• Product name: Report on Feasibility Analysis of Continuous Device Extracting Carbon Black and Rubber Oil from Waste Rubber
  • Product ID: WJ-6
  • Added time: 2015-07-28
  • Views : 235

  I. Background and significance of project development

  With the increasing social modernization, on one hand, the rubber industry has been vigorously developing, and the rubber products have been widely used in all works of life; but on the other hand, more scrap articles are produced and accumulated to big amount as a result of erode-resistant characteristic of the rubber, thus posing a big public hazard to the environment and hygiene. What is worse, the problem has become more severe in recent years; hence, people vividly described it as “black pollution”. Compared with developed western countries, China are very inexperienced in handling the pollution of scrap rubber, besides, the fund and market are big problems too.

  China today has leapfrogged to the first place in the world list of annual car output, exceeding 0.10 billion in 2009. Running cars are not less than 100 million vehicles, according to each car tyres replaced 2 times per year on average calculation. Waste tires left are over 800million every year and the number will continue to rise by double digit yearly. 70% of waste tires are not reclaimed for use, besides, less than half of waste bias tires are reclaimed. China is currently suffering from an insufficient rubber source, which is mainly exported from outside countries. Hence, to improve the management of reclaiming waste tires has called an immediate action.

  A simplest method to handle rubber wastes is to produce reclaimed rubber powder and refine oil. Comparatively, producing reclaimed rubber restricts the future development of reusing rubber wastes as a result of its disadvantages like the high manufacturing cost, narrow sales channel and short service life of plastic runway and other products made. Oil refining has attracted people’s attention with its good sale, fast turnover speed on current fund and high margin. For instance, the average price for recycling waste tires in China is 1050 RMB/ton at present; the rate of oil refined from waste tires is up to 45% plus the production cost like fuel, labor, water and power expenses; therefore, to produce one ton of tire oil will only cost about 2300 RMB, compared with its current market price---3800RMB/ton to 4800RMB/ton.

  The main engine of oil chemistry equipment with waste tires deployed in China mainland, mainly uses vertical fixed processor with processes below: first, the waste tire is put via the cracking processor top by the operator; second, seal the feed inlet and the processor bottom will slowly heat the tire with residues, coal or firewood left as the fuel. Generally, the cracking processor has a volume with 5 stere and one-ton feed. Thus, it usually takes 12 hours to refine once. After the process is completed, it is required to cease for another 12 hours. The open the taphole the bottom of the processor will be opened for dumping the dreg after the processor cools down; the material will be fed from the processor inlet and then enter to next circulation.

  The vertical oil-refining processor using waste tires in China cannot meet environmental protection requirements on its disposal of three wastes during manufacturing; besides, it has a low output and doesn’t have capability to produce continuously. Thus, to fulfill the economic benefits will require more oil-refining processors to work together.

  We have worked jointly with the expert team of Guangzhou industrial university and Hangzhou Academy of Chemical and Medical Engineering to design and release a series of oil-refining devices with unique features of Shangqiu Donghe Corporation, after the research of all experts and years of tackling key technological matters, based on the actual situation and national status.

  II. Main features of latest series of devices (take WJ-8 type for example)

  1. Dispose the waste rubber tires comprehensive to produce two products---carbon black and tire oil at the same time

  2. Each set of device is comprised of ten parts.

  2.1. Pre-treatment device for raw materials

  2.2. Rapid and continuous feeder

  2.3. Integrated rotary cracking device

  2.4. Automatic slaging system with characteristics of safety and environmental protection

  2.5. Whirlwind dedusting device with oil steam

  2.6. Rapid condensation system

  2.7. Exhaust purification, recycle and combustion system

  2.8. Heat source supply system

  2.9. Environmental protection and exhaust system for heat source

  2.10. Central electric control system

  3. Domestic Initiation:

  3.1 This device has rapid, continuous and canned feeding and tapping system and the efficiency is more than three times to the traditional Intermittent Operation Equipment.

