RECYCLING TO ENERGY

RECYCLING OF WASTE TYRES WITH PYROLYSIS

 OUR FACTORY

Our facility is established in 43.000 m2 area.

It is consist of 3 main plants;

1.Granulation Plant : Having a closed surface area of 2.000 m2

2. Pyrolysis Plant : 2.400 m2 closed surface area
3. Power Generation Plant : 1.200 m2 closed surface area

Merkez : Organize Sanayi BOlgesi 17.Cad. No:3 ERZİNCAN 0446 251 12 61 fax : 0446 251 10 06
RECYCLING PLANT

Capable of processing 40 ton/day waste tyres %25 of waste car tyres is steel.
In our plant seperation of steel is done in 2 ways;

1. Steel is pulled out from big tyres, removed from bus and lorry, with steel
draw machines. Its ratio is ranging % 10 – 15 of tyres.

2. Other tyre group (small car tyres) and

tyres free from steel bead ring is shredded
directly with shredder into size of 0–18
mm. Remaining steel is pulled with
magnets resides on the conveyor bants.
After cleaning the steel the amount of
tyre will be 30 ton
- 2 main units under this plant;
- Granulation
- Pyrolysis plants
RECYCLING PLANT
1-Granulation Plant

THICK WIRE STEEL DRAW STEEL DRAW

STEEL CUTTING MACHINE MACHINE

SHREDDER2

THIN WIRE PYROLYSIS

CLEANING GRANULATOR2 GRANULATOR3
PLANT

GRANULATOR3A
GRANULATOR2A

TEXTILE
SEPERATION

VIBRATING SEEVE

GRANULATE
PRESS 0-0,5 mm 0,6-2 mm
GRANULE GRANULE 2-4 mm GRANULE
1-Granulation Plant

End of shredding process 3 sizes of granules are

obtained;

0-0,5 mm: Rubber pads, gaskets , door seals etc.

manufacturing sector.
0,6– 3 mm: Synthetic pitch, sports grounds, floor
surfacing for kindergardens,
2-4 mm: Tracking roads, synthetic grass sports area
18 mm : Used for Pyrolysis process

Production Capacity is 20 ton / day

PYROLYSIS PLANT MODUL-I

18mm
18mm GRANUL
HEATING UNIT GRANUL

18mm
GRANUL

PYROLYTIC OIL

REACTOR

COOLING UNIT
PYROLYSIS PLANT MODUL-I
 PYROLYSIS PLANT MODUL-II

PYROLYTIC OIL
DIESEL OIL

DESTILATION UNIT
PYROLYSIS PLANT MODUL-II

Pyrolysis is a thermochemical decomposition of organic material at elevated

temperatures in the absence of oxygen.

Pyrolysis process is occured in reactors. We have 2 reactors with a capacity of

5,5 ton granules with the size of 18 mm.

First phase of the pyrolysis process is gasification. The light product is stored
in gaseous state.
The discharged pyrolysis gas
is cooled down and the
pyrolytic oil is condensed
and then collected in the oil
drum. Solid residues
remining in the reactor is
carbon black.

Total Production Capacity of

Reactors are 11 ton/days.
PYROLYSIS PLANT MODUL-II
 Obtained Products & Ratio

Product Name Ratio(%)

Pyrolytic Oil 48-52
Carbon Black 42-40
Pyrolytic Gas 10-8

Ratio(%)
8,0

50,0 Pyrolytic Oil

40,0 Carbon Black
Pyrolytic Gas
 PYROLYTIC OIL

Equivalent to crude oil. Incase of distillation naphtha, gasoline, diesel, fuel

oil and bitumen can be obtained.

