Frequently Ask Questions

Depending on the Territory / Country guidelines, local license or permission may have to be obtained. In case of India, following documents are perquisite:

• NOC from Local Municipal Corporation.
• DIC (District Industries Centre) registration.
• NOC from PCB (Pollution Control Board.

Sorry, we do not take up conversion of Batch type plants to Continuous Type plants.

The operating conditions of the system are monitored with implementation for Temperature and Pressure controls at plant.

Yes, depending on the Territory or Country and governed by local regulations / norms, a requisite permission may have to be obtained. We at Pyrocrat Systems LLP is one of the established pioneer in field of Pyrolysis plant and will support all clients with necessary information and documents to obtain permission from Pollution Control Board with India. In case of overseas clients, relevant data can be supported from our head office to meet the local conditions / norms.

No. The input-out ratio remains same unless there is change of raw material, catalyst or operating style of the pant.

Our Company facility meets the standard of EU emissions and Pyrocrat System LLP is CE certified.

Our process is not Incineration but Pyrolysis process. The raw material is processed under oxygen free atmosphere and no direct heating of the raw material.

With the help of air lock valves and nitrogen generator oxygen can be prevented from entering into the reactor.

3 Shifts of 8 hours each, Assumption: 26 working days per month

Pyrocrat System LLP are design to work around the year however we recommend taking a half yearly preventive maintenance of 10 days each. Apart from this general wear and tear is recommended over the six days of operation for 3 to 4 hours.

Pyrocrat Systems LLP plants are highly efficient design systems ensuring emission control and fail safe system thereby ensuring no environmental hazards.

Following yield data is variable on raw material quality.

A) Pyrolysis Oil: Recovery of 50% to 85% on Waste Plastic and 40% to 50% on Used Tyre

B) Charcoal: Recovery of 10% to 15% on Waste Plastic and 30% to 35% on Used Tyre

C) Pyrolysis gas: Recovery of 15% to 20% on Waste Plastic and 40 to 60% on Used Tyre

D) Wax: Nil to 10%

The plant modules are designed for rated capacities so it is not possible to enhance the plant capacity by minor / major standalone equipment.

Yes. The feedstock of tires (or plastic) should have particle size less than 25mm.

Depending on the need of client and location specific, the plant design configuration can be offered as Semi-Automatic or Fully- Automatic. As standard plant operations, the plant is Semi-Automatic which has no manual handling of in process material or finished products.

The Shedder is NOT part of the Standard scope of supply under Pyrocrat Systems LLP. However, depending on client specific requirement to use different raw material (Types of Waste Plastics and Used Tyres) we can recommend and supply the Shredder.

Our advance designed 9th Generation and above plant are environment friendly. Our Pyrolysis plants DO NOT emit any hazardous Gases or Fumes or Liquid discharge. We have necessary technical expertise to comply with European Air & water emission norms.

All machinery and technology is designed and developed at Pyrocrat. All machinery is manufactured in India. We do not source any technology, equipment from other countries.

Detailed information will be given once NDA (A non-disclosure agreement) and Sales Agreement are signed and deposits have been paid.

• All civil work including design & construction of foundations drains, drain sumps, neutralization sumps, supports of all units and mass concreting of all units (if required).
• Unloading, storage, insurance and security of equipment at site. Crane or lifting arrangement & labour for machinery movement and placement.
• Electricity, water and air supply at the required parameters at the inlet of the equipment offered.
• Any other machinery or services not mentioned specifically as forming part of seller’s offer.
• Skilled and Unskilled labour during installation and commissioning, spanners and toolbox, welding machine etc. required by seller’s commissioning engineer

Carbon Black is commonly sold as solid fuel in form of Carbon Bricks or Pallets. The other uses in powder form are – Charcoal Soil enrichment, Paint industry, Ink industry, Filler in manufacturing Plastic & Rubber, high value products like Activated Charcoal, etc. The present realisation for Carbon Black ranges approximately INR 1.00 to INR 3.00 per kilo.

No need for segregation and cleaning with Tolerance of 5% dust + 5% moisture. PVC and Polycarbonate content should be less than 5%. A more detailed sorting of plastics used as raw material is enlisted below:

• Waste Plastic
• Electronic scrap
• Mixed plastic (HDPE, LDPE, PE, PP, Nylon, Teflon, PS, ABS, FRP)
• Multi Layered Plastic
• Waste Tyres
• Rubber
• Plastic or rubber parts from vehicles
• Waste oils etc.

Note:

1. It is recommended that the calorific value of raw material must be above 7000KCal/Kg.
2. Particle size: Less than 25mm, density more than 0.2MT/KL
3. Most of the Waste plastic generated around the world is suitable for our Pyrocrat Systems LLP design supplied plants.