  3.2 The matching pressure release device is capable of increasing the value added of oil product to a large degree through deeply processing the oil product.

  3.3 Manufacturing the whole set of device should be carried out in an environment of no smoking and no smell, thus the device having excellent safety and environmental protection property.

  3.4 The split treater of the key equipment for this achievement has a horizontal integrating revolving structure, and comparing this structure with the bygone old equipment, it is found the fuel for the new equipment is fuel oil, and the residue generated in the burning course of fuel oil can fully reach to the exhaust discharge standards of all countries in the world, thus it being able to be used in any countries.

  3.5 High effective fuel gas heating system: when the temperature of the heated gas reaches to 150℃, a large amount of gases----methane to butane---that cannot be fluidified in common temperature and pressure will be generated. And these gases can generate a large amount of heating energy after being burned fully in our specially designed gas burner, thus saving energy to a large degree.

  3.6 The latest technology and the whole split and oil product collecting system developed by the company can be used for this device, and the produced fuel oil has some advantages such as high quality and high oil output rate.

  4. The company’s promise:

  All series of equipments sold by our company can be enjoyed the perfect after-selling service and the free repair service for one year as well as the maintenance service for the whole service life, thus completely resolving the customers’ troubles after buying.

  III. Product and Raw Material Market

  With the rapid advance of the global economy, the demands of rubber market to carbon black become more and more. And among the numerous rubber products, the market price of the cheapest N330 carbon black is 2600 RMB/ton, however, the carbon black produced by our revolving response treater can be the raw material to produce N330 carbon black except being able to be fuel, thus it having a large market demands and a wide prospect.

  Energy source has been the main factor limiting the economic development of each country since the 1990s with the daily increasing trend of petroleum in short supply, the petroleum explored in the whole land of the globe will be exploited out in 35 to 45 years! Seeking new energy sources has become the question all countries in the world focus on. China has a broad tract and a large population, and with the rapid development of the market economy and the popularization of vehicles and machinery, the demands to petroleum is increasing continuously and China has changed from a petroleum exporting country to an importing country. In the first half year of 2009, we still need to import 200 million tons of crude oil from foreign countries to be able to meet the demands of domestic market except the domestically produced crude oil in accordance with the news publicized by China Petroleum & Chemical Corporation. Since 2010, the international price of crude oil increases time and again, and the price of each bucket of crude oil has exceeded 85dollars (quotation from OPEC in April 2010).

  Then whether the sources of the raw materials for refining oil can be guaranteed?

  At present, China annually output on car ranks to the fist in the world with an output of more than 0.10 billion pieces in 2009, running cars are not less than 100 million vehicles, according to each car tyres replaced 2 times per year on average calculation. And the number of annually brought waste and old tires is more than 800 million pieces. Therefore, a country will not need to worry about the supply of its raw materials, if it establishes one hundred factories, with an annual ability to dispose 45000 pieces of tires annually so as to extract carbon black and tire oil.

  IV. Main Technological Characteristics

  1 This device has rapid, continuous and canned feeding and tapping system and the efficiency is more than three times to the traditional Intermittent Operation Equipment.

  2. The heating method of the new equipment is indirect heating method, and the advantages of this method are as follows:

  ①. When some problems occur in the system, closing the induced draught fan can cut the heating source in sudden to ensure the system’s safety.

  ②. The heat exchange distance is more than that of the old equipment by 5-7 times, thus having a higher thermal efficiency.

  ③. Extend greatly the service life of main equipment, and the service life of the new equipment is longer than that of the old one by 2-3 times.

  3. Equipment’s Shape: beautiful and decent, and economic and practical.

  4. Catalyzing heat split technology and chemical extracting technology for product; we can provide special catalyst according to different requirement of customers. The catalyst can decrease the sulfur content and density and solidifying point, improve the smell and color, remove the impurity of the fuel oil. It solve the problem which plagued plastic recycling project with the disadvantages of lots of impurity, bad smell and difficult to store. Take the fuel oil from tyres for an example, the color of oil will be changed from black to transparent red, and the oil can keep longer time for store with better oxidation-resistance.