But in our factory it is directly used as a fuel in our generators for production
of electricity.
CARBON BLACK

Most common usage areas;

• Asphalt concrete material
• Cable
• Conveyor belt
• Hose, mop
• Black bags
• Spare parts for cars
• Isolation
• Pigment in rubber materials
• Basefloor material
• Raw materal for plastic manufacturing
• Rubber mixture with dough
(Tire production)
PYROLYTIC GAS

Equivalent to natural gas. Used for own requirements in our factory

such as heating and in the kitchen.
POWER GENERATION

Annually 40.000.000 kW

with 4 Wartsilla generators

each with 3 MW production capacity,

totally 12 MWh electricity production

VIEWS FROM FACILITY
PYROLITIC FUEL OIL PLANT
PYROLITIC FUEL OIL PLANT
PYROLITIC FUEL OIL PLANT
CONTAINERISED PYROLITIC FUEL OIL PLANT
GENERAL VIEWS
GENERAL VIEWS
GENERAL VIEWS
GENERAL VIEWS
Our Products
CONTAINERIZED POWER GENSET SOLUTIONS
CO GENERATION POWER SOLUTIONS
POWER GENERATION
WASTE TYRES & ENVIRONMENT
A lot of vital hazards to environment in the storage area of waste tyres;

Chemical and visual pollution,

Annually ,In Turkey approximately 400.000 ton waste tyres from 14 million vehicles are revealed.

It is hard to decompose in nature. Decomposition of one waste tyre needs nearly 150 year .

The most noticeable problem associated with large tyre piles is the fire hazard they present. Once a
tyre pile catches fire, it is very hard, if not impossible, to extinguish. Harmful gases emitted into the
atmosphere has serious damage. (Carbon black, volatile organic and semi-volatile organic, multi-ring
aromatic hydrocarbons, oils, sulfur oxides, nitrogen oxides, nitrosamines, carbon oxides, volatile
particles and As, Cd, Cr, Pb, Zn, Fe and so on. Such metals)

Diseases such as encephalitis and dengue fever have also been reported around scrap tyre piles,
particularly in areas with warmer climates which are an ideal breeding ground for disease-carrying
mosquitoes

Elimination by burning emits big amount of carbon and harmful gases into the atmosphere
EU countries, have committed to provide 22% of total energy consumption from renewable sources (
particularly from waste ) (27 November 2001 directive ( 2001/77/EC ) )

All renewable energy policies has been determined to aimed at promoting this goal.

In cooperation with the universities projects such as EU COMBIO ve EU ALTENER are made and the
pyrolysis process products were given priority ,
In the EU, especially biomass pyrolysis oils and bio oil has become an alternative to motor fuel .

In Finland, the pyrolytic oils is burned in turbines to produce electrical energy. In the Netherlands, 350
MW gas -fired power plant is producing energy through the burning of bio oil.

Brazil, is one of the best examples in the world especially in wide use of energy derived from recycling
of wastes in the vehicles

In the United States and Canada,it is common to use of waste in power generation . USA, 4% of the
total energy production is obtained from recycling of waste products.
IMPORTANCE & GAINS OF THE PROJECT

Due to the rapid depletion of natural resources and reduction of raw materials recycling
makes a positive impact on the economy ,

Provide new business opportunities and gives the opportunity to benefit from natural
resources for future generations ,

In Turkey annual amount of waste tyres is 400,000 tons in 2014 ( LASDER data) which can
contribute to the economy by recycling but recycling rate of it is approximately 3%.

Unlike Turkey recycling rate of it is approximately 96% in countries of the European Union.

100% environmentally friendly , do not have an emissions into the environment during
production , producing no waste at the end is process.

