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Tyre -/Plastics Processing South Africa Introduction and Overview of innovative, new technology

Tyre -/Plastics Processing South Africa Introduction and Overview of innovative, new technology. Global Economist Forum, Bloemfontein 29 – 31st, October 2013. Tyre -/Plastics Processing South Africa. Technology- Concept by : Martin Walzer / C4 Solution AG, Switzerland Presentation by :

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Tyre -/Plastics Processing South Africa Introduction and Overview of innovative, new technology

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  1. Tyre-/Plastics ProcessingSouth AfricaIntroductionandOverviewof innovative, newtechnology Global Economist Forum, Bloemfontein 29 – 31st, October 2013

  2. Tyre-/Plastics ProcessingSouth Africa Technology-Conceptby: Martin Walzer / C4 Solution AG, Switzerland Presentationby: Douglas Lund / Benchmark Construction & Development, South Africa

  3. Environmental problems

  4. South Africaistakingaction

  5. Whatis REDISA • REDISA isthe initiative toorganizeandcollectoldtires • Producers andimportersarecommitedtopay R2,30/kg on newtiressold • REDISA providesnotechnicalsolutionforprocessingoldtires „wasteintoworth“ isthepurpose – not thesolution

  6. REDISA plan foroldtires

  7. Our „wasteintoworth“ businessmodel consistingof 2 Units: UNIT 1 • Recycling oftirestorubberchips /steel • Recycling/cleaningofplasticstochips UNIT 2 • „upgrading“ – refiningmixtureofrubber/plasticstofuels = „worth“

  8. UNIT I - Recycling oftires in detail • Car tires / trucktires / ML tires • Fromolddepositsordirectlyfrommarket (REDISA) • De-beadingandcutting ML-tiresandbigtrucktires • Processing rubberchips <20mm (fibersincluded) with innovative technology • separatingsteelfromrubbercompletly • Cleaningsteelwireandpressingtobriquets

  9. Recycling ofplastics • Forthisbusinessmodelweassumetopurchaserecycledplasticsfrommarket • Plastics chips <20mm foruse in refinery

  10. UNIT II - Refining • Innovative technologytorefinerubber (60%) andplastics (40%) to clean fuels • High conversion rate (~85%) touseableproducts • Output of clean productsaccordingtoindustryspecifications • „kerosene-optimized“ process due togood hydro-carbon-structureofrubber/plasticsmixture (upto 60% kerosene potential)

  11. UNIT I - tirerecycling 140.000 tpy

  12. Truck tires < 140cm Truck tires > 140cm ML tires ML tires Howitworks - UNIT I tirerecycling Sorting / Preperation Sorting / Preperation debeading Shredder stage 1 cutting Shredder stage 2 Storage Steel cleaning Steel separating Steel compacting Steel(compactedtobriquets) rubberchips <20mm fibers

  13. machinerytirerecycling

  14. Steel processing

  15. 4-5 to/h Unit

  16. Tirerecycling / balancesheet

  17. Tirerecycling / productyields

  18. UNIT II - refinery ART = advancedrefiningtechnology 120.000 tpy

  19. UNIT II - ART = advancedrefiningtechnology • This technologyisdesignedtorefine bio-feedstockandwastematerialscontaining hydro-carbonslikerubberandplastics. • 90% iscommonrefiningtechnologyyou will find in crude-oilrefineries in similarlayout. • The innovation in thisprocessis an upstream plant componentcalled „reactor“ toconvertandvaporizetherawmaterials. • Feedingthereactorisrequiredtobe liquid product, depending on usedrawmaterialsthepre-processinghastobeadjusted.

  20. ART – layout • The overallsystem, thelayoutandimplementationofprocessesismadeaskerosene-optimized • theyieldandkerosene potential ofrefining a mixtureofrubberandplastic (mainly PE/PP) canberelatively high. Reasonsare: • Very positive relationshipbetweencarbonand hydrogen • Noorverylittleoxygen in therawmaterials • Favorable „molecularstructure“ oftherawmaterials, especiallyplastics PE/PP mixedwithrubber • Low aromaticcontentofplastics • „cheap“ placesto break upthemolecules

  21. plastics Rubber chips Gas – therm. Howitworks - UNIT II refining polymerization Pre-processing REACTOR DISTILLATION Gas olefintreatment gasoline Petrol 95octane cleaning kerosene fraction Further treatment (merox, etc.) Jet Fuel A-1 ASTM D1655 Carbonblack silicats hydrotreatment LCO Fuel Oil Diesel fueloil LCO ZnO anorganics, dirt, etc. HCO – therm.

  22. balancesheetandvolumeofsales

  23. balancesheetandvolumeofsales

  24. Market data Imports andexports Kerosene (Jet A-1) andpetrolareveryvaluableproductswith high andstabledemand. SouthAfricaimportsmoreJetFuelandpetrolthanitexports.

  25. Market data JetFuelconsumption Total JetFuelconsumption in 2010 was 2.319 millionsoflitres. The productioncapacityofthisplannedrefineryis 82 millionsoflitres, whichrepresentsapprox. 3,5% marketshare.

  26. Market data Demand / refiningcapacitybalance

  27. Market data JetFuelpriceanalysisandhistory

  28. Market data JetFuelpriceanalysisandhistory

  29. Financial resultInvestment Overviewandprofitcalculation

  30. UNIT I tire recyclingplant 140.000tpy Investment overview The estimationofthe total costs, runningcostsofthe plant isbased on theexperiencebuildingandrunningexistingplants in Europe. In thisoverviewisincluded: • thenecessaryplanning (basicanddetailengineering) • permitapplicationandengineeringrequiredbyauthorities • wholemachineryand plant controlunit • delivery, insurance, installation, commissioning

  31. UNIT I tire recyclingplant 140.000tpy Financial result

  32. UNIT II ART refinery 120.000tpy Investment overview The estimationofthe total costsofthe plant isbased on theexperiencesfromrefineryconstruction, supportedbytherecentwork on anotherprojectwithsimilarprocessingcapacity. In thisoverviewisincluded: • thenecessaryplanning (basicanddetailengineering) • permitapplicationandengineeringrequiredbyauthorities • plant controlunit, MSR-T • steelconstruction, piplineconstruction, etc.

  33. UNIT II ART refinery 120.000tpy Investment in detail

  34. UNIT II ART refinery 120.000tpy Financial result

  35. UNIT II ART refinery 120.000tpy Financial result

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