reinforcing filler in tires, contributing to their strength and
durability. During pyrolysis, carbon black is recovered and can be used in various
applications, including as a pigment in rubber, ink formulations, or as a reinforcing
filler.
• Steel Belts and Beads: Tires contain steel wires or belts for reinforcement. These are
recovered as steel wire and can be recycled for various purposes after being separated
from the pyrolysis output.
 • Textile Fibers: Nylon or polyester fibers are often used in tires to reinforce them. During
pyrolysis, these fibers can break down into useful hydrocarbons or remain in the solid
residue (char) that can be used for different applications.
• Oils and Additives: Tires also contain oils and a variety of additives like antioxidants,
accelerators, and plasticizers. These additives can contribute to the chemical
composition of the pyrolysis oil produced.

The composition of tires is complex, and each component plays a role in the output
obtained from pyrolysis. Rubber and carbon black are particularly valuable outputs, with the
potential for reuse in various industries. Separating and efficiently processing these
components is crucial for maximizing the efficiency and value of the pyrolysis process.

ASPECT SPECIFICATION

Raw Material Source Waste Tires

Raw Material Size Up to a maximum diameter of 1.5 meters

Pre-treatment Removal of steel and other non-rubber

components

Shredded Input Tire Size 2 to 15 centimeters

Output Size 1-6 mm size

Quality Standards - Consistency in tire size and composition

- Minimal contaminants and foreign materials

3.2 Equipment Functions and Specifications

The following are the equipment with their functions and specifications in the design plant:

Hydraulic Tire Cable Extractor

Description and Function

This equipment comprises a motor, hydraulic system, extraction hook, mouth, main machine
frame, and more. Its fundamental operating principle involves the motor powering the
hydraulic system and oil cylinder, with a hook affixed to the cylinder's drawbar. The back-and-
forth motion generated by the oil pump and cylinder moves the hook.Using it involves placing
the tire onto the hook's mouth, extending the hook to grasp the tire's lip, and starting the motor.
With the powerful extracting force of the oil cylinder, the wire cable is then effortlessly
extracted as a complete ring, streamlining the process efficiently.

Equipment Category: Cable Extractor

Feed size of tire: up to 1.75 m

Capacity: 60-80 tires/h

Power: 18.5KW

Overall dimensions: 4.5 x 1.0 x 1.7m

Equipment weight: 2ton

No. of Unit/s: 2

Whole tire Shredder

Description and Function

The tire shredding machine operates on a principle of employing a spindle motor with low-
speed, high-torque rotation to tear apart waste tires biaxially, breaking them into pieces. These
broken materials are then discharged through the blade's angle. A roller screen comes into play,
allowing materials sized equal to or less than 15 cm to pass through the screen, entering the
subsequent processing stage. Any finished products larger than 15 cm are cycled back into the
crushing chamber for further shredding until the rubber blocks reach the desired size before
being discharged. This process is facilitated by the use of a double shaft configuration,
enhancing the efficiency of tearing and reducing the larger materials effectively during
reprocessing within the shredder.

Equipment Category: Shredder

Capacity: 5-8 T/h

Output Size: 2-15 cm

Power: 22.2 KW

Hopper Size: 2 x 2 m

Overall dimensions: 3.2 x 2 x 1.9 m

Equipment weight: 5.7 ton

No. of Unit/s: 1

Rubber Powder Granulator

Description and Function

The rubber granulator serves to break down rubber extracted from the steel wire separator,
reducing it to particle sizes as small as 1mm. Subsequently, these particles undergo further size
refinement through sieving and recycling processes to attain their final desired dimensions.
This granulator's unique design enables the production of consistently uniform, high-quality
rubber granules, boasting an exceptional separating efficiency that removes over 99% of fibers
during production. This efficiency stems from its specialized construction, ensuring a
meticulous and precise breakdown of rubber materials while effectively isolating and
eliminating fibers, resulting in an output of superior quality rubber granules.

