Are there any Government Licenses or Permissions required for setting up Pyrolysis plant?
Can the existing inefficient Batch type plant be converted to Continuous Type Process?
Sorry, we do not take up conversion of Batch type plants to Continuous Type plants.
Can the operating conditions of the system be monitored?
The operating conditions of the system are monitored with implementation for Temperature and Pressure controls at plant.
Do we need consent from Pollution Control Board to install Pyrolysis 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.
Does the input-output ratio change with the plant capacity?
No. The input-out ratio remains same unless there is change of raw material, catalyst or operating style of the pant.
Does your facility meet the ‘EU standards of emissions’ under ‘Waste Incineration Directive?
How is oxygen prevented from entering the reactor?
With the help of air lock valves and nitrogen generator oxygen can be prevented from entering into the reactor.
How many shifts should you run the plant? and how many hours per shift?
3 Shifts of 8 hours each, Assumption: 26 working days per month
How much is the downtime for maintenance per annum?
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.
If the pressure relief valves open to vent the overpressure, will there be gases released into the air?
Pyrocrat Systems LLP plants are highly efficient design systems ensuring emission control and fail safe system thereby ensuring no environmental hazards.
In your experience what is the typical yield of the product in a normal product facility?
Is it possible to upgrade the plant capacity by adding some equipment?
The plant modules are designed for rated capacities so it is not possible to enhance the plant capacity by minor / major standalone equipment.
Is it recommended to remove the Steel wires from Radial Tyres before it can be processed?
Yes. The feedstock of tires (or plastic) should have particle size less than 25mm.
Is the plant offered by you Semi- Automatic or Fully- Automatic?
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.
Is the Waste Plastic or Used Tyre Shredder part of your Standard supply?
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.
Is there any environmental hazard associated with setting up a Pyrolysis plant?
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.
Is this system manufactured in China or any other Country?
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.
Please send detailed information of the Machinery that you offer to sell.
Detailed information will be given once NDA (A non-disclosure agreement) and Sales Agreement are signed and deposits have been paid.
What all equipment’s client needs to arrange by the time of commissioning?
- 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
What are the end user markets for Carbon Black produced in the Pyrolysis plant?
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.
What are the recommended specifications of raw material?
|PET (Polyethylene terephthalate)||Plastic Bottles for Soda and Water, Microwave Food Trays, Some of Textiles||Less than 5% uniformly mixed with rest of the raw material.|
|HDPE (High-density polyethylene), PE (polyethylene)||Plastic Bags, Milk Jugs, Detergent Bottles, Cosmetic Bottles, Watering cans, Corrosion protection for steel pipelines, Folding chairs|
Folding tables, Heat-resistant fireworks display mortars, Hula hoops, Meter & Valve Boxes, Natural gas distribution pipe systems, Plastic bags, Plastic lumber, Plastic surgery applications (skeletal and facial reconstruction), Portable basketball system bases
|PVC (Polyvinyl chloride)||Shrink Wrap, Pipe, Siding, Blister Packs, Laminate Flooring||Less than 1% uniformly mixed with rest of the raw material.|
|LDPE (Low Density Polyethylene) , LLDPE (Linear Low Density Polyethylene)||Bags for Dry Cleaning and Produce, Stretch Wrap, Wire Coverings||Recommended|
|PP (Polypropylene)||Bottle Caps, Appliances, Automotive Parts, Computer Parts||Recommended|
|PS (Polystyrene)||Cutlery, Cups, CD Cases, Packing Peanuts, Food Containers, Styrofoam||Recommended|
|Agricultural Waste||Any Agricultural Waste||Not Recommended|
|Road Waste||Any Road Waste||Tolerance: 5% of dust + 5% moisture|
|Tires/Rubber||Vehicle tyres, rubber parts of vehicle, bushes etc||Steel wires to be removed before processing.|
What are the safety features in the plant and machinery supplied by you?
- 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.
What happens if plant is stopped midway?
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.
What if all the electric power goes off, will gas be released into the air?
In case of electricity failure, the Gas is not vented in the air as our system has provision for Gas storage facility.
What is alternate fuel for heating the reactor other than process byproduct Hydrocarbon Gas?
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.
What is the Catalyst in Pyrolysis plant?
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.
What is the distillation process? And what is the use in Pyrolysis 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.
What is the effect of international crude oil prices fluctuation on Pyrolysis Plant as a business?
|Fall in International crude oil prices||Fall in polymer prices (because polymers are manufactured from Crude oil)|
|Rise in International crude oil prices||Rise in polymer prices (because polymers are manufactured from Crude oil)|
What is the level of Customer support that you offer?
- 7 days training on plant operation
- Detailed operation, maintenance and troubleshooting guidelines
- Telephonic guidance after sales
- Visit of engineer in case of issue
What is the percentage of your existing Clients using Waste Plastic and Used Tyres?
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.
What is the process for purchasing the pyrolysis plant from Pyrocrat Systems LLP?
- 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.
What is the production cost and selling cost of pyrolysis oil?
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.
What is the proposed organisational chart for effective operation of Pyrolysis Plant?
What is the technologies used to control air, water and solid emission from plant?
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.
What is the usage of Gas generated during the process?
Hydrocarbon Gas generated is fully utilized for operating the Reactors in plant. The usage makes zero support fuel required to operate the Pyrolysis plant.
What kind of raw material can be used in this process? What is its availability?
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.
What kind of Tyres are recommended – Nylon or Radial?
Both can be used with equal ease however removal of Steel wires is must before the feed to Plant.
What will be the life of plant? How is the maintenance schedule and after sales support?
Which industrial equipment use Pyrolysis Oil as fuel?
Would it be possible to visit Pyrocrat’s commercially operating reference Pyrolysis plant?
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.