Processing of metal-free end-of-life tyres (EOLTs) to fuels and products: an experimental study with process simulation and economic analysis from an Australian perspective

Abstract

AbstractThe aim of this experimental study, process simulation and economic analysis is to assess the applicability of pyrolysis technology for processing end-of-life tyres and to evaluate the economic viability of a 60 ton/day EOLT processing facility: a case-specific study within Australia. The experimental work and characterization of feedstock and products were carried out in-house. Capital costs for major equipment were collected from suppliers. The running cost of the processing facility is calculated on the basis of the current labour and utility costs. An economic model is developed based on the information generated from the experimental program and those obtained from suppliers. From the analysis, it is evident that the pyrolysis process for processing EOLT promises a significant upside in economic terms. A conservative conclusion of 20% light oil, ~ 65% furnace oil and 7% carbon black, generated as pyrolysis products, depicts a cash-flow positivity for a 60 tonne per day (TPD) plant that can be run using the generated fuel gas for under 4 years. This is in addition to the benefit of the zero landfill requirement. Apart from the base calculations, the sensitivity of six different scenarios is analysed by mainly changing the land cost and bank investment. Depending on the scenario, the calculated internal rate of return varies between 15 and 35%. While Australia generates significant quantities of EOLT, the techno-economic results confirm that pyrolysis technology for processing EOLT is a viable solution in Australia. However, a dedicated supply chain needs to exist to make pyrolysis plants an attractive investment at defined locations. Graphical abstract