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F. No.23-61/2015-HSMD
Government of India
Ministry of Environment & Forest 86 Climate Change
HSM Division
2nd Floor, Jal Block
Indira ParyavaranBhawan
Jor Bagh Road, Aliganj
New Delhi - 110003
Date: 24th November, 2015
OFFICE MEMORANDUM
Subject:-Standard Operating Procedures (SOPs) with regard to recycling
from Waste Pneumatic Tyres, used PET Bottle Scrap, lead
scrap/used lead batteries and recovery of TPO from tyre scrap
-reg.
The matter herein pertains to Standard Operating Procedures
(SOPs) with respect to recycling of:
Waste Pneumatic Tyres/ tyre Scrap
Used PET Bottle Scrap
Lead scrap/used lead batteries
Recovery of Tyre Pyrolysis Oil (TPO) from tyre scrap.

The aforesaid SOPs have been finalized on the basis of recommendations of

the Technical Review Committee constituted under Hazardous Waste
(Management, Handling and Trans-boundary Movement) Rules, 2008. The
SOPs indicate the technical requirement with respect to environmentally
sound operation of such units and import of such waste for the purpose of
recycling and recovery.

o93

In this reference undersigned is directed to convey that State Pollution

Control Board (SPCB)/ Pollution Control Committee (PCC) shall ensure
compliance with these SOPs before issuing any authorization under
Hazardous Waste (Management, Handling and Trans-boundary Movement)
Rules, 2008 or Consent to Operate (CTO) under Air (Prevention 86 Control of
Pollution) Act, 1981 and the Water (Prevention and Control of Pollution) Act,
1974. Compliance with these SOPs shall be certified by SPCB/PCC on the
basis of inspection. The certificate shall accompany the CTO and
Authorization as inspection report for all purposes.
Existing authorization and CTO for such units shall also be
reviewed and such inspection certificate of compliance to SOP shall be
provided to these units, if requested for.

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As far as import of tyre scrap for pyrolysis purpose is concerned, no
such application for import will be considered in the Ministry, until
accompanied by inspection certificate indicating compliance of the unit with
the prescribed SOP. These SOPs are available on Ministry's website
(http: / www. moef.
in/ division/ importexport). CPCB is requested to
upload SOPs on their website.
This issues with the approval of the Competent Authority.
-9cQ1/4.
(Dr.Shruti Rai Bhardwaj)
Joint Director/ Scientist D
To:
Member Secretary , State Pollution Control Boards/ Pollution Control
Committee ( as per the list enclosed)
Copy to:
Shri S.M. Bhatnagar, Joint Secretary (Customs), Central Board of
Excise and Customs, North Block, New Delhi-110001
Joint Director General of Foreign Trade, DGFT, Udyog Bhawan, H
Wing Gate No. 2, Maulana Azad Road, New Delhi-110011
The Under Secretary, Ministry of Petroleum and Natural Gas, Supply
Section, ShastriBhawan, New Delhi-110001
5. Member Secretary, Central Pollution Control Board (CPCB),
PariveshBhawan, East Arjun Nagar, Delhi-1 10032