Our Recycling project reduces carbon emissions due to its production technology and waste-
to- energy concept. Due to this aspect, our facility was accepted by the Ministry of
Environment and were recorded to carbon market by ‘Department of Climate Change’

We applied to take the Gold Standard in th he voluntary carbon market

 Granulation Building(include building infrastructure) 2000 m2 250,00 USD 500.000,00 USD
Shredder 1 set 200.000,00 USD 200.000,00 USD
Granulation Plant Granulator (18 mm) 2 set 225.000,00 USD 450.000,00 USD
Capacity 60 Granulator (5 mm) 2 set 175.000,00 USD 350.000,00 USD
ton/day Steel Draw Machine 2 unit 50.000,00 USD 100.000,00 USD
Ventilation and Filter system 1 set 150.000,00 USD 150.000,00 USD
Forklift 1 unit 50.000,00 USD 50.000,00 USD
TOTAL AMOUNT 1.800.000,00 USD

Pyrolysis Building (includes atelier room and infrastructure) 2000 m2 250,00 USD 500.000,00 USD
Office Building 500 m2 300,00 USD 150.000,00 USD
Telescopic Forklift 1 unit 150.000,00 USD 150.000,00 USD
Silo (20 ton) 2 unit 20.000,00 USD 40.000,00 USD
Granular conveyor system 2 set 100.000,00 USD 200.000,00 USD
Pyrolysis Plant
Pyrolysis system (15 tons / day) 2 set 3.000.000,00 USD 6.000.000,00 USD
30 ton / day
Oil Storage Tank (100 tons) 4 unit 75.000,00 USD 300.000,00 USD
Oil Storage Tank (30 tons) 4 unit 50.000,00 USD 200.000,00 USD
Gas Storage Tank (100 m3) 2 set 100.000,00 USD 200.000,00 USD
Maintenance and turn bench atelier (with all equipments) 1 set 200.000,00 USD 200.000,00 USD
Oil Destilation system (15 tons / day) 1 set 1.000.000,00 USD 1.000.000,00 USD
TOTAL AMOUNT 8.940.000,00 USD

Infrastructure
Energy Infrastructure ,landscaping and walls,plumbing, lightning protection and grounding 1 set 1.000.000,00 USD 1.000.000,00 USD
Works
,furniture, all necessary work interior and exterior of the building, weighbridge (80 tons)

Generator Building (includes control room) 2000 m2 250,00 USD 500.000,00 USD
Power Plant Gen Set (3 MW ) 4 unit 3.000.000,00 USD 12.000.000,00 USD
(Electricity Generator commissioning and installation Works 1 set 3.000.000,00 USD 3.000.000,00 USD
Production Plant) Crane (10 tons) 1 set 80.000,00 USD 80.000,00 USD
Power transmission line connection and acceptance works 1 set 600.000,00 USD 600.000,00 USD
TOTAL AMOUNT 15.500.000,00 USD