Equipment Category: Granulator

Capacity: 4-5 T/h

Output Size: 1-6 mm

Power: 44 KW

Overall dimensions: 4.3 x 2 x 2.4 m

Equipment weight: 4.9 ton

No. of Unit/s: 2

Magnetic Separator
Description and Function

Incorporated into its design is a unique magnetic circuit that utilizes high-performance NdFeB
rare earth permanent magnets as the magnetic source. This results in a powerful magnetic field
with strong suction, offering maintenance-free operation, energy conservation, safe and
reliable usage, and adjustable feed settings to accommodate different particle requirements.
The electromagnetic coils, crafted from high-temperature-resistant insulated aluminum and
copper conductors, ensure continuous operation, while achieving a magnetic metal removal
rate of up to 99.7%.

Equipment Category: Separator

Capacity: 5-8 T/h

Feeding Size: 1-6 mm

Drive Power: 5.5 KW

Drum Speed: …….

Drum Width: 800 mm

Drum Diameter: 1600 mm

Overall dimensions: 1.96 x 1.2 x 1.6m

Equipment weight: 4.9 ton

No. of Unit/s: 1

Rubber Storage Tank

Description and Function

In a waste tire pyrolysis plant, the granulated rubber storage tank stands as a pivotal element in
the process chain. This tank, typically a robust cylindrical structure crafted from durable
materials like steel, functions as a temporary repository for the output of the pyrolysis process
- the granulated rubber. Its primary role revolves around accommodating the continuous output
of the pyrolysis system, ensuring a steady flow of material. From an operational perspective,
the storage tank ensures a seamless operation by providing a buffer for material output,
allowing the pyrolysis plant to run continuously. It plays a critical role in managing material
flow, preventing bottlenecks, and optimizing the efficiency of the entire pyrolysis system.

Equipment Category: Storage Tank

Capacity: 3.5 T

Material: Stainless Steel

Tank Width: 2000 mm

Tank Height: 3500 mm

Tank Upper Diameter: 610 mm

Tank Lower Diameter: 250 mm

No. of Unit/s: 3

Apron Feeder

Description and Function

The apron feeder within a waste tire pyrolysis plant stands as a critical conveyor
system, its robust design comprising interlinked metal plates facilitating the seamless
movement of shredded tire materials through various process stages. Serving as the
conduit between initial processing and subsequent phases, its adjustable speed and
sturdy construction ensure a consistent material flow, optimizing operational
efficiency and throughput. This feeder not only guarantees a controlled and uniform
distribution of materials but also enhances safety by containing and managing
material movement, contributing to a safer working environment. Its adaptability and
integration capabilities into the plant layout make it an essential component, enabling
a smooth, continuous operation pivotal to the overall effectiveness of the tire pyrolysis
process.

Equipment Category: Conveyer

Movement Mode: Linear

Appearance: Close Type

Chain Material: Heat-treated Alloy

Capacity:Max 8 T/h

Installation Slope: 0-30 degrees

Pan Speed: 0.10-0.25 m/s

Power: 2 KW

Maximum Feeding: 1500 mm

Pan Width: 3000 mm

No. of Unit/s: 3

Conveyor Belt
Description and Function

The conveyor belt in a waste tire pyrolysis plant serves as the central transport system, its
continuous loop structure designed to efficiently shuttle shredded or processed tire materials
between different pyrolysis stages. Functioning as the linchpin of material movement, this
belt's motorized mechanism and adjustable controls ensure a steady flow of materials,
preventing congestion and enabling a seamless transition for subsequent processing or storage.
Integral to operational efficiency, it not only optimizes material distribution but also enhances
safety by containing and regulating material movement, while it's adaptable design allows for
customization to suit the plant's layout and integration into automated systems, making it an
indispensable element for a smooth, controlled, and efficient tire pyrolysis process.

