Pirotex pyrolysis plant
- Equipment Photos
- Pyrolysis equipment layout
- Scheme of gas, heat, fuel and electricity production
- Approval Documents
- Cooling Technology and Unloading
Byuers of Pirotex
- Praha, Czech Republic 2017
- Stavropol territory 2017
- Leningrad region 2016
- Kyrgyzstan 2016
- Kaluga 2015
- Khakassia 2015
- Khabarovsk 2015
- Karelia 2015
- Nizhniy Novgorod 2014
- Naberezhnye Chelny 2014
- Vladivostok 2014
- Vladivostok 2014
- Tatarstan 2014
- Colombia 2013
- Murmansk Region 2013
- Miass 2013
- Naberezhnye Chelny 2013
- Novokuznetsk 2013
- City in the Middle Russia 2012
- Kazan 2012
- Domodedovo 2012
- Yaroslavl 2012
- Kaliningrad 2011
- Nizhny Novgorod 2011
- Stupino 2011
- Vyborg 2010
- Kemerovo 2010
- Slantsy 2010
- Sosnovy Bor 2010
- Krymsk 2010
- Ravda, Bulgaria 2009
- Belene, Bulgaria 2009
- Magnitogorsk 2008
- KVARK-500 Drum Furnace
- UGLAS-800 Gas Generator
- Gas Generator
- Mini Oil Refinery Plant
- Konstanta line for processing of carbon
- Mini Oil Refinery GRIZOX-50
1. What are the technical requirements for the Unit PIROTEX installation area?
To install a unit the site of 8,0х12,0m is required. The surface should be made of reinforced concrete: the concrete foundation thickness is not smaller than 120 mm; the reinforcement is a 8 mm carcass net with a 250х250 mm mesh. There is no special requirements for the wall material. According to our customers' experience the whole unit covers the area of 3,0-4,0 hundred square meters.
2. Does the unit require closed premise?
Yes, the unit should be installed in a closed ventilated premise with its height not less than 7 m. In case of open area unit installation the customer is warned of all the possible consequences and takes responsibility for the installation.
3. What auxiliary equipment for PIROTEX operation is needed?
To operate the unit properly the 18m long monorail is needed. It is an auxiliary recommended equipment. Some other load-lifting equipment with lift capacity of not less then 3,2 tons can be used (if it is already present at your factory).
4. What minimal remoteness of the unit from residential buildings is allowed?
In accordance with sanitary rules and standards, the sanitary zone for this type of waste is 300 meters from residential area.
5. What water amount is necessary for PIROTEX operation?
For the functioning of the unit PIROTEX the industrial water entry in volume of 3,8 cbm/h or 40,0 cbm tank is required.
6. What generating capacity is necessary for PIROTEX operation?
The required generating capacity is 25 kW/h.
7. How many people for the unit maintenance are needed?
In a shift You need 2-3 persons trained by our experts.
8. What additional area can be required?
It is necessary to provide an additional area for rubber storage, crusibles cooling and maintenance and carbon residue storage.
9. What hazardous emissions and in what amount does the unit produce?
The emissions from operating unit does not exceed those stated in the Thresh-hold Limit Values (TLV). Recall that it is relevant while following the process regulations in the operation of the unit.
10. Is any permission to operate the unit required?
Exemplary list of documents and bodies for approvals and permission of hazardous waste recycling activity can be found in the section “Pirotex documents” on our website.
11. How much does the unit delivery cost?
The cost of equipment transportation to the place of installation is paid by the customer. The unit price includes installation, personnel training and commisioning.
12. What is the price of the unit and the time of manufacture?
The prices stated in the price-list on our website are relevant. The time of the unit and auxiliary equipment manufacture is 150 calendar days after the payment of 60% value of the agreement.
13. Is it possible to make a purchase on lease?
We use a simplified tax system without VAT which means that it is the customer who deals with the questions of payment through leasing company.
