Catalytic Thermal Decomposition Process - EU Agenda

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Delivering Eco Energy Systems

Catalytic Thermal Decomposition Process

Appoints E-Khanate WorldWide Pvt. Ltd as their Alliance – Channel Partner

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Company Introduction

Young and upcoming business company with strong vision engaged in the design, development & distribution of Renewable Energy,

Power Generation, Electronics & Communication Systems.

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ATOZ GREEN INNOVATIONS Pvt. Ltd was incorporated as Manufacturer of leadacid batteries. Constant innovations have helped the Company to produce the finestrange of power backup systems, renewable energy systems specially solar systems,electronic consumables & customized products . The Company has been steadilyprogressing by taking necessary initiatives and keeping up with the latest market andtechnology updates. All together contributing into a durable, genuine, long lasting,standard quality product and customer satisfaction by delivering value for money.

ATOZ GREEN INNOVATIONS Pvt. Ltd collaborates with E-KHANATE WORLDWIDE Pvt. Ltd. for its global expansion.


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What is Plastic

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Ø The term “plastics” includes materials composed of various elements such ascarbon, hydrogen, oxygen, nitrogen, chlorine, and sulphur.

Ø Plastics are macromolecules, formed by polymerization.

Ø It is one of the few new chemical materials which pose environmental problem.

Ø Polyethylene, polyvinyl chloride, polystyrene is largely used in the manufacturingof plastics.


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Waste Plastic

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Humansproducingasmucha300MillionTonsofplasticeachyear,ofwhichonly5%isrecycled.

Moreresourcesused-MorePlasticWasteGenerated!!!

Wasteplasticsbecomingmajorstreaminsolidwasteglobally.

Morethanfivetrillionpiecesofplastic,collectivelyweighingnearly269,000Tons,arefloatingintheworld’soceans,causingdamagethroughoutthefoodchain,newresearchhasfound.(TheGuardian)

Indevelopingcountrieswasteplasticsposingproblems totheenvironmentandhumanhealthduetothelackofenvironmentallysounddisposalpractices

In2010about4.8- 12.7millionmetrictonsofplasticsweredumpedintheocean!


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Disposal Methods

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Direct Burning

Thermal degradation in the absence of air or oxygen

Thermal processing with a limited amount of air or oxygen at very high temperatures.

ThesepracticesignorethefactthatwasteplasticscanrepresentagreatpotentialforresourceconservationasthiswastecanbeconvertedintoavaluableresourceusingCatalyticThermalDecompositionProcess(CTDP).


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What is Catalytic Thermal Decomposition Process (CTDP)

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Catalytic Thermal Decomposition Process (CTDP) is a thermo chemical decomposition of organic material at elevated temperatures in the absence of oxygen (or any halogen). CTDP is also known as pyrolysis.


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What is Catalytic Thermal Decomposition Process (CTDP)

Ø 17%-32% is solid residue, which can be used as a heating source similar to lean coal

Ø 15%-18% is combustible gas which is recycled back to the furnace as heat

The process of Catalytic Thermal Decomposition Process (CTDP) breaks down the feedstock in to the following products

Ø Up to 60% of the output is mixed fuel (depends on feedstock), which can be used in industrial boilers, generators, or can be further refined into diesel and gasoline by the refinery.


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Process Flow Chart

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Thermal depolymerisation is a depolymerisation process using hydrous Catalytic Thermal Decomposition Process (CTDP) for the reduction of complex organic materials (usually waste products of various sorts, often biomass and plastic) into light crude oil.

It mimics the natural geological processes thought to be involved in the production of fossil fuels.

Under pressure and heat, long chain polymers of hydrogen, oxygen, and carbon decompose into short chain petroleum hydrocarbons


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About Process

The whole Catalytic Thermal Decomposition Process (CTDP) system iscomposed by 13 parts, which are reactor ,transmission device, catalyticchamber, cooling tube, heavy tank ,oil-water separator, condenser, light oiltank, safety device, vacuum system, de-dusting system, draft fan, chimney.