Equipment Category: Conveyer

Movement Mode: Linear

Appearance: Close Type

Chain Material: Heat-resistance Nylon

Capacity:8 T/h

Power: 2 KW

Conveying Angle: 0-25 degrees

Belt Speed: 0.5-2 m/s

Belt Width: 650 mm

Belt Thickness: 9 mm

Dimension: 11500 mm x 1290 mm x 1802 mm

No. of Unit/s: 3

Auger Reactor
Description and Function

An auger reactor is a specialized component employed in waste tire pyrolysis to facilitate the
controlled thermal decomposition of tires into valuable byproducts. This reactor comprises a
cylindrical chamber with an auger (a rotating screw-like mechanism) running through its
length. As tires are fed into the reactor, the auger's rotation serves to convey and evenly
distribute the tires along the chamber's length while subjecting them to high temperatures in
the absence of oxygen, initiating the pyrolysis process. The heat causes the tires to break down
into gases, pyrolysis oil, and carbonaceous residues. The design of the auger reactor allows for
efficient mixing and heating of the tire feedstock, promoting thorough and uniform
decomposition, thereby maximizing the yield of desired products like pyrolysis oil and
ensuring an effective waste tire pyrolysis process

Equipment Category: Reactor

Reactor diameter: 3.5 meters

Reactor length: 12 meters

Auger diameter: 1.25 meters

Auger rotation speed: 10 revolutions per minute (RPM)

Feed rate Capacity: 120 tons per day

Pyrolysis temperature: 550 degrees Celsius

Material: Stainless Steel

Power: 300 KW

No. of Unit/s: 1

Shell and Tube Heat Exchanger

Description and Function

In waste tire pyrolysis, the shell and tube heat exchanger serves as an essential component by
facilitating efficient heat transfer between the hot gases generated during tire decomposition
and a secondary fluid, typically a coolant or oil, without commingling them. This vital
apparatus, consisting of a shell housing numerous tubes, enables the controlled regulation of
temperatures within the pyrolysis reactor. As the hot gases pass through the tubes, their heat is
effectively transferred to the surrounding fluid, aiding in cooling the gases and heating the
secondary fluid. This meticulous temperature control not only ensures the optimal conditions
required for tire breakdown but also enhances the overall efficiency of the pyrolysis process,
contributing to the successful extraction of valuable byproducts like pyrolysis oil and carbon
black while maintaining operational safety.

Equipment Category: Heat Exchanger

Tubes Material: 316 stainless steel

Tubesheets Material: 316L stainless steel

Shell Material: 316L stainless steel

Gaskets: Nitrile rubber/cellulose fiber

Shell Diameter: 15 in

Tube Length: 5 ft

Tube Diameter: 0.625 in

Operating Pressure (Shell Side): 300 psi

Operating Pressure (Tube Side): 150 psi

Operating Temperature: 300 degree F

Power: 10 KW

No. of Unit/s: 2
Falling Film Vertical Condenser

Description and Function

In waste tire pyrolysis, a falling film vertical condenser assumes a critical role by efficiently
condensing the vapors emerging from the tire decomposition process. This specialized
condenser features a vertical design where the vapors, laden with valuable components like
pyrolysis oil and gases, descend down in a thin film along the condenser walls. As these vapors
make contact with the cooler surface, heat exchange occurs, causing condensation and the
transformation of vapors into liquid form. The condensed liquid, comprising pyrolysis oil and
other valuable byproducts, accumulates at the bottom of the condenser, ready for collection
and further processing. This condensation process aids in recovering and separating the desired
substances from the pyrolysis vapors, enhancing the efficiency of the overall waste tire
pyrolysis operation and enabling the extraction of valuable resources from the process.

