2G BioPOWER Enviro UK Tyre Pyrolysis
2G BioPOWER Creating a business to convert tyres into oil, extract carbon black and steel Reviewed ~ 20 technologies Partnered with Scandinavian Enviro Systems (Enviro) in 2013 UK agreement since 2015 The aim is to build the first plant in the UK based on Enviro s technology
Who are 2G BioPOWER? Howard Jackson ex construction industry and motor sports. Was pivotal in the introduction of biofuels into motor sport. Mike Tooke Chartered Energy Engineer. Consultant in the application of thermal processes for waste recycling. Robert Oakley (advisor) previously Managing Director of Eco-Oil, a waste oil recycling company.
Used Tyres Today In the next 24 hours, within the UK, we will dispose of 1,000 tonnes of tyres. Disposal costs at least 25 per tonne Current uses of waste tyres include: As a fuel in the manufacture of cement in the UK Export as a fuel Shredding and milling for use in playing surfaces
Wasting a Waste Each tonne of tyres can be processed into ~ 300 of oil, steel and carbon. Using tyres as a fuel means we are currently sending 200,000 of re-usable product up in smoke every day. Uses in artificial turf and equestrian surfaces are raising health concerns. Carbon Black companies use 1,600 litres of oil to manufacture each tonne of the carbon black burned.
The Alternative The alternative is to recover the materials from tyres and reuse them: Used in the recovery Process Sale or Power generation Re-cycled Re-used in rubber manufacture
Scandinavian Enviro Systems Over 20 years development Probably the leading thermal tyre reprocessing technology in the World Commercial demonstration plant in Åsensbruk in Sweden Enviro s recovered Carbon Black (rcb) first to be commercially re-used in rubber products. Full scale plant construction starting in 2017
Why SES? Issue Significant energy and cost is required to produce wire free crumb required for continuous processes Steel extracted through crumbing has rubber remnants that reduce its value Batch processes using external heating lead to poor and uneven heat transfer Some processes leave volatiles (hydrocarbons) in the carbon which can render it valueless For carbon to be saleable it has to be milled and beaded Enviro Solution As a batch process Enviro uses tyre shred (with steel wire) thus minimizing pre-processing The steel produced is clear of rubber and has minimal carbon remaining Tyre shred is heated using a hot gas thus achieving good heat transfer & distribution The Enviro process is run until volatiles in the carbon have been reduced to the required level The Enviro solution includes carbon milling and beading Oil condensation control is required to ensure Flash point is within tolerances 3 stage condensation: primary oil fraction FP>66 C
Tyres are readily available Commercial Potential 15 1 Tonne 185 300 in commodities per tonne of tyres 100 Govt incentives not required Potential further developments to gain more value from the oil
Commercial Potential 15 Clean steel 1 Tonne 185 Approved by Volvo Cars for use in rubber components 100 Approved by Wärtsilä for power generation* ~ 50% renewable * https://www.envirosystems.se/en/press-releases/scandinavian-enviro-systems-publ-tyre-pyrolysis-oil-tpo-approved-as-fuel-in-wartsilas-power-plants-2017-04-28/
Enviro rcb in Volvo Truck Tyres Enviro and Volvo Trucks new partnership in progress Enviro s recycled carbon black may soon be approved for use in truck and bus tyres as a result of discussions between Volvo Trucks and Enviro through the RISE circular economy research project. Volvo Trucks would like the opportunity to influence tyre producers to use recycled carbon black in their operations, says Thomas Sörensson, CEO of Enviro. Last year, Volvo Cars approved the use of environmental rubber containing Enviro s recycled carbon black after a long quality test process. Volvo Cars has since then significantly increased the use of environmental rubber. Because our recycled carbon black is already approved for industrial use by both Volvo Cars and several international tyre manufacturers, we ve been able to start discussions with Volvo Trucks in concrete terms. https://www.envirosystems.se/en/news/enviro-and-volvo-trucks-new-partnership-in-progress/
Carbon Black Market CB Market Enviro/ 2GB Progress General Rubber Goods 2,000,000 Tonnes per annum Compounders End Producers Volvo Car Components Alvenius pipe seals Trelleborg, Eastland, VIP Passed Tests Tyre Factory Tyre Company Vanlead - China Largest tyre manufacturer in Tyres 8,000,000 Tonnes per annum Tyre Factory Tyre Factory Tyre Factory Tyre Factory Tyre Company Tyre Company China: Enviro MOU for plant Volvo Trucks Facilitating Enviro rcb testing in Tyres Tyre Manufactures Evaluating Enviro rcb in Tyres
EnviroCB 550 EnviroCB 550 is the Carbon Black recovered from used car and truck tyres by Enviro s technology. Reduces CO 2 emissions by 60% when compared to virgin carbon black The first to be used in new rubber components: for Volvo Cars and Alvenius Has been endorsed by Vanlead tyre manufacturer in China as the best they have ever tested Approved for use in plastics masterbatches by major manufacturer.enviro has signed an MoU with the Vanlead Group as a first step towards creating a new recycling facility in Guangdong in Southern China. The agreement is the outcome of positive results from demanding tests of rubber mixtures intended for tyres that the Vanlead Group performed on Enviro's materials over a period. The intention of both parties is to start building a turn-key recycling plant already in 2017
Implementation Outline
Project Scale Scale is based on 5 reactors and duplicated post reactor processing. Tyres Per Annum Recoverables: Oil Recovered Carbon Black Fuel Carbon Steel 30,000 tonnes 11,000 tonnes 8,500 tonnes 1,200 tonnes 4,100 tonnes The balance is dry gas which is used to heat the process.
Project Timeline Planning 9 months Construction 18 months Commissioning 3 months First year of operation ~ 70% capacity Second year of operation ~ 95% capacity
Financial Summary Plant scale - 30K tonnes of tyres per annum CAPEX 25,000M +/- OPEX 2,500 +/- Revenue 10,000 +/- Payback 5 years Revenue Feedstock Gatefee Recovered Carbon Black Residual Fuel Oil (1%S) Steel Briquettes Off-spec carbon RHI Capacity 30k tonnes of tyres per annum Staff 35 Operating 24/7 Uptime 80% (~7k hours/year)
UK Progress
Progress Progress so far Proof of technology performance rcb proven in tyre and non-tyre applications Oil technically approved in engines Partnership with Engineering Consultancy (AF) Focus now primarily on commercial: Offtakes for recovered Carbon Black Maximum revenue from oil Tyre supply partners
UK Tyres & Offtakes Gained expression of interest from 2 major tyre retailers rcb: 2 UK tests so far (compounder and a manufacturer) Contact with tyre manufacturers Working closely with Enviro on international offtakes Oil: approved by Wärtsilä for use in medium speed engines (power or CHP application) Meets UK DfT criteria for a 2 nd Gen biofuel (subject to desulphurisation) higher value options identified
TPO in Power Generation TPO 11,000 tonnes per annum 48,000 MWh 20-60,000 MWh Power despatchable Depends on heat quality Oil ~50% renewable Potential for incentives support
Sites and Partners Sites broadly available mainly due to failure of several waste-to-energy plants In master plan for Thames Enterprise Park Discussions with 3 potential investors so far in 2017; enquiries roughly every 3 months. Generally have waste management experience and sites In contact with major international waste management company Progressing potential for synergies in respect of reverse tyre logistics
Current & Potential Stakeholders Technology Enviro Site / Planning Oil Used for Power rcb Sales GRG, Tyre Companies Tyre Supply Major tyre Retailers Operation Engineering & Construction ÅF