  5. The equipped environmental protection fittings are more perfect, such as waste gas burner, and flue dust chamber.

  6. The equipment has reasonable design and advanced manufacturing technologies and a high automation degree and complete safety facilities.

  V. Products and Industries Applicable for Revolving Response Treater

  1. Waste and old rubber tire

  2. Waste industrial mixed plastics, and allow multi-kind flotsams exist at the same time, but PET is an exception.

  3. Waste oils. For example: waste diesel and engine oil, waste engine oil, and waste oil residue, etc.

  4. Waste cable skin (suggests dechlorination treatment first and then oil refining)

  5. Waste crude oil

  6. Regeneration of waste PMMA (polymethyl methacrylate)

  VI. Technological Process

  Pretreat and crush waste tires and send them to split processor with no break negative pressure order to catalyze and heat in order to filter out oil steam; oil steam shall pass light and heavy components separation device; light component shall enter the condenser and meanwhile residues shall be discharged automatically in succession. But the liquefied part shall be condensed to rubber oil; and the part that cannot be liquefied shall be input into heating supply system for burning by way of combustion gas purification system.

  Schematic Drawing of Technological Process: (including medium control system)

 

  Security

  The security of main device, the main components of the exhaust gas that cannot be liquefied are alkenes class from C1to C4, whose direct burning is dangerous. Therefore, we shall first make them pass water seal of the first safety device before burning up them as fuels, and further make them pass the gas burner of the second safety device; then the complete safe production shall be realized.

  VIII. Environmental Protection Treatment of the three wastes in the course of production.

  1. Exhaust gas

  By means of full combustion in water seal and gas burner of safety devices, the pollution of exhaust gas shall be eliminated and a large amount of fuel shall be saved. Water shock spraying desulfurization dust collector shall be used to discharge smoke and dust; the discharge of smoke and dust shall meet related standards of GB13271—2001

  2. Waste liquid

  Faintly acid waste water shall produce in the course of treatment of oil products (about 50 kg waste water each ton oil, small volume and tractable); after neutralization by adding faintly alkaline liquor, the neutral waste water shall be harmless with three-grade filtration and be discharged into special evaporation processor to vapor (heat source is the flue residual heat of main processor).

  3. Waste solid

  The residue left from catalysis and split of waste tires is carbon black; there is no waste solid left.

  IX. Analysis of Economic Benefit

  1. Technical parameter of equipment

Serial
No.
Items
Contents
1
Equipment type
LWJ-6 type
LWJ-8 type
WJ-9 type
2
Raw material
Scrap rubber
Scrap rubber
Scrap rubber
3
Structural form
Horizontal rotation
Horizontal rotation
Horizontal rotation
4
24-hour disposal amount
12 tons raw material
15 tons raw material
20 tons raw material
5
24-hour oil yield
5.4 tons fuel oil

7    6.75 tons fuel oil

9 tons fuel oil
6
Operating pressure
Constant pressure
Constant pressure
Constant pressure
7
Rotate speed of
main machine
0.4 turn/minute
  1.       0.4 turn/minute
0.4 turn/minute
8
Power
3.0kw
3.0kw
5.5kw
9
Mode of cooling
Water cooling
Water cooling
Water cooling
10
Consumption of
cooling water (T/h)
4
6
6
11
Kind of drive
External gear drive
External gear drive
External gear drive
12
Heating mode
Hot air
Hot air
Hot air
13
Mounting means
Having base
Having base
Having base
14
Noise dB(A)
≤85
≤85
≤85
15
External dimension of
main machine
(length×width)
6000×2200
6200×2800
7100×2800
16
Working form
Continuous
operation
Continuous
operation
Continuous
operation
17
Weight of main
machine (T)
16.5
21
26
18
Production period
20 days
20 days
20 days

 