Equipment Category: Condenser 1

Tubes Material: 316 stainless steel

Tubesheets Material: 316L stainless steel

Shell Material: 316L stainless steel

Shell Diameter: 24 in

Tube Length: 5 ft

Tube Diameter: 0.75 in

Baffles: Segmental baffles

Power: 10 KW
Design Pressure: 150-200 psi

Design Temperature: 500-600 degree F

Power: 25 KW

No. of Unit/s: 1

Equipment Category: Condenser 2

Tubes Material: 316 stainless steel

Tubesheets Material: 316L stainless steel

Shell Material: 316L stainless steel

Shell Diameter: 18 in

Tube Length: 5 ft

Tube Diameter: 0.5 in

Baffles: Segmental baffles

Power: 10 KW

Design Pressure: 100-150 psi

Design Temperature: 400-500 degree F

Power: 25 KW

No. of Unit/s: 1

Buffer Tank
Description and Function

A buffer tank serves as a crucial intermediary component designed to regulate and stabilize the
flow of materials within the system. Typically positioned between various stages of the
pyrolysis process, this tank acts as a temporary storage unit for the intermediate products or
substances produced during tire decomposition, such as pyrolysis oil, gases, or other
byproducts. Its primary function involves equalizing flow rates, smoothing out fluctuations,
and ensuring a consistent supply of materials to downstream processes or equipment. By
providing a buffer or storage capacity, the tank accommodates variations in production rates,
enabling a continuous and steady flow of materials through the pyrolysis system. This helps in
optimizing overall efficiency, allowing for smoother operations and better control over the
extraction and processing of valuable products derived from waste tire pyrolysis.

Equipment Category: Buffer Tank

Equipment Material: 316 stainless steel

Equipment Length: 6 m

Equipment Diameter: 2 m

Equipment Volume: 10,000-15,000 Liters

Design Pressure: 50-100 psi

Design Temperature: 150-250 degree C

Power: 50 KW

No. of Unit/s: 1

Dedusting Tower
Description and Function

A dedusting tower serves as a critical component for removing particulates and impurities from
the gases produced during the tire decomposition process. This tower features a tall structure
through which the hot gases from the pyrolysis reactor are passed. Inside the tower, the gases
come into contact with a series of filters or scrubbing mechanisms designed to capture and
remove solid particles, such as carbon black, dust, and other contaminants suspended in the gas
stream. By utilizing various filtration or scrubbing techniques, including cyclones, electrostatic
precipitators, or wet scrubbers, the dedusting tower effectively separates and collects these
particulates, ensuring that the gas emitted from the pyrolysis process meets environmental
regulations and reducing environmental impact by minimizing the release of harmful
substances into the atmosphere.

Equipment Category: Dedusting

Dust collection efficiency: 99%

Airflow rate: 30 m³/h

Dust removal method: Bag filter

Dust capacity: 10 m³

Power: 50 KW

Equipment Diameter: 2.5 m

Equipment Height: 10 m

Equipment Weight:500 kg

Outer shell: Carbon steel

Inner lining: Stainless steel

Filter bags: Polyester

No. of Unit/s: 1

Desulfurization Tower
Description and Function

A desulfurization tower reduces the sulfur content present in the gases generated during tire
decomposition. This tower consists of a specialized structure through which the gas stream
from the pyrolysis reactor passes. Inside the tower, various desulfurization agents or processes,
such as chemical scrubbers, absorption materials, or catalytic converters, are employed to react
with and remove sulfur compounds present in the gas. By facilitating chemical reactions that
capture sulfur elements, the desulfurization tower effectively reduces the sulfur content in the
gases, contributing to environmental compliance and mitigating potential air pollution by
minimizing the emission of sulfur-containing compounds, thus enhancing the environmental
sustainability of the waste tire pyrolysis process.

Equipment Category: Desulfurization

Purification efficiency: 99%

Airflow capacity: 30 m³/h

Equipment Diameter: 2 m

Equipment Height: 10 m

Equipment Weight:500 kg

Power: 50 KW

Outer shell: Stainless steel

Inner lining: Stainless steel

No. of Unit/s: 1

Oil Storage Tank

Description and Function

An oil storage tank serves as a critical reservoir for storing and managing the collected
pyrolysis oil produced during the tire decomposition process. This tank, typically designed
with specific capacity and safety features, functions as a temporary storage facility for the
extracted oil before further processing or distribution. Its primary role involves the containment
and preservation of the pyrolysis oil, safeguarding it from contamination and external elements.
Additionally, the tank enables logistical efficiency by providing a centralized location for
storage, allowing for proper inventory management and facilitating subsequent transportation
or refining processes for the extracted oil, contributing to the overall efficiency and control of
the waste tire pyrolysis operation.

