This comment was written by Tire Pyrolysis Experts on 6 Feb 2025.
Scrap Tyre Oil Plant
Tyre pyrolysis is a thermochemical decomposition process that breaks down rubber polymers in the absence of oxygen. This process occurs within a sealed reactor under controlled temperature and pressure, typically ranging from 300°C to 700°C. In the absence of oxygen, the rubber undergoes thermal cracking, decomposing into smaller molecules and yielding various valuable products.
End Products of Tyre Pyrolysis
The pyrolysis of scrap tyres generates three main end products:
Pyrolysis Oil (Tyres Oil): This is the primary product, constituting 40-50% of the output. It's a complex mixture of hydrocarbons with properties similar to diesel fuel, making it suitable for various industrial applications.
Carbon Black: Accounting for 30-35% of the yield, carbon black is a fine powder primarily used as a reinforcing agent in rubber products and as a pigment in inks and paints.
Steel Wire: Present in the tyre's structure, steel wire is recovered during the process and can be recycled by the steel industry.
Classification of Tyre Pyrolysis Plants
Tyre pyrolysis plants can be broadly classified into two main types based on their operational mode: batch plants and continuous plants. Each type has its own advantages and limitations, making them suitable for different scales of operation and business needs.
Batch Pyrolysis Plants
Batch plants process scrap tyres in discrete, separate batches. The tyres are loaded into the reactor, the pyrolysis process is carried out, and the products are collected before the next batch begins.
Advantages:
Lower initial investment cost, making them suitable for small to medium-scale operations.
Simpler design and easier maintenance.
Flexibility to process different types of tyres or waste materials in separate batches.
Limitations:
Lower efficiency due to downtime between batches for loading and unloading.
Higher labor requirements for manual operation.
Limited scalability for large-scale industrial applications.
Continuous Pyrolysis Plants
Continuous plants operate non-stop, with a constant feed of scrap tyres into the reactor and continuous extraction of end products.
Advantages:
Higher efficiency and productivity due to uninterrupted operation.
Reduced labor costs as the process is largely automated.
Better suited for large-scale industrial applications with high processing capacities.
Limitations:
Higher initial investment and operational costs.
More complex design and maintenance requirements.
Less flexibility in processing different types of tyres or waste materials simultaneously.
Profit Analysis of Tyre Pyrolysis Plants
To better understand the economic viability of tyre pyrolysis plants, let's analyze the profit margins of two common types: Continuous Type and Batch Type (Basic Type). The following data is based on a comparison of a 50 TPD (tons per day) continuous plant and four sets of 15 TPD batch plants.
Continuous Type (1 set of 50 TPD)
Daily Costs:
Waste Tires: 62T x 1,900 CNY/T = 117,800 CNY
Fuel: 0.8T x 4,900 CNY = 87 CNY (used for pre-heating)
Electricity Consumption:
Pyrolysis: 120 kW/h x 24h x 0.8 CNY/kWh = 2,304 CNY
Shredding: 650 kW/h x 12h x 0.8 CNY/kWh = 6,240 CNY
Labor Cost: 6 workers x 300 CNY x 2 shifts = 3,600 CNY
Wearing Parts: 300 CNY/day
Total Daily Cost: 130,331 CNY
Daily Income:
Pyrolysis Oil: 62T x 0.4 x 4,900 CNY = 121,520 CNY
Steel Wire: 62T x 0.18 x 2,700 CNY = 30,132 CNY
Carbon Black: 62T x 0.3 x 950 CNY = 17,670 CNY
Total Daily Income: 169,322 CNY
Daily Profit: 169,322 CNY - 130,331 CNY = 38,991 CNY/day
Batch Type (Basic Type - 4 sets of 15 TPD)
Daily Costs:
Waste Tires: 62T x 1,900 CNY/T = 117,800 CNY
Fuel: 4 units x 0.4T x 4,900 CNY = 7,840 CNY
Electricity Consumption:
Pyrolysis: 4 units x 45 kW/h x 24h x 0.8 CNY/kWh = 3,456 CNY
Labor Cost: 10 workers x 300 CNY x 2 shifts = 6,000 CNY
Wearing Parts: 600 CNY/day
Total Daily Cost: 135,696 CNY
Daily Income:
Pyrolysis Oil: 62T x 0.4 x 4,900 CNY = 121,520 CNY
Steel Wire: 62T x 0.18 x 1,800 CNY = 20,088 CNY
Carbon Black: 62T x 0.3 x 750 CNY = 13,950 CNY
Total Daily Income: 155,558 CNY
Daily Profit: 155,558 CNY - 135,696 CNY = 19,862 CNY/day
GEP ECOTECH: Your Trusted Partner in Tyre Oil Solutions
At GEP ECOTECH, we specialize in providing cutting-edge tyre pyrolysis solutions tailored to the specific needs of our clients. With years of experience in the solid waste recycling industry, we understand the challenges and opportunities associated with tyre oil production. Whether you are setting up a new tyre pyrolysis plant or optimizing an existing one, our expertise ensures that you achieve maximum efficiency, profitability, and compliance with environmental regulations.
Why Choose GEP ECOTECH for Your Tyre Oil Plant?
✅ Proven Expertise & Experience
GEP ECOTECH has successfully delivered high-performance pyrolysis systems to customers worldwide. Our deep industry knowledge helps clients avoid common pitfalls and design a system that meets both operational and regulatory requirements.
✅ Custom-Engineered Solutions
Every project is unique. We offer tailored plant configurations, from small-scale batch systems to large-scale continuous pyrolysis plants, ensuring optimal performance based on your feedstock, capacity, and business objectives.
✅ Advanced Technology for Maximum Output
Our tyre pyrolysis technology is designed for high oil yield, energy efficiency, and minimal emissions. We integrate advanced pre-processing systems (such as shredders and dewatering units) and post-treatment solutions to enhance product quality and marketability.
✅ Comprehensive Support & Risk Mitigation
Setting up a tyre oil plant involves various risks, from regulatory approvals to process safety and profitability challenges. With our extensive industry experience, we help clients navigate these complexities, offering end-to-end support—from feasibility studies and engineering design to installation, training, and after-sales service.
✅ Sustainable & Profitable Investment
Our solutions align with global trends in waste-to-energy and circular economy initiatives. By choosing GEP ECOTECH, you invest in a technology that not only generates profits but also contributes to environmental sustainability.
Let's Build Your Tyre Oil Business Together
Are you planning to invest in a scrap tyre oil plant? Do you want a high-performance, cost-effective, and risk-free solution? GEP ECOTECH is here to help! Contact our team today to discuss your project and discover how we can maximize your returns while minimizing operational risks.