  2. The area of the site is 600m2, including 300m2 workshops and 1000m2 material storage and auxiliary area.

  3. Daily production cost

  Take the pretreated waste tires as raw material, and LWJ-8 type as equipment;

  Economic benefit analysis of LWJ-8 type equipment

  a. Raw material: 24tons waste tires×1050 RMB/ton=25200.00RMB

  b. Fuel:24tons*0.02/ton*800RMB/ton=384.00RMB

  c. Water and electricity: 44 kw*22 hours*0.71RMB/kw. =687.28 RMB

  d. Workers’ salary: eight (persons)×60.00 RMB/person=480.00 RMB

  e. Device depreciation 500.00RMB/day

  f. Tax (remark): free from tax for environmental protection project

  g. Other: 100.00 RMB

  h. Total: 30711.28 RMB

  4. Daily turnover (calculated that of WJ-8 type device)

  Daily output of carbon black by WJ-8-type device

  Tires oil: 20 tons* 45%=9 tons× 4000RMB/ton=36000.00RMB

  Carbon black: 24tons*35%=8.4tons*1500.00RMB/ton=12600.00RMB

  Wire:24tons*15%=3.6tons*1200RMB/ton*=4320.00RMB

  5. Gross profit

  Gross profit=daily turnover-daily cost=36000.00RMB+12600.00 RMB+4320.00RMB-30711.28RMB

  =22208.72 RMB

  Monthly profit: 22208.72 RMB /day×25 days=555218.00 RMB

  Yearly profit (ten months): 5552180.00 RMB

  X. Calculation of capital recovery

  Monthly profit: 555218.00 RMB, put into operation within 30 days after device enters factory; capital can be totally recovered shortly in normal production condition.

  XI. Conclusion

  The above analysis and calculation show that it shall be beneficial both to the country and civilians to extract carbon and rubber oil from scrap rubber. It is feasible in terms of technique, with advantages of small investment, much raw material, rapid recovery and favorable prospect; therefore, it is an optimal choice to invest.

  Shangqiu Donghe Special Equipments Co., Ltd

  June 2014

  Company Profile

  Shangqiu

  Donghe Special

  EquipmentsCo., Ltd(China's environmental protection industry association member unit) is the first china environmental protection departments approved the "green star" technology companies in refining oil industry from waste rubber ,waste plastic. The unique processes refining oil from waste rubber and waste plastic have has won six national patents.

  The environmental protection energy-saving horizontal rotation system refining oil from scrap plastic and scrap rubber is independent research and development from our company, and wins praise from customers in the market. The equipment uses device of full automatic feeder and slag-out, and has characteristic of clean, a high degree of automation, strong safety performance, the handling capacity, easy to operate and so on, improving the productivity greatly, and yield better economic returns for customers.

  Ancillary products named atmospheric and vacuum distillation unit can change the quality of fuel oil from the device of rotary type waste rubber and waste plastic, and also use all liquid chemical raw materials just like waste oil, waste engine oil, wasted raw oil and coal tar into production, the daily capacity of the single production line from 6 ton to 300 ton, we can offer the equipment of small quantities and intermittent production or mass and continuous production to your need.

  Our company pursues the ideal of "eliminate the black and white garbage, benefit future generations", and actively promotes the spirit management of "people-oriented, pay attention to personal accomplishment; spontaneous independent, efficient and pragmatic", which is our highest goal to let our customers have exactly what they require: the pursuit of efficiency and the development of combination. After our efforts, we gradually perfect the technology. Our products is covering 26 provinces in the country and exported to Southeast Asia and neighboring countries now. We have lots of customers and agents in Thailand, Malaysia, Philippine, Taiwan and other cities. We put more effort to the development of European and American markets now. Strive to make a greater contribution for the world environmental protection.

  Note: "Green Star" is established with the approval of national environmental protection department, it is special identification of environmental protection registered by China's environmental protection industry association and is used to represent the Chinese green environmental protection product brand logo

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