PROJECT GRAND TOTAL 27.240.000,00 USD

 CURRENT STATE -Processed Waste Tire 30 Tons CURRENT STATE -FACTORY EXPENSE ACCOUNT
Monthly Income Annual Income
PRODUCTS Unit (ton) Sale Price Daily Income EXPENSE ITEMS UNIT COST DAILY COSTS MONTHLY COSTS ANNUAL COSTS
( 1 month considered as 25 days) (1 year considered as 300 days)
Scrap Steel Wire 7,5 100,00 USD 750,00 USD 18.750,00 USD 225.000,00 USD Waste Tires 30 20,00 USD 600,00 USD 18.000,00 USD 216.000,00 USD
Carbon black 4 150,00 USD 600,00 USD 15.000,00 USD 180.000,00 USD Staff Salary + Social Security Expense+ Personal Accident Insurance + food + service 60 750,00 USD 1.500,00 USD 45.000,00 USD 540.000,00 USD
Pyrolytic Gas 1 Used for
as aown
fuel requirements in ourforfactory
in our generators such asofheating
production the system and in the kitchen
electricity. Management Staff 3 5.000,00 USD 500,00 USD 15.000,00 USD 180.000,00 USD
Pyrolytic Oil 5 . Electricity + Water 1 16.000,00 USD 533,33 USD 16.000,00 USD 192.000,00 USD
Produced Electricity Energy(Day-Ahead Market) 0,65 USD 1.690,00 USD 42.250,00 USD 507.000,00 USD Machine Maintenance Costs 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
Produced Electricity Energy(if accepted as Renewable Energy ) 13,30 USD 3.458,00 USD 86.450,00 USD 1.037.400,00 USD Fuel 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
0 - 0,6 mm Granular 2,5 110,00 USD 275,00 USD 6.875,00 USD 82.500,00 USD Unexpected Expenses 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
0,8 - 3 mm Granular 5 150,00 USD 750,00 USD 18.750,00 USD 225.000,00 USD TOTAL EXPENSE 3.333,33 USD 100.000,00 USD 1.200.000,00 USD
2 - 4 mm Granular 5 150,00 USD 750,00 USD 18.750,00 USD 225.000,00 USD ANNUAL DIFFERENCE-1 (If energy is sold in Day-Ahead Market) 244.500,00 USD
TOTAL INCOME-1 (If energy is sold in Day-Ahead Market) 30 4.815,00 USD 120.375,00 USD 1.444.500,00 USD ANNUAL DIFFERENCE-2(If energy is sold in Renewable Energy Market) 774.900,00 USD
TOTAL INCOME-2(If energy is sold in Renewable Energy Market) 6.583,00 USD 164.575,00 USD 1.974.900,00 USD
Each generator has a capacity of 3000 kwh and under %85 load 2600 kwh energy can be produced.In this case 500 kg fuel is consumed. We can produce energy for 2,5 hour with the
obtained pyrolytic oil

SECOND STATE AFTER 01.06.2016- Processed Waste Tire 40 Tons SECOND STATE AFTER 01.06.2016 -FACTORY EXPENSE ACCOUNT
Monthly Income Annual Income
PRODUCTS Unit (ton) Sale Price Daily Income EXPENSE ITEMS UNIT COST DAILY COSTS MONTHLY COSTS ANNUAL COSTS
( 1 month considered as 25 days) (1 year considered as 300 days)
Scrap Steel Wire 10 250,00 USD 2.500,00 USD 62.500,00 USD 750.000,00 USD Waste Tires 40 20,00 USD 800,00 USD 24.000,00 USD 288.000,00 USD
Carbon black 10 400,00 USD 4.000,00 USD 100.000,00 USD 1.200.000,00 USD Staff Salary + Social Security Expense+ Personal Accident Insurance + food + service 60 750,00 USD 1.500,00 USD 45.000,00 USD 540.000,00 USD
Pyrolytic Gas 2,5 Used for
as aown
fuel requirements in ourforfactory
in our generators such asofheating
production the system and in the kitchen
electricity. Management Staff 3 5.000,00 USD 500,00 USD 15.000,00 USD 180.000,00 USD
Pyrolytic Oil 12,5 . Electricity + Water 1 17.000,00 USD 566,67 USD 17.000,00 USD 204.000,00 USD
Produced Electricity Energy(Day-Ahead Market) 0,19 USD 12.844,00 USD 321.100,00 USD 3.853.200,00 USD Machine Maintenance Costs 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
Produced Electricity Energy(if accepted as Renewable Energy ) 0,40 USD 27.040,00 USD 676.000,00 USD 8.112.000,00 USD Fuel 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
0 - 0,6 mm Granular 1 350,00 USD 350,00 USD 8.750,00 USD 105.000,00 USD Unexpected Expenses 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
0,8 - 3 mm Granular 2 400,00 USD 800,00 USD 20.000,00 USD 240.000,00 USD TOTAL EXPENSE 3.566,67 USD 107.000,00 USD 1.284.000,00 USD
2 - 4 mm Granular 2 400,00 USD 800,00 USD 20.000,00 USD 240.000,00 USD ANNUAL DIFFERENCE-1 (If energy is sold in Day-Ahead Market) 5.104.200,00 USD
TOTAL INCOME-1 (If energy is sold in Day-Ahead Market) 40 21.294,00 USD 532.350,00 USD 6.388.200,00 USD ANNUAL DIFFERENCE-2(If energy is sold in Renewable Energy Market) 9.363.000,00 USD
For 15 tons new horizontal reactor contract is signed with the manufacturer so the manufacturing of the system is nearly completed. Total amount to be paid for the
TOTAL INCOME-2(If energy is sold in Renewable Energy Market) 35.490,00 USD 887.250,00 USD 10.647.000,00 USD
new system is 500.000,00 USD'dir.
Each generator has a capacity of 3000 kwh and under %85 load 2600 kwh energy can be produced.In this case 500 kg fuel is consumed. We can produce energy for 6,5 hour with the
obtained pyrolytic oil