•Catalytic Thermal Decomposition Process (CTDP) can be used to reprocess thetyres into fuel gas, fuel oil, solid residue (steel wire) and carbon black.•A Catalytic Thermal Decomposition Process (CTDP) method which producesactivated carbon and high-grade carbon black.•The waste tyres are mainly composed of long chain of C-H molecules.•The major source is from process of Catalytic Thermal Decomposition Process(CTDP), separation and compounding of Oil.•The technology of Catalytic Thermal Decomposition Process (CTDP), cracking,monomerisation of used tyres is always a hot topic.


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Finish Products

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Catalytic Thermal Decomposition Process (CTDP) Oil (Fuel Oil)

The essential product of Plastic Catalytic Thermal Decomposition Process (CTDP)process is Catalytic Thermal Decomposition Process (CTDP) oil referred as fuel oil (30to 60 % of total quantity feed) which is used as a fuel component for heating in firechamber. Catalytic Thermal Decomposition Process (CTDP) oil has flash Point between60 to 93.3 °C.Purest quality of Catalytic Thermal Decomposition Process (CTDP) oil comparable toindustrial diesel: selling price comparable to industrial diesel LDO( light diesel oil)

Carbon Black

The vital product of Catalytic Thermal Decomposition Process (CTDP) plant is carbonblack referred as "charcoal"(15 to 30% of total quantity feed). Carbon black hasIndustrial and commercial use.


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Finish Products

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Hydrocarbon GasThe smaller molecules eventually vaporize and exit from the reactor. These vapors can be burned directlyto produce power or condensed into an oily type liquid, generally used as a fuel. Some molecules are toosmall to condense. They remain as a gas (10 to 20% of total quantity feed) which can be burned as fuel.

Ø Quality of the fuel is directly dependent on following factorsa. Machine Designb. Type of wastec. Type of Catalystd. Process

Ø In general the waste available for Catalytic Thermal Decomposition Process (CTDP) is end of the life non-recyclable plastic.

Ø Can be a mix of PP, PE, LDPE, HDPE in different ratios.

Ø Paper Mill Plastic


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Raw Material Details

List of suitable raw materials for Catalytic Thermal Decomposition Process (CTDP)

• Waste Tyres• Rubber or rubber parts from vehicles• Electronic Scrap• Mixed Waste from waste paper mill• Mixed (HDPE, LDPE, PE, PP, Nylon, Teflon, PS,ABS,FRP etc)• Multi layered• The choice of feedstock and process can impact the value of the finished products


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3D Drawing (Factory Line)

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Proposed Factory Layout for 14 MT / Day

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Plant / Equipment Details Sr . No Description Material

1Catalytic Thermal Decomposition Process (CTDP) Reactor with LAP burner for Gas. 50mm Cerawool insulation BQ 516 gr 70 plates

2 Receiver Tank M. S. Plate3 Oil water separator M. S. Plate with BS 10 Table D. Flanges4 Condensor (Horizontal or Vertical as per design) M. S. Plate & ERW C-Class Heavy Pipes5 Gas Bubbler (Safety Equipment) M. S. Plate with BS 10 Table D. Flanges6 Storage Tank (Heavy Oil) M. S. Plate with BS 10 Table D. Flanges7 Storage Tank (Medium Oil) M. S. Plate with BS 10 Table D. Flanges

8Gas Scrubber tank with high pressure non clogging nozzles, gear pump and packing (Dedusting & Gas Cleaning) M. S. Plate with BS 10 Table D. Flanges

9 Chimney 40ft long 10" & 12" diameterERW C-Class Heavy duty Pipe with bottom cone

10 Electric Winch for wire removal Fabricated11 Flaring system for burning exhaust gases Proprietary12 Control Panel Manual13 Automatic Burners with filtration system Proprietary14 Vacuum Air System Included15 150 TR Cooling Tower Included16 40 KVA DG Set Included