Pyrocrat System LLP plant ensures layered safety features in the plant such as:

• Airlock feeding system
• Airlock carbon removal system
• Automatic pressure release valves
• Automatic temperature control valves
• Ingenious design of vapour lines and condensers to prevent clogging and pressure builtup.
• Reactor operation having very negligible positive pressure
• Use of flameproof motors
• Use of expansion joints
• No smoking or naked flame allowed inside the plant.

In case the plant operation stops for any reason the molten Waste Plastic or Used Tyre particles inside the reactor solidifies.  No sooner the plant is restarted with proper utilities (Mainly Electricity) the Reactor is again heated to melt the Waste Plastic or Used Tyre setting the whole plant under restart. Pyrocrat Systems LLP recommends installing a full load Standby Diesel Generator.

In case of electricity failure, the Gas is not vented in the air as our system has provision for Gas storage facility.

The alternate fuel to Hydrocarbon Gas to fire the Reactor could be Pyrolysis Oil or Industrial Diesel. The Pyrolysis Oil or Industrial Diesel is used for approximately first two hours of Reactor start-up after which it is switched to Hydrocarbon Gas.

Pyrocrat Systems LLP uses an easy to acquire Catalyst. It is an environment friendly chemical to increase the rate of reaction with a usage of 0.1% to 0.5% of the raw material weight feed to the plant.

Distillation is a method of separating mixtures based on differences in volatilities of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction. Pyrolysis Oil (PO) is the mixture of Diesel + Kerosene + Petrol like fractions approximately: 30 to 35% of each. Diesel, petrol and Kerosene like fraction cane be separated by using fractional distillation.

In waste plastic and Tire Pyrolysis, both raw material and finished product prices are indirectly based on international crude oil prices. Give below is the cause and effect table:

• 7 days training on plant operation
• Detailed operation, maintenance and troubleshooting guidelines
• Telephonic guidance after sales
• Visit of engineer in case of issue

Though processing plastic is more challenge but due to our highly innovative plant design technology our clients are using on average 70% Waste plastic compared to 30% Used Tyres.

Given below is the process for purchasing the pyrolysis plant from us:

• Client contact through email
• Send ‘FAQ’s’ & ‘Know Your Customer (KYC) Form’ for client through email.
• Client fills up the ‘KYC Form’ and emails it back to Pyrocrat.
• On screening of “KYC Form’ Pyrocrat shall disclose budgetary proposal report.
• Technical meeting with Pyrocrat technical team at Head Office, Navi Mumbai.
• Post technical discussions, the client express his conditions and pre-requisites before placing the order.
• Pyrocrat satisfies the client’s conditions and ensures client’s understanding of the plant and machinery.
• Client releases the purchase order to Pyrocrat Systems for rated Pyrolysis plant.

Based on the feedback of our established clientele in India, the production cost of Pyrolysis Oil presently ranges: INR 18.00 to 23.00 per liter with Waste Plastic as raw material and INR 22.00 to 26.00 per liter with Used Tyre as raw material. The present sale realisation of high quality Pyrolysis Oil produced from our plant ranges approximate INR 43.00 to INR 46.00 per liter.

Our facilities are designed for zero emissions and are based on a green and environmentally friendly technology. Scrubbers and condensers are built inside the system and in cooling area. No hazardous Gases, Ash or other hazardous materials are released from the system. All streams are designed to condensed, scrubbed or cleaned before being released from the plant.

Hydrocarbon Gas generated is fully utilized for operating the Reactors in plant. The usage makes zero support fuel required to operate the Pyrolysis plant.

Pyrolysis Plant established by Pyrocrat can process both Waste plastic and Used Tyres. As we live in era of Use and Throw the Plastic Waste is available across the Territories of the World.

Both can be used with equal ease however removal of Steel wires is must before the feed to Plant.

Our Reactors life expectancy is approximately accounted for 15 years of normal operation as per the company operating guidelines. Given below are the type of maintenance and specifications of our support by Pyrocrat System:

• Regular Preventive Maintenance: to be carried out by client at his own cost. Pyrocrat tech team will train and offer guidance time to time.
• Maintenance due to manufacturing defect: Pyrocrat will carry out the necessary maintenance free of cost in case of manufacturing defects.
• Operational Maintenance: In case of any maintenance resulting from the improper operation/handling of equipment, the cost for the same will be incurred by the client. Pyrocrat System will offer necessary support and guidance.

Typical industrial applications of pyrolysis oil as a fuel:

• Boilers
• Furnaces
• Hot Water Generators
• Hot Air Generators
• Thermic Fluid Heater
• Electric Generators (mixed with 50% diesel)
• Diesel Pumps(mixed with 50% diesel)

Yes, we have number of commercially operating Pyrolysis plants supplied by Pyrocrat Systems LLP for which plant visit can be arranged. Prior permissions have to be obtained from our established clients in advance.