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The Concept



Pyrolysis Technology

Thermo-chemical decomposition of organic materials in the absence of oxygen at elevated temperature is termed as Pyrolysis. This generally takes place at a temperature level of 300°C -430°C (800°F) and pressure situations. This process is a case of thermolysis and is mainly used in the process of charring of organic materials. The process helps in production of liquid and gaseous products leaving carbon rich residue. Pyrolysis in its extreme conditions is termed as carbonization. This process is mainly brought in the process of chemical industry.   Pyrolysis in its special form is also known by dry distillation, destructive distillation or cracking.          Example:  
  • To transform medium-weight hydrocarbons from oil into lighter ones like gasoline
  • To convert bio-mass into syngas
  • To turn waste into safely disposable substances
  • To produce charcoal, methanol, activated carbon and other chemicals from wood
  • To convert ethylene dichloride into vinyl chloride for making PVC
  • To produce coke from coal

Process Details

Pyrolysis is mainly a batch process system. The plastic and waste tire is fed into the reactor vessel, which is heated by using gas, wood, coal and oil under controlled pressure and temperature. In this process, molecular restructuring of rubber takes place by converting it into vapors and gases. The vapors produced are then transferred to a separation tank and further passed through condensers where it is converted into liquid form called tire oil. Some of the gases generated cannot be condensed into vapor form and these are known as pyro-gases and the main constituent of this gas is Methane and other combustible gases, which are mainly used in heating reactors. Being toxic in nature, these gases cannot be stored and are sent for burning in separate zones.    Steel and carbon black are the products that are also generated during this process. Water is used as a cooling medium in the condensation process in the heat exchangers and is continuously re-circulated in the entire process. The carbon black from the reactors are pulled out for being packed in the bags and the oil moves to the storage tank directly, while the steel wire is pulled out at the last stage of the entire process.

Advantage Of Vertical Reactor Pyrolysis

Whenever someone thinks about a pyrolysis plant, a shabby image of site having conventional horizontal rotary type of plant, having stacks of wood at one corner and large amount of entangled steel at the other one, with carbon black and oil spilled all around with stinky odor in the surroundings, comes in mind.

Before going down word to know more about Why Vertical, If you have not gone through the “About Machinery”, We would  request you to please read "About Machinery” topic first. This will give you better understanding about the present topic.

“A comparison between Two Technology i.e.-ChineseHoz. And Over Vertical Plant”

S.No. Vertical Stationary Plant
1. More Safer because its vertical construction and stationary feature- Out let pipe always remains away from material. So no chances of choking. hence no chances of extra ordinary pressure in the vessel
2. In Vertical Reactor system the total capacity is divided in three parts i.e. one main reactor and two supporting reactor
3. In this system the Reactor is made with Two Layer of steel plate with a air gap in-between the two plates. And inner shell is made of Hot Die steel
4. In this system the Inner shall is heated up through hot air heat exchange system. i.e. – The Metal part do not come in contact with direct flame of burning material
5. The life of reactor is almost double than conventional system because of point –C & D
6. Plant never comes to zero production. Even if there is break down in one or two reactors
7. This system gives almost continuous process. As when first reactor is fired (heating cycle), the staff will prepare second reactor and in the mean time the third reactor will be in cooling cycle. So after every six hour you get out put from the system
8. Low fuel consumption – Ideally Fuel is required to fire the first reactor. If you make gas storage system, the next reactor shall be fired by the gas of previous reactor
9. Heat Loss is very low due to its constructional and design features

Benefit Of Vertical Reactor Pyrolysis

“A comparison between Two Technology i.e.-ChineseHoz. And Over Vertical Plant”

S.No. Vertical Stationary Plant
1. Due to smaller quantity of material used, the cooling time is low. Each cycle takes maximum 12 hours. So each reactor can be charged twice in 24 hours
2. Due to controlled temperature heating – The quality of carbon black is better then the other system. So there are are chances of industrial use of this carbon black
3. The content of Carbon particle in condensed oil is lower. Since the out let for oil vapors is from the top of the reactor and the inner material is stationary
4. The point no. 7 is self explanatory about safety of this system. The out-let of rector can never be blocked due to heavy material
5. The quality of steel wire separated from tyre is without deformation. So we get better price of steel
6. Steel Scrap obtained from Vertical reactor
7. No Heavy foundation Required. Normal cement/Kota stone Industrial Flooring is sufficient to place the plant. This saves initial capital and also one can plan to run the plant in rental premises
8. Reduced cycle time (9 to 11 hour) means each reactor can be used twice in 24 hour. Based on above facts, quantity of material that can be process in 24 hour in three reactors will be 16-18 tons(max)
9. E waste can be processed
10. Point no 12 is self explanatory about commercial viability of the vertical technology. Almost in same investment one can earn upto 2-3 times more profit

 


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