STANDARD OPERATING PROCEDURE

Import and Recycling of Waste Pneumatic Tyres
I. Background
1.1 As per UNEP guidelines, used pneumatic tyre is defined as a tyre that
has been subjected to any type of use and/or wear. Those used, partly
worn tyres can be re-used without further treatment i.e. direct re-use
which may include (i.) Tyre fitted to second-hand vehicles that are
sold, or obtained from vehicles that are scrapped; (ii.) Old (out-of-date)
tyres that ate used for less demanding applications; and (iii.) Tyres
that are exchanged for reasons other than that of having reached the
end of of their life, such as the vehicle owner's fitting a set of high
performance tyre or new wheels.
1.2 Further, as per UNEP guidelines, waste pneumatic tyre is defined as a
tyre that cannot be used for its original intended use any further.
However, such waste pneumatic tyres may be re-treaded for further
use or can be recovered by being cut, shredded and then used in
several applications, such as footwear, sports ground surfaces and
carpets. They can also be used in the form of tyre-derived fuel for
energy recovery.
1.3 As per HWM Rules, 2008, 'waste pneumatic tyres' are listed at item no
B-3140 of Schedule-III can be imported into the country only for the
purpose of resource recovery, recycling or 'direct re-use'. Since the
tyres for 'direct re-use' are also included in this definition, both 'waste
pneumatic tyres' and 'used pneumatic tyres' come under item B3140 of schedule-3 part-B of the HWM Rules, 2008 - thus require
prior permission from Ministry of Environment would be necessary for
import. However, as per the OM No: F. No.23-4/2009-HSMD dated
24/11/2014 issued by MoEF, import of used tyres for direct re-use
has been prohibited in the country.
1.4 Used pneumatic tyres have not been categorized as hazardous wastes
as per Schedule-I and II of HW Rules, 2008. Provisions under HWM
Rules, 2008 may only apply in case of import of waste pneumatic
tyres.
1.5 The main constituents of used tyres are steel, rubber and fibre in
varied proportions depending upon the duty of the tyre. The
environmental and safety concerns in the recycling arise due to fire
hazard, emission of fibre and fine carbon particles and odour
nuisance.


2. Import of Waste Pneumatic Tyres
2.1 Permission for import of waste pneumatic tyres may be permitted to
actual users having requisite permissions and adequate facilities as
recycling waste pneumatic tyres for resource recovery or utilization.
Import may be permitted for following applications;
Crumb rubber and downstream products
Utilization/ Co-processing in Cement Kilns
(c) Tyre Pyrolysis Oil
2.2 Requirements for seeking permission for Import of Waste
Pneumatic Tyres
A person desirous to import waste pneumatic tyres shall comply with
following documentary requirement;
2.2.1 He should be an actual user
2.2.2 Shall possess valid consent to establish granted by the State
Pollution
Boards/ Pollution
Control
Control
Committees(SPCBs/PCCs) under the Water (Prevention and
Control of Pollution) Act, 1974 (25 of 1974) and Air (Prevention
and Control of Pollution) Act 1981 (21 of 1981);
2.2.3 The applicant unit should possess 'consent to operate' issued by
concerned State Pollution Board under the Water (Prevention
and Control of Pollution) Act, 1974 and Air (Prevention and
Control of Pollution) Act 1981
2.2.4 Certificate of fire clearance form concerned authorities.
2.2.5 Documents showing proof of compliance with the minimum
facilities in the form of photographs, video, documents etc.
2.2.6 Should possess valid IEC certificate issued by office of the DGFT
3. Minimum required facilities and operating practices
3.1.1 (a) Production of Crumb rubber/ reclaimed rubber

C\1
a.

The applicant desirous of importing waste pneumatic tyres to produce

crumb rubber/ reclaimed rubber should have the following
equipment/facilities:

De-beading machine without manual intervention or with

safety guards wherever manual intervention is involved, to
ensure safety of workers.
Strip cutter and chip making machines should have safety
guards to ensure safety of workers.
The Cracker/ Shredder should have adequate arrangement
for capturing fibre and fugitive particulates leading to
cyclone separator/bag filters. The cracker/shredder should
also have magnetic separators to remove any iron particles.
For controlling the noise from these machines they should
have acoustic enclosure.
The grinder/ pulveriser which further reduces the crumb
size should necessarily have adequate arrangements to
extract fibres and fine particles through suction and bag
filters.
All the conveyors, vibrating screens and transfer points
including packing should be covered and fitted with suction
system connected to bag filters.
The whole process area should have proper ventilation
system.
Adequate fire fighting arrangements in terms of fire hydrants
have to be installed in the premise of the units in such a way
that it should cover all the areas of the plot.
workers
All
should
have
personal
protective
equipment/gadgets such as safety apron, masks, shoes,
gloves, goggles, helmet and earplugs.
3.1.2: Production of Reclaimed Rubber

In addition to the above requirement the following environmental

safeguards should be provided during the process of converting the
crumb rubber into reclaimed rubber:

Guards should be provided on machines where manual feeding

is involved;
Adequate ventilation system should be provided in the process
area in view of the high temperature environment and
generation of fumes.