14. Who is going to perform the functions of a maintenance service?
A maintenance service is established on the territory of the manufacturing plant.
15.How can sorbent and activated carbon be obtained on Pirotex auxiliary equipment?
Activation process should begin with removal of scrap metal from carbon residue. Pre-shreddering should be done next (with fractions of 50-500 μm). Only then the required product(activated carbon or sorbent with its micro- and mezopores maximum openning)can be obtained in rotary drum-type furnace in superheated vapour environment under the temperature of 850-1030C.
16.How can the forced crucible cooling reduce the carbon residue cooling time?
In case of Pirotex plant the forced crucible cooling is carried out by air-water stream through 8mm wall. The thickness of carbon residue is 60-75 cm and its weight is 121-160 kg. All this allows reducing of cooling time up to 4.5 hours and unloading crucible safely.
If carbon residue is not cooled down a spontaneous ignition may occur and may lead to unpredictable results. For this reason pyrolysis cycle of 1.5 tons of mechanical rubber goods may last for 1.5 days.
17.What material is preferable for Pirotex crucibles production?
For crucible production the heat-proof ductile alloy metal (12x18N10T or 12x18N12T) is used. Such metal can stand sudden heating or cooling for a long time allowing for a possible burnout control(for 3 000 - 7 000 hours in course of time).
18.How to carry out pyrolysis process in Pirotex plant without liquid fraction loss during condensation?
As hydrocarbon secondary decomposition takes place during condensation it may lead to up to 10% of liquid fraction loss. For this case Pirotex plant is provided with pyrolysis fan that pumps out gas and vapour. Frequency controller automatically change the rotation of impeller in accordance with collector pressure.
19.How to clean Pirotex plant?
Pirotex plant is cleaned by wet coagulation system with pyrolysis fuel produced by the plant itself. The cleaning is carried out without interrupting of pyrolysis process which makes separation of heavy fractions from medium and light possible and allows operating of the equipment without any additional mechanical cleaning.
The only thing to be cleaned is a crucible bend (with its total size of 67 cm). A special device made by american manufacturers is used for this purpose. It helps to automatically get rid of clog
within 20 seconds.
Clean viscosity oil is repyrolized when sufficient quantity of it is collected(100-200kg).
20.What burners are used in Pirotex plant?
Pyrolysis fuel obtained from mechanical rubber goods pyrolysis consists of dispersed carbon in the form of thin needles of 2-5 nm in size. These needles taken by gas-vapour mixture may clog passes of any complex burner devices (both foreign and domestic) in which pressure feed is used.
After analysis of a large number of Pirotex buyers complaints on clog and damages the Pirotex manufacturers developed special burners for this certain type of oil.
Such burners can work both on pyrofuel and pyrogas which means the separate usage of two types of burners (one for fuel combustion and other for gas combustion)is not required. The burner mode needed is chosen by simple changing of the valve position.
The peculiarity of such burners is a simplicity of its operation and high performance factor. The burners automatic control allows using them in safe-mode operation.
21.Is it possible that during pyrolysis process gas goes out?
Gas comes into system under constant pressure that excludes the possibility of an incident.
22. What sulfur content does pyrolysis oil obtained from processing of mechanical rubber goods has?
The sulfur content of pyrolysis oil obtained in Pirotex is 0.86 – 0.95 %.
This means the pyrolysis oil falls under the category of “sweet crude oils” (low sulfur content).
23. What should be done if sulfur content of 0.86-0.95 is considered to be too great?
In this case an equipment for desulfurisation of pyrolysis oil can be pruchased. The equipment allows to decrease the sulfer content up to 0.1 – 0.3% by hydrogen pyroxid degradation based on formid acid promoter. With the release of raffinate in the quantity of 75-80% from total mass of obtained product through dimethyl formamide (DMF) or acetonitrile (AN) (which is less efficient but more popular) there will be a residue in a form of extract of 20-25% from the total mass. This extract will contain all the rest sulfur amount removed from raffinate.