NEW INVESTMENT PLAN -Capacity will be increased to 60 Tons Waste Tire INCASE OF NEW INVESTMENT PLAN FACTORY EXPENSE ACCOUNT
Monthly Income Annual Income
PRODUCTS Unit (ton) Sale Price Daily Income EXPENSE ITEMS Birim Maliyet Günlük Gider Aylık gider Yıllık Gider
( 1 month considered as 25 days) (1 year considered as 300 days)
Scrap Steel Wire 15 250,00 USD 3.750,00 USD 93.750,00 USD 1.125.000,00 USD Waste Tires 60 20,00 USD 1.200,00 USD 36.000,00 USD 432.000,00 USD
Carbon black 18 400,00 USD 7.200,00 USD 180.000,00 USD 2.160.000,00 USD Staff Salary + Social Security Expense+ Personal Accident Insurance + food + service 65 750,00 USD 1.625,00 USD 48.750,00 USD 585.000,00 USD
Pyrolytic Gas 4,5 Used for own requirements in our factory such as heating the system and in the kitchen Management Staff 5 5.000,00 USD 833,33 USD 25.000,00 USD 300.000,00 USD
Pyrolytic Oil 22,5 Used as a fuel in our generators for production of electricity. Electricity + Water 1 19.000,00 USD 633,33 USD 19.000,00 USD 228.000,00 USD
Produced Electricity Energy(Day-Ahead Market) 0,19 USD 23.712,00 USD 592.800,00 USD 7.113.600,00 USD Machine Maintenance Costs 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
Produced Electricity Energy(if accepted as Renewable Energy ) 0,40 USD 49.920,00 USD 1.248.000,00 USD 14.976.000,00 USD Fuel 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
TOTAL INCOME-1 (If energy is sold in Day-Ahead Market) 60 34.662,00 USD 866.550,00 USD 10.398.600,00 USD Unexpected Expenses 1 2.000,00 USD 66,67 USD 2.000,00 USD 24.000,00 USD
TOTAL INCOME-2(If energy is sold in Renewable Energy Market) 60.870,00 USD 1.521.750,00 USD 18.261.000,00 USD TOTAL EXPENSE 4.491,67 USD 134.750,00 USD 1.617.000,00 USD
Each generator has a capacity of 3000 kwh and under %85 load 2600 kwh energy can be produced.In this case 500 kg fuel is consumed. We can produce energy for 12 hour with the
ANNUAL DIFFERENCE-1 (If energy is sold in Day-Ahead Market) 8.781.600,00 USD
obtained pyrolytic oil
ANNUAL DIFFERENCE-2(If energy is sold in Renewable Energy Market) 16.644.000,00 USD
New investment plan for reactor with 15 ton capacity, 1 shredder and 2 shredder rotor is necessary-Approximate Cost is 1.500.000,00 USD.
Adress:
TR - Postane, Levent Sitesi, I6 No:7 34940 Tuzla, Istanbul, Turkey

Telephones:
Headquarters Pbx : +90 216 395 20 34
Support Center : +90 553 973 70 01( TR )

URL:
http://www.berrindustry.com

E-Mail:
General Information : [email protected]

Skype:
Berr.Industry
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