STANDARD OPERATING PROCEDURE

Import and recycling of used/Scrap PET Bottle for the production
of PET flakes
Background
1.1

Plastics are synthetic organic materials produced by

polymerization. There are two main types of plastics:
thermoplastics and thermoset polymers. Thermoplastics are
those which repeatedly soften and melt so that they can be
recycled into new plastics products. Examples are
polyethylene, polystyrene and polyvinyl chloride, Poly-ethyleneterephthalate (PET) among others. Thermosets plastic can
melt and take shape only once and can not be recycled by
repeated heat treatments; Examples are Polyester ,
Polyurethane foam, Bakelite, Urea-formaldehyde, Melamine ,
Epoxy .

1.2

Poly-ethylene-terephthalate (PET) is a thermoplastic produced

from ethylene glycol and terephthalic acid. Globally, there is
rapid increase in use of PET based beverage bottles. Virgin PET
bottles are widely used for packing carbonated beverages,
mineral water, shampoos etc. Large quantities of used/scrap
bottles are thus generated which can be recycled.

1.3

RecycledPET flakes are used as the raw material for a range of

products that would otherwise be made from virgin material.
These include polyester fibres (a base material for the
production of clothing, pillows, carpets, etc.), polyester sheets,
strapping, or back into PET bottles. Technologies are also
available to produce food grade plastic, from used PET bottles
by hydrolyzing down to monomers, which are purified and then
re-polymerised to make new PET.

Import of PET Bottle Scrap

2.1
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a.

Permission for import of PET Bottle Scrap or used PET bottle

flakes may be permitted to actual users having requisite
permissions and adequate facilities for recycling of PET Bottle
Scrap to produce PET flakes or fibers (to make staple fibre,

pillows, carpets, polyester sheets, strapping etc.) or non-food

grade PET bottles.
2.2

Requirements for seeking permission for Import of PET

Bottle Scrap
Any person who intends to import used PET bottles scrap ( for
recycling has to have the following:

2.2.1 Valid consent to operate from concerned State Pollution

Control Boards/Pollution Control Committees(SPCBs/PCCs)
under the Water (Prevention and Control of Pollution) Act,
1974 (25 of 1974) and the Air (Prevention and Control of
Pollution) Act 1981 (21 of 1981);
2.2.2 Registration as per the provisions under Rule-9 (b) of Plastic
(Management 86 Handling) Rules, 2011 from the concerned
State Pollution Control Board.
2.2.3 Fire
safety
certificate
department/authority.

from

the

concerned

3. Requisite facilities and standard operating procedures for PET

recycling units:

3.1 The raw material i.e. bales of used PET bottle scrap should be
received and stored only under a shed with impervious flooring.
3.2 The unit should have a mechanized washing line comprising of
conveyor, crusher, wet separation of caps and labels from PET
chips/flakes, alkaline/detergent hot washing followed by rinsing with
hot water . There should not be any spillage of water during washing
cycle and also there has to be a proper system of collecting labels
and crushed caps.After washing the chips are conveyed
pneumatically to the dryer and then filled in the bags or conveyed
directly to the fibre making section.
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3.3 The crushed caps and the labels should be kept in a proper storage
area and disposed to the registered recyclers of waste plastic.

3.4 The unit should have ETP for effluent generated in the washing line.
The treated waste water should be recycled within the plant to the
extent possible. The sludge from ETP should be stored under covered
shed and disposed off as per the conditions stipulated by the SPCB.
3.5 The unit should have the adequate arrangements for fire-fighting.
3.6 The unit should install adequate pollution control devices so as to
comply with norms as stipulated in Consent to Operate.