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Equipment Technical Parameter Sr. No Item Contents

1 Equipment type IE-102 Raw Material Tires / Plastic3 Structural form Horizontal Rotation4 24 Hour Capacity Plastic 6.5 ton / Tires 8.5 Ton5 Oil yield 38-70 %6 Operating Pressure7 Material of Reactor 516 GR 708 Thickness of Reactor 16mm9 Rotate Speed of Reactor 0.8turn / minute

10 Total Power 20.2KW11 Mode of Cooling Water Cooling12 Cooling area for Condensor 70sqm13 Kind of Transmission Internal 14 Noise db(A) ≤8515 Size of Reactor (D X L) 2600 X 660016 Working form Intermittent operation17 Delivery Time 12 weeks18 Approx Weight 32T


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Safety Features

Safety

ØManufactured and designed to give maximum product yield with high safety.ØQualified welding procedure ensures the quality of welding seam.ØNormalised 516 gr 70 plates are used for Reactor with optional x-ray detection forwelding.ØVacuum system to remove combustible gases from reactor before de-slagging of carbonand thus avoiding explosion.ØAutomatic Burners for complete process control.ØIt is dangerous to burn incondensable gas (C1 to C4) without any safety measures. Inour process, it is transferred first through the safety device and then burnt in the burner orFlare system.ØAutomatic flaring system to burn the incondensable gas to maintain safe pressure in theentire plant.ØAutomatic PLC or Logic control system for handling the entire process automatically.

Pollution Control System

ØCounter Flow Wet Scrubber system to remove Sulphur and dust from flue gas.ØThe extra incondensable gas will be recycled for heating the reactor, hence no gaspollution.ØReactor Sealing is designed to maintain heat during process and cool faster afterprocess.


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USP Catalytic Thermal Decomposition Process (CTDP)

Ø Reduce plastic waste pollution

Ø Get tipping fees associated with plastic sourcing.

Ø Reduce greenhouse gas emissions (GHG emissions) related to incineration and oil extraction.

Ø Reduce dependency on foreign oil and exposure to volatile oil prices.

Ø Create additional revenue through mixed fuel sales from waste.

Ø Create green jobs for local community.

Ø Create strong environmental stewardship with local community by better waste management practice.


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Catalytic Thermal Decomposition Process (CTDP) Oil Test Report


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Services We OfferWith a wide range of our technical expertise and products, we can

provide customized solution and best of services to our clients as per their requirement to fulfill their challenging needs and value for

investment to the best of their satisfaction.

Ø Planning & Scheduling.Ø Configuration Design &

Management.Ø Preparation of Specification.Ø Technology Selection.Ø Site selection. Ø Feasibility Study.Ø Detailed Project Report.Ø Basic Design.Ø Procurement Services.

Ø Detailed engineering.Ø Review of Drawing & Engineering

Documentation.Ø Site Preparation.Ø Construction & Erection.Ø System Installation.Ø Testing & Commissioning.Ø Maintenance & Repairs.Ø System Upgradation.


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Our ClientsØRight Control & Instruments.

ØIndecor Slides Pvt. Ltd.

ØThane Municipal Corporation.

ØAkshar Inspire Life.

ØKalyan Dombivali Municipal Corporation.

ØTriratna Prerna Mandal.

ØPhotonix Solar

ØKapstone Construction Pvt. Ltd.

ØLeelavati Automations

ØShirpur Varwade Municipal Council

ØTribal Development Corporation Government of Maharashtra.

ØProject Office ShahapurTribal Development Ministry Government of Maharashtra.

ØJharkhand New & Renewable Energy Development Authority

ØProject Office BorivliTribal Development Ministry Government of Maharashtra.

ØAmbika Steel

ØRoyal Ecco Power Pvt. Ltd

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Catalytic Thermal Decomposition Process - EU Agenda

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