Equipment Category: Storage Tank

Equipment Material: Stainless Steel

Equipment Diameter: 3.5 meters

Equipment Height: 12 meters

Equipment Capacity: 180 barrels (28,316.85 liters)

Equipment Orientation: Vertical

3.3 Material Balance

Material balance calculations are the foundation of process design, enabling the determination
of raw material requirements and product yields. These calculations are invaluable for
synthesizing products with specified compositions, assessing final compositions after blending,
evaluating processing yields, and evaluating separation efficiency in mechanical separation
systems. In essence, material balance calculations ensure the efficient production of high-
quality products with minimal waste and energy consumption (Toledo,2007).
 Table # Waste Tire Pyrolysis Mass Balance

The material balance are summarized in Table 5. The material balance reveals that a feedstock
rate of 120 tons per day results in a gas fraction of 40.8 tons per day. As a consequence,
approximately 39 tons per day and 15.17 tons per day of distillate and heavy oils will be
produced, respectively, during the pyrolysis process. Additionally, steel wire and carbon black
will be generated at a rate of 18 tons per day and 40.8 tons per day, respectively. Besides the
thermal energy supplied to the reactor to promote the reaction, the feedstock and products
formed during pyrolysis will also contribute to satisfying the process energy requirements.

Process design starts with material balances. The amount of raw materials used and goods
generated were calculated using a material balance that was taken throughout the whole
operation. The compositions and stream flows of the process are determined by balances over
individual units. The factory is designed to operate in a perpetual cycle of manufacturing. To
guarantee that the plant operates continuously for the full twenty-four hours, it will be run in
three eight-hour shifts.

Fundamentals of mass balance

The general conservation equation for the process system can be written as:

Material out = Material in + Generation - Consumption – Accumulation

Assumptions made are:

Accumulation = 0 (steady state)

Generation = 0 (no chemical reaction)

Therefore, Material out = Material in

Mass Balance over the Cable Tire Extractor:

Basis: 120 Tons/day of Feed

100% Waste Tire (M1) Cable Tire

(M(M1) Extractor 90% Wire Chips (M3)

10% Steel Wire (M2)

(M3)
 For Waste Tire:
M1 = 1.00×120T/day
M1 = 120 T/day
For Steel Wire:
M2 = 0.10×120 T/day
M2 = 12 T/day
For Wire Chips:
M3 = 0.90×120 T/day
M3 = 108 T/day
Therefore M3 = M1-M2

M3 = (120-12) = 108 T/day

M3 = 108 T/day

Mass Balance over the Magnetic Separator:

1. Accumulation – 5.56%

Magnetic
Wire Chips (M3) Wire Chips (M5)
Separator

Steel Wire (M4)

For Waste Tire:

M4 = 0.056×108 T/day
M4 = 6 T/day

Total mass balance:

M5 = M3-M4
M6 = (108 - 6) T/day
M6 = 102 T/day
Mass Balance over the Reactor:

Syn Gas (M7)

Pyrolysis Gas
665.33 T/day
(M8)

Wire Chips (M5) Reactor (550)

Carbon Black
(M6)
19.33 T/day

Total mass balance:

M8 = M5 – (M6+M7)
M8 = 102 – (40.8 + 1.02 T/day )
M9 = 60.18 T/day

Mass balance over Distillation:

Pyrolysis Gas (M8)

Distillation Light Oil (M10)

Heavy Oil (M9)

Total mass balance

M8 - M9 = M10

M10 = (54.17 – 15.7) T/day

M10 = 39 T/day
 CHAPTER 4

Economic Study and Analysis

4.1 Direct Cost

I. Indirect Cost

A. Fixed Cost
 B. Variable Cost

II. Cost Price And Selling Price

III. Cash Flow

IV. Economic Indicators

A. Break Even Point

B. Internal Rate of Revenue

C. Rate of Return

D. Payback Period