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STANDARD OPERATING PROCEDURE

Recycling of Lead scrap/used lead acid batteries
1. Requirements for seeking permission for import of Lead
scrap/used lead acid batteries for recycling:

1.1.1 Any unit desirous of importing lead scrap/ used

lead acid batteries should have valid registration
from the concerned SPCB/PCC. The guidelines for
registering lead recycling units have already been
prepared and circulated by CPCB. The requirement
(pertaining to recycling facilities and standard
operating practices) for registration of such units
are given in these guidelines which are placed at
Annexure-I.
1.1.2 For considering the applications for import of lead
scrap/ used lead acid batteries, the following are
also required in addition to the valid registration:
1.1.3The valid CTOs and authorization;
1. 1.4The analysis reports of stack emissions, waste
waters, ambient air, work zone environment, soil
and ground water specially in respect of lead
content;
1.1.5The latest blood analysis report in respect of lead of
workers engaged in the unit from accredited
laboratories;
1.1.6 In addition to the above, those desirous of
importing used lead acid batteries the following
requirements also have to be met:
The application must specifically be only for fully
drained used lead acid batteries, as un-drained
batteries' import is not permitted;
The applicant must have mechanical battery breaking
equipment with acoustic enclosure, dust and fume
extraction system as well as wet separation system for
lead and plastic;

Annexure-I
STANDARD OPERATING PROCEDURE

Secondary Lead Recycling Units

1. Grant of Registration by SPCBs/PCCs
1.1.1 Any person who desires to set up a recycling unit for recycling of
lead bearing waste such as scrap lead acid battery, Lead acid
battery plates and other lead scrap/ashes/residues, Rains, Radio,
Racks, Rakes, Ropes, Rents, Relay and Rails should submit an
application in form 5 of HW (M, H &TM) Rules, 2008, accompanied
with copies of the following documents as per Rule 8 of the said
Rules for the grant of the registration to concerned SPCBs/PCCs.
Consent to establish granted by the State Pollution Control
Boards/Pollution Control Committees(SPCBs/PCCs) under the
Water (Prevention and Control of Pollution) Act, 1974 (25 of 1974)
and the Air (Prevention and Control of Pollution) Act 1981 (21 of
1981);
An undertaking that the applicant has set up and installed all the
equipment required for recycling of lead bearing scrap. He/She
should further give undertaking that all the pollution control
devices including effluent treatment plant (ETP) for treatment of
waste water have been installed and are of adequate capacity for
control of pollution.
Certificate of registration issued by the District Industry Centre or
any other government agency authorized in this regard;
Proof of installed capacity of plant and machinery issued by the
District Industry Centre or any other government agency
authorized in this behalf.
Proposed Membership of common TSDF for final disposal of slag
after recycling of lead bearing waste;
Process flow sheet of recycling or reprocessing of hazardous waste
along with the details of equipment installed;

vii Details of Air Pollution Control Systems (APCS) installed in the unit
along with the diagram and their specification;
viii. Details of Effluent Treatment Plant (ETP) with for treatment of
acidic wastewater and discharge from scrubber
ix. Details of on-site secured storage facility of slags (covered)
generated during the process