24. What is the price of such equipment?
The price of the equipment for desulfurisation is settled in individual way and depends on the volume of pyrolysis oil obtained.
25. What consumables are needed for pyrolysis oil desulfurisation?
For desulfurisation of 1 ton of pyrolysis oil and getting the mentioned above figures the following is needed:
hydrogen pyroxid – 80 litres
formic acid – 120 litres
dimethyl formamide (DMF) – 800 litres.
By adding this quantity of materials to 1 ton of pyrolysis oil 1.6 tons of product with sulfur content of 0.1-0.3% and 0.4 tons with sulfur of 3-6% are obtained.
Please note this method is not very efficient as the emission of dimethyl formamide from desulfurised pyrolysis oil is too low for its secondary usage due to its boiling point.
Pyrolysis oil fractions boiling under 160 degrees Celsius will be mixed with dimethyl formamide and will polute it causing dimethyl formamide losing its solvent properties.
That's why such method makes sense only after pyrolysis oil refining when benzine, diesel and black oil (mazut) fractions are obtained.
26. Are there other ways for pyrolysis oil desulfurisation?
The reducing colomn can be pruchased. The equipment is a know-how technology. It serves for emission of pyrolysis oil fraction with the sulfur content of 0.89-0.95% boiling under 180 degrees Celsius. The fractions in amount of 12-15% from the total mass are obtained.
These fractions contain the following solvents: methylbenzene, xylene,bensole, pentane and sulfur content of 0.28-0.38%.
After it the desulfurisation in accordance with the variant No.1 takes place (hydrogen pyroxis, formic acid, dimethyl formamide). After the needed quantity of raffinate and extract are obtained, raffinate should be processed in reducing column once again under the temperature of 172 degrees Celsius for emission and secondary usage of dimethyl formamide.
Another variant is a desulfurisation by ozonization plant. The product is desulfurised up to 0.5-0.6%.
In case the fuel contains mercaptain sulfur there is a method of lime desulfurisation. Pyrolysis oil obtained from mechanical rubber goods pyrolysis contains mercaptain sulfur in a very small amount or does not contain it at all. That is why this method does not used for this type of oil.
All other methods of sulfur removal from oil-containing liquids are too difficult
and are possible only after or in the course of refinery process with applying of very expensive
platina-nickel catalysers, great amount of hydrogen, high pressure and high temperature. As a result the equipment is very complex and expensive and brings profit only when large amount of feedstock is processed.
27. Does the system for carbon activation work separately from Pirotex plant? Can it be used to make active carbon from other wastes except for carbon black?
Yes. Any carbon-contaning substances like coconut shell, wood processing wastes, black coal, etc., can be activated.
The only difference is in technology that allows to activate micro-, mezo- and macropores of different substances. There is a special technology for every product and the Zhelezno manufacturing plant has most of them.
The price of technology which is considered to be the most important part of the product is included into price of equipment.
28. What are the chemical specifications of biodiesel?
Pyrolysis oil is not a biodiesel. Please check the corresponding documents about fractionising on Technokomplex website here and here.
29. Does we need to refine bio-diesel produced through refining equipment to have it used for trucks ?
It is essential. The pyrolysis oil output is the following: diesel – 54%, benzine – 22%, black oil (mazut) – 24%.
A modern, tested and profitable equipment for production volumes of any amount is available in case a question of sulfur content in mentioned products arises.
30. Information about terms of delivery of any Technokomplex equipment:
The equipment is offered on EXW basis.
The Customer conludes the Contract with any transport company he likes and the company is responsible for Goods delivery. Technokomplex has a huge experience in international delivery and can provide customs registration of the Goods for the Customer.
Upon the final payment the Costumer is informed on equipment readiness for shipping. The Customer requests transport company to provide containers for the Goods on the territory of manufacturing plant.