Learn How to Start a Tyre Pyrolysis Business in India

A tyre pyrolysis plant is a Waste to Energy (WTE) model that converts waste tyres into pyrolysis oil. Apart from used tyres, a WTE plant can convert waste plastic into beneficial fuel oil and valuable diesel. WTE plants are hugely popular among businesses and enjoy the support of environmental agencies monitoring waste management in the country. The WTE process positively impacts our environment by disposing of waste environmentally soundly and generating handsome profits for plant owners. Along with these benefits, the pyrolysis method for treating scrap tires is highly accepted. The derived oils and syngas can be used as biofuels, feedstock (carbon black), etc.; this business proposition will be a lucrative investment. The Pyrolysis oil (or bio-oil) has a higher calorific value, low ash, low residual carbon, and low sulfur content. Pyrolysis Plants prevent the disposal of hazardous waste (oil, plastic, rubber, etc.) from landfills. This oil can be used as fuel for steam and construction/highway aggregate and provides superior insulation. This write-up will guide you on how to start a tyre pyrolysis plant in India.

Popular Tyre Waste Recycling Businesses in India

In India, waste and discarded tires are recycled using various methods, such as retreading, mechanical recycling, and waste-to-energy pyrolysis techniques. The following are the tire recycling businesses in India.

Collection and Storage of waste tires Business

Waste tires are collected from various sources, such as tire dealers and garages, and put into tyre yards designed according to the guidelines issued by CPCB. These businesses sort tyres based on size, type, and condition and supply them to tyre recyclers, retreaters, and pyrolysis plants.

Retreading Business

Retreading is reusing the worn-out tire by replacing the worn-out tread with a new one. Retreading involves buffing the tire to remove worn-out tread, applying new tread material, and curing the tire in a specialized oven. Retreading is also emerging as a popular business and has been recognized as a crucial link in the tyre recycling sector.

Pyrolysis oil (Waste-to-energy) Business

Pyrolysis is heating waste tires in the absence of oxygen to break down complex organic compounds into simpler molecules, such as pyrolysis oil, gas, and char. The process produces pyrolysis oil, which can be used as a fuel, and carbon black, which can be used as a filler in various industrial applications.

Mechanical & Physical Recycling Business

Mechanical recycling involves shredding the waste tires into smaller pieces and using them as raw material in various applications, such as playground surfaces, sports fields, and road construction. Some waste tires are reused or repurposed by converting them into tire swings, planters, and other decorative items.

Waste Tyre Pyrolysis Oil Business

Tyre pyrolysis oil is made in India by pyrolysis technique, which involves heating waste tires without oxygen (an anaerobic process) to break down the complex organic compounds into simpler molecules, such as pyrolysis oil, gas, and char. The following is an overview of the process of making tyre pyrolysis oil in India:

How tyre pyrolysis oil is made

• Waste tire collection and sorting: The collection stage is the first step in starting a tyre pyrolysis plant. The waste tires are collected and sorted by size, type, and condition.
• Shredding of tires: The waste tires are shredded into smaller pieces to facilitate pyrolysis.
• Feeding the shredded tires into the pyrolysis reactor: The shredded tires are fed into the pyrolysis reactor, which is heated to around 400-500°C without oxygen.
• Pyrolysis of the tires: The shredded tires are pyrolyzed in the reactor, which breaks down the complex organic compounds into simpler molecules, such as pyrolysis oil, gas, and char.
• Separation of pyrolysis oil: The oil is separated from the gas and char using a condenser and a series of filters.
• Refining of pyrolysis oil: The oil is refined to remove impurities and improve quality, such as by distillation, hydro-treating, and fractionation.
• Storage and distribution: Refined pyrolysis oil is stored in tanks and distributed in various applications, such as fuels for boilers, generators, and industrial processes.

It is important to note that tyre pyrolysis oil in India is subject to various regulations and guidelines, including the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016, and the Pollution Control Board (PCB) regulations. The pyrolysis process must be carried out in a controlled and safe manner to minimize environmental pollution and health hazards. Also, importing used tyres for pyrolysis is prohibited.

Steps in Starting a tyre pyrolysis plant

If you are wondering how to start a tyre pyrolysis plant, you must go through the following stages of the business setup process.

Step 1: How to start a tyre pyrolysis plant: Conduct market research

Before beginning a tyre pyrolysis plant, it is essential to conduct proper market research to identify the demand for pyrolysis oil, sourcing waste tyre and other competing products in the local market. This will help you determine the potential profitability of the business.

Step 2: How to start a tyre pyrolysis plant: Secure Funding

You must secure the needed funding to purchase the equipment and cover the initial operating costs. This can be done through bank loans, venture capital, or other funding sources.

Step 3: How to start a tyre pyrolysis plant: Select a suitable location

You must select a suitable location for your tyre pyrolysis plant that is easily accessible and has adequate infrastructure, such as power and water supply. The site should also comply with local zoning regulations and environmental guidelines.

Step 4: How to start a tyre pyrolysis plant: Purchase equipment

 You must purchase equipment for the pyrolysis process, such as a pyrolysis reactor, condenser, scrubber, and storage tanks. You may also need to buy auxiliary equipment, such as a shredder, conveyor belt, cans, etc.

Step 5: How to start a tyre pyrolysis plant: Hire personnel

You must hire personnel to operate and manage the tyre pyrolysis plant. This may include a plant manager, operators, maintenance personnel, and administrative staff.

Step 6: How to start a tyre pyrolysis plant: Obtain the necessary licenses and permits

You must obtain licenses and permits from the local authorities, such as the concerned State Pollution Control Board (PCB), the State Industrial Department, the Labor Department, and the Ministry of Environment and Forests (MoEF). This list of licenses and permits can include

Business Registration: Business registration, also called incorporation certificate, is vital for any kind of business setup, including production or recycling units

Pollution NOC from SPCB/ PCC: 1. In the case of Waste-to-Energy Plants, the industrial discharge is mainly air polluting, and a substantial quantity of water is used in the process, so the pyrolysis plant is categorized in the red category. In case DG sets of 5 MVA & more are used, the emissions of SO2 will occur due to the use of liquid fuel. Therefore, the unit must apply to the SPCB at the OCCMs portal for Consent to Establish CTE and then Consent to Operate CTO. The documents needed in this case will include

The following documents are required for the NOC Pollution Control Board:

• Layout plan of the industry (Details of sources related to sewage treatment and emissions must be mentioned along with the plan)
• Information on DG set
• Sheet showing information related to process flow
• Analysis report relating to solid waste, effluent, hazardous wastes, and fuel gases
• Information on the instruments installed for pollution control
• Quality Report of air emission analysis
• Consent Fee
• Environmental Clearance (if applicable)
• Details of water requirements
• Diagrammatic Representation of the Monitoring Facility
• CGWA NOC (if required).

Factory license: For this license, the proponent has to apply to the state’s Labor Department, where the unit is proposed to be set up. The standard documents needed for obtaining this license can include schematics of the plant, details of location, details about machinery/ equipment and the manufacturing process, a land ownership/ lease proof-type flow chart of the manufacturing process, etc.

MSME Registration: An enterprise shall be classified as a micro, small, or medium enterprise based on investment in the unit, machinery, and turnover fall in a specified bracket not exceeding five crore rupees: micro, not exceeding fifty crore rupees: small, and not exceeding two hundred and fifty crore rupees: medium). A permanent registration number is given to the Udyam (business)after the registration. There is no need to renew this registration. Having PAN and GSTIN is required for Udyam Registration, effective from 01.04.2021.

Hazardous Waste Management Authorisation: The entrepreneur must apply for waste management authorization and ensure that he follows the SOP and other regulations specified by CPCB for properly recycling and managing tire waste—the documents.

EPR Registration: MoEFCC, in 2022, laid down the EPR responsibilities of producers, recyclers, and retreaters of tyres by notifying the HWM Amendment Rules,2022. This has made the EPR registration for Waste Tyres mandatory for these entities on the CPCB’s centralized EPR portal. The centralized portal for the waste tire management system has become active, and it is compulsory for all the stakeholders listed above to register themselves to continue operations in the country. The present EPR obligation module is limited to online submission of information related to quantities of tyres introduced into the market by producers and generation of EPR obligation. The CPCB will issue a registration number with a validity of two years. Applicants will have to renew the registration in their specific categories after every two years.

Conclusion

Once you have obtained the licenses and permits, secured funding, purchased the equipment, and hired personnel, you can start the operations of your tyre pyrolysis plant. It is crucial to run the plant in compliance with local regulations and environmental guidelines to ensure safe and sustainable management of waste tires. Starting a tire pyrolysis plant in India can be a tiresome and time-consuming process, and it is recommended to take the assistance of professionals and guidance in the legal obligations to ensure proper compliance with all regulatory requirements and best practices when researching how to start a tire pyrolysis plant.

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