x. Details of covered storage space for raw material having impervious

flooring and finished products. Acid proof flooring in batteries
storage and breaking areas.
1.1.2 After receiving the application, the designated officer/officers should
examine it and the shortcomings if any be communicated to the
applicant within 7 working days of receiving the application.
1.1.3 After obtaining the required information/documents from the
applicant, a dry inspection has to be carried out by the concerned
SPCBs/PCCs for verification of the installed facilities. In the
inspection report, the inspecting officer/officers shall certify that he
has seen the recycling facility and also shall detail out the pollution
control equipment installed in the recycling unit and put his
signature.
1.1.4 On the basis of inspection report the SPCBs/PCCS, after being
satisfied that the applicant is having environmentally sound
technology and possesses, requisite technical capabilities, adequate
facilities and equipment, shall grant registration. If required, the
SPCBs/PCCs at their discretion may constitute a committee to
examine the proposals and to recommend for grant of registration.
1.1.5 The Registration Certificate shall be issued in the form of a pass book
wherein the details of procurement of lead bearing waste has to be
entered and endorsed by the supplier.
1.1.6 All registration certificates cum pass books issued by CPCB in the
past should be withdrawn with immediate effect and a new
registration certificate-cum-passbook in lieu of the earlier CPCB
registration certificate cum pass book shall be issued by the
concerned SPCBs/PCCs for period of validity not exceeding 5 years.
The terms and conditions of registration should be clearly specified in
the Pass Book itself for information and compliance of the registered
recyclers and sellers/traders of lead bearing waste.
1.1.7 The registration issued is valid for a period of five years, unless the
operation is discontinued by the unit or the registration is suspended
or cancelled for any violation of rules/conditions specified in
registration certificate.
1.1.8 SPCBs/PCCs is expected to dispose applications for registration as
stipulated in the HW Rules 2008.

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1.1.9 Within a period of six months from grant of registration, SPCBs/PCCs

shall carry out performance evaluation of the pollution control devices
including ETP for assessing adequacy (meaning whether capable of
controlling pollution or not) of pollution control equipment. The
inspection report has to be certified by the inspecting officer/officers
that he has seen all the pollution control devices which are part of
APCS including ETP in running condition and the devices are capable
of controlling pollution.
1.1.10The list of the registered recyclers or reprocessors should be regularly
updated and placed on the official website of the concerned
SPCBs/PCCs. Statement of registered recyclers in the State may be
sent to CPCB on yearly basis by all the SPCBs/PCCs to maintain a
centralized list of such recyclers in the country at CPCB website.
1.1.11Apart from valid registration, the registered recycling facility can only
operate if it has valid 'consent to operate' under the Water (Prevention
and Control of Pollution) Act, 1974, Air (Prevention and Control of
Pollution) Act 1981 and valid authorization as per HW(H,M86TM),
Rules 2008 for generation, storage, handling and disposal of lead
bearing waste.
2. Minimum required facilities, operating practices and standards
for secondary Lead recycling units.

2.1.1Type of furnace installed (Rotary/ Mandir Bhatti)

Rotary furnace with suction hood connected with APCS over
the charging point exists.
Mandir Bhatti with suction hood connected with APCS over
the charging point and molten metal tapping point exists.
2.1.2 Furnace connected with expansion chamber, cooling
tubes/ducts, Cyclone/Multi Cyclone, Bag filter with pulse
jet/mechanical shaker arrangement, Alkaline Scrubber with
arrangement of alkali dosing, 86 connected with ETP, ID fan and
stack of minimum 30 meter height as shown in the enclosed
process flow sheet.
2.1.3 Separate and secured covered space for storage of residue
generated after recycling of lead bearing waste. The floor of the
storage area should be impervious.

2.1.4 Separate covered storage space for 1 raw material having

impervious acid proof flooring and finished products.
2.1.5 ETP based on physic-chemical treatment of wastewater
2.1.6 Manual battery breaking area should have acid proof flooring
with acid collection pit connected with ETP
2.1.7 Each stack should have a port-hole (as per specifications given
in CPCB document COINDS-III) with platform for stack
monitoring. There should be an easy ladder for safe access to
stack monitoring platform.
2.1.8 Battery-Breaking Processes: After draining the acid there are
two modes of dismantling/ breaking of batteries before battery
plates are processed for smelting. The first mode is manual
where the battery is cut from the top, plates are removed and
left over acid is drained. The second mode is where the battery
is mechanically broken along with the casing.
2.1.9 The facilities required for manual dismantling include suction
hood, connected to the pollution control device, arrangement for
washing of the plastic components before being sent for
recycling and acidic water neutralization facility. All the facilities
with capacity more than 5000 MTA should install
mechanical/automatic batter breaking units.
2.1.10 Facilities required for mechanical/automatic breaking include
arrangements for noise control and dust and fume extraction
system and acidic collection / neutralization facilities and ETP
for treatment of lead and acidic wastewater
2.1.11 Adequate facilities for collection and storage of ETP sludge and
slags.
3. SPCBs/ PCCs may prescribe the following standards for
Emission/Discharge for Lead
Lead in work area, NIOSH 8-hr avg (mg/ m 3) : 0.05
Lead in emission through stack (mg/ Nm 3) * :10.0 (already
notified)

Lead in effluents (mg/1)

general standard)

:0.10 (notified

Lead in factory premises near boundary wall 24-hr avg

(pg/m3) : 1.0
(* Nm3 - normal cubic meter)
e. Workers Blood lead levels: As a practice, all lead related
units should periodically examine their workers at least once
in year for lead level in blood as well as urine. Persons with
higher lead levels (greater than 42 micrograms /dl) should
be shifted immediately to non-lead activity areas and given
special medical treatment till the lead levels come back to
acceptable level (10- micrograms /d1).
4. Steps to minimize fugitive emissions of Lead
The design of hood/fume collection system from the
smelting/refining operations (from metal tapping point,
charging doors, furnace joints etc.) should be capable of
collecting lead emissions and transfer to the air pollution
control system.
The storage and handling of all the raw materials,
intermediates and products should be in covered area/shed
having concrete floors and mechanized equipment should be
used to handle these materials as far as possible.
The floors in the loading area should be kept wet through
sprinklers to reduce the chances of lead particles/dust getting
airborne.
Any water used for washing, rain water etc, should be collected
through separate pits (to delink this from the regular drain) for
removing metallic lead etc and the pit should have fine screens
for passage of clear water.
v. The
movement
of
vehicles
to
the
administrative/working/production areas should ensure that
only the trucks/vehicles involved in the material
handling/transportation reach the work areas, and their tyres
are washed before they leave these areas.
***

STANDARD OPERATING PROCEDURE

Import and recycling OF Waste Tyre Scrap for the production of Tyre
Pyrolysis Oil
Background
0.

1.1 Pyrolysis is a thermal degradation process carried out in the absence of

oxygen/air so that combustion of material does not take place.
Pyrolysis of tyres and rubber products produce low-grade oils, pyrolysis
gas (pyro-gas), carbon-black-char and steel. Technologies are available
to produce high quality oils comparable viscosity and calorific values
comparable with diesel and gasoline type fuels. However, it was
reported that tyre pyrolysis has not been economically viable in United
States as full-scale operations could not be achieved due to costly
clean-up operations.
1.2 Environmental and safety concerns in these plants arise due to fire
hazards, emission of fine carbon particles and odor nuisance and need
for flaring of excess pyro gas.
1.3 Most of the tyre pyrolysis units in the country are batch processes
producing primarily oils for use as fuel oil in industrial furnaces. The
pyro-gas generated form pyrolysis process is used as fuel in the
pyrolysis process. In these plants the full tyres are fed to the pyrolyser
manually and at the end of the process the steel wire and carbon are
taken out manually. This leads to lot of carbon spillage, exposure of
workers to fine carbon particles and working in the unconducive
environment in the pyrolyser. In some of the plants some explosions
also have been reported due to frequent opening of the reactors in the
hot conditions. The flare system is also not properly designed. Since the
system is not completely closed, the odor problem is prevalent
throughout the plant. These are some of the major shortcomings of
such plants.
Requisite facilities and standard operating procedures for the
production of Tyre Pyrolysis Oil:

The applicant desires to import waste pneumatic tyres to produce

pyrolysis oil and carbon-black-char may be considered only the units
have requisite facilities as given below:
2.1 Batch process:

2.1.1

The feed to the pyrolysis reactor should be devoid of steel.

After removal of steel wire the tyre can be put either in the

2.1.2

2.1.3
2.1.4

2.1.5

2.1.6
2.1.7

2.1.8
2.1.9
2.1.10
2.1.11

form of crumbs or chips (which can be made simply by

cutting without going for the shredding process).Further
the feeding arrangement of the rubber crumb to the
reactor should be mechanised.
The initial heating of the reactor should be done by liquid
fuel or gas. The flue gas should be released to the
environment through a chimney of at least 30 metres
height.
After initial heating, during the pyrolysis process, the pyro
gas generated within the plant should be used as a fuel.
Excess pyro gas if any should be flared through properly
designed flaring system of adequate capacity considering
the emergency situation in which the entire gas may have
to be flared. The flaring should be done at a minimum
height of 30 metre.
Adequate instrumentation for measurement and control
of temperature and pressure along with safety
interlocks in case of increase of temperature or pressure
to cut off heating of the reactor should be provided.
Automatic control systems such as Programmed Logic
Control (PLC) shall be adopted. It should be ensured that
the reactor is under positive pressure all the time.
In order to control fugitive emissions from the reactor
during operation, proper sealing should be ensured.
The collection of the oil from the condensers should be
in closed vessel and storage also should be in closed
tanks with suitable vents. There should be no manual
handling of oil. Transfer of oil should be through pumps.
At the end of the pyrolysis process the reactor has to be
cooled before the removal of carbon. During this process,
the reactor should be purged with nitrogen.
The removal of carbon should be started after the
reactor's temperature has come down to below 500C.
The removal of carbon should be through a mechanised
system and it should be ensured that no spillage takes
place during the collection of the carbon in the bags.
Adequate number of sensors along with alarm system
should be provided at suitable locations throughout the
plant to detect any leakage of flammable vapors from the
system.

2.1.12
2.1.13

2.1.14
2.1.15
2.1.16

2.1.17

Adequate firefighting system like sprinklers and fire

hydrant with necessary pumping system and water
storage should be provided.
The plot size should be adequate for storage of crumb or
cut tyres, oil and carbon black in addition to the pyrolysis
plant and accessories as well as enough space for
movement of fire tender in case of any emergency. A
minimum indicative size of small plant is about 3000
square metres.
The plant shall possess clearance certificates issued by
concerned departments.
The carbon black and the oil obtained from the process
should be supplied only to actual users/processors.
The waste water generated in the process from
condensers or any scrubbers should be properly treated
in an effluent treatment plant and the sludge generated
should be sent to TSDF.
Oil containing water condensate should be treated in
suitable ETP. Oily sludge/residues should be disposed
through TSDF.

2.2 Continuous Process:

The continuous plants operating in the country do not suffer from

most of the environmental and safety problems encountered in
the existing batch plants. However, even for the continuous
pyrolysis plants the following facilities have to be ensured:
2.2.1 The feed to the reactor is in the form of crumbs, it should be
ensured that during handling/ transfer of the crumbs there
should be suitable system for suction and collection of fugitive
fibres.
2.2.2 The feeding system should be provided with a air-lock
arrangements so that no air enters the reactor during feeding.
2.2.3 The initial heating of the reactor should be done by liquid fuel or
gas. The flue gas should be released to the environment through
a chimney of at least 30 metres height.
2.2.4 After initial heating, during the pyrolysis process, the pyro gas
generated within the plant should be used as a fuel.
2.2.5 Excess pyro gas if any should be flared through properly designed
flaring system of adequate capacity considering the emergency

situation in which the entire gas may have to be flared. The

flaring should be done at a minimum height of 30 metre.
2.2.6 Adequate instrumentation for measurement and control of
temperature and pressure along with safety interlocks in case of
increase of temperature or pressure to cut off heating of the
reactor should be provided. Automatic control systems such as
Programmed Logic Control (PLC) shall be adopted. It should be
ensured that the reactor is under positive pressure all the time.
2.2.7 In order to control fugitive emissions from the reactor during
operation, proper sealing should be ensured.
2.2.8 The collection of the oil from the condensers should be in closed
vessel and storage also should be in closed tanks with suitable
vents. There should be no manual handling of oil. Transfer of oil
should be