Technological and economical feasibility of a 40,000 t/y tyre - - PowerPoint PPT Presentation

▶
technological and economical feasibility
SMART_READER_LITE
LIVE PREVIEW

Technological and economical feasibility of a 40,000 t/y tyre - - PowerPoint PPT Presentation

Feb 14, 2024 275 likes •580 views

Technological and economical feasibility of a 40,000 t/y tyre pyrolysis plant: results of a H2020 SME Phase 1 study Dr Frank Riedewald, Managing Director, Composite Recycling Ltd, Cork, Ireland Dr Maria Sousa-Gallagher, Process and Chemical

slide-1
SLIDE 1

Technological and economical feasibility

  • f a 40,000 t/y tyre pyrolysis plant:

results of a H2020 SME Phase 1 study

Dr Frank Riedewald, Managing Director, Composite Recycling Ltd, Cork, Ireland

frank.riedewald@comp.recycling.com www.crlltd.com

Dr Maria Sousa-Gallagher, Process and Chemical Engineering, University College Cork, Ireland ETRA conference, 18th March 2016

slide-2
SLIDE 2

Waste Tyre Pyrolysis

Contents

  • 1. Requirements for a commercial process
  • 2. Composite Recycling Ltd’s process
  • 3. Technical assessment
  • 4. Market analysis
  • 5. Financial assessment

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 672558.

slide-3
SLIDE 3

Requirements for a commercial process

slide-4
SLIDE 4

Scale

Requirements for a commercial process

Scale Scale Scale Scale

slide-5
SLIDE 5

Scale – Amount of tyres

Requirements for a commercial process

Economies of scale and sales of: P-oil, rCB & steel

slide-6
SLIDE 6

Requirements for a commercial process

  • 1. Scale of plant (40,000 - 100,000t/y)
  • 2. Whole tyres – no shredding, no granulating
  • 3. Continuous
  • 4. Simple (low tech, low pressure, existing technology)
  • 5. Accessible markets for all products

Economic tyre recycling process

slide-7
SLIDE 7

Composite Recycling Ltd’s process

slide-8
SLIDE 8

Reactor

Pyrolysis vapours

Composite Recycling Ltd’s process

Direct heat transfer – tyres are insulators Carbon black Steel

slide-9
SLIDE 9

Composite Recycling Ltd’s process

Whole process

slide-10
SLIDE 10

Technical Assessment

slide-11
SLIDE 11

Concept layout of a 40,000 t/y plant

Technical assessment

slide-12
SLIDE 12

Scrap tyre feeding system

Technical assessment

slide-13
SLIDE 13

Pyrolysis chamber – hot dip galvanizing

MOC = 316 SS

Technical assessment

slide-14
SLIDE 14

Carbon black recovery

Technical assessment

slide-15
SLIDE 15

Carbon black recovery Analysis: rCB is free of rubber

Technical assessment

slide-16
SLIDE 16

Steel removal – hot dip galvanizing

Steel is galvanized

Technical assessment

slide-17
SLIDE 17

Safety - Hot dip galvanizing

Technical assessment

slide-18
SLIDE 18

Pyrolysis oil - conventional

Technical assessment

Pyrolysis oil

slide-19
SLIDE 19

Market analysis

slide-20
SLIDE 20

Market value of products – P-oil, rCB, steel

Market analysis

Product Market price Market Competitors Tipping fee €97/t

  • Not given

P-oil €218/t Heavy fuel oil €400-600/t rCB €30/t Coal €75-600/t Steel €80/t Recycled €75-200/t

Valid: December 2015

slide-21
SLIDE 21

Financial Assessment

slide-22
SLIDE 22

40,000 t/year or 4m tyres/year

Oil (50%) €218/t €4,360,000 Carbon Black (30%) €30/t €360,000 Steel (10%) €80/t €320,000

Financial assessment

Gate Fees €97/t €3,880,000 Gas (10%) Self-sustaining

slide-23
SLIDE 23

Financial assessment

General assumptions

Parameter Assumption Location Europe Currency Euro Operating time 7,500/h, 85% uptime Loan period 10 years Interest rate 6% Inflation 3% Plant life 20 years Discount rate 10% Government support None (financial) Shifts 5 Personnel 33

slide-24
SLIDE 24

Financial assessment

Financials 40,000t/y plant; amounts in thousands

Year 1 2 3 8 9 10 Revenues 9,830 10,125 10,429 12,090 12,452 12,826 Expenditures Capital 28,377 Capital payments

  • 3,856 -3,856 -3,856 -3,856
  • 3,856 -3,856

Operating cost

  • 1,029 -1,060 -1,092
  • 1,266 -1,304 -1,343

Overall expenditures -3,856 -8,416 -8,553 -8,694

  • 9,464 -9,633 -6,821

Profit

  • 3,856 1,414 1,572 1,735

2,625 2,820 6,005 Discounted Cash Flow -3,856 1,414 1,572 1,735 2,625 2,820 5,404 Cumulative Cash Flow -3,856 -2,442 -870 865 11,288 14,107 19,511

Measure Value IRR (10 years) 20% NPV (10 years) €2.1m Payback period 2.5 years

40,000t/y minimum throughput

  • f an economic plant
slide-25
SLIDE 25

Financial assessment

Financials 40,000t/y plant – effect of shredding

Measure Value IRR (10 years) 20% Measure Value IRR (10 years) Negative

Shredding €25/t

slide-26
SLIDE 26

Future profitability

Market analysis

Product Price (today) Price (future) Reason IRR (Sensitivity) P-oil €218/t €400/t Oil price increase 100% rCB €30/t €100/t rCB upgrade 40%

€400 = ~$80/bbl in 2020

slide-27
SLIDE 27

Use proven, existing technologies IRR over 20%

Summary

M

2

N

slide-28
SLIDE 28

The next steps 1.Investment, H2020 Phase 2 2.Demonstration plant

M

2

N

Composite Recycling Ltd

slide-29
SLIDE 29

References

  • 1. M. Felisa Laresgoiti et al.; Chromatographic analysis of the gases obtained in

tyre pyrolysis; J. Anal. Appl. Pyrolysis 71 (2004) 917–934.

  • 2. P.T. Williams, Pyrolysis of waste tyres: A review, Waste Management, 33

(2013) 1714-1728; see: http://eprints.whiterose.ac.uk/77990/

  • 3. P. Rathsack, F. Riedewald, M. Sousa-Gallagher, Analysis of the pyrolysis oil
  • btained from whole tyre pyrolysis with molten zinc as the heat transfer

media using comprehensive gas chromatography mass spectrometry, J. Anal.

  • Appl. Pyrolysis, 116 (2015) 49-57.
  • 4. M. Stelmachowski; Conversion of waste rubber to the mixture of

hydrocarbons in the reactor with molten metal; Energy Conversion and Management 50 (2009) 1739-1745.

  • 5. F. Riedewald, P. Conway, M. Sousa-Gallagher, Tyre recycling utilising molten

metal, Loss Prevention Bulletin, August, 2015.

  • 6. F. Riedewald, M. Sousa-Gallagher, Novel waste printed circuit board

recycling process with molten salt, MethodsX (2015).

Composite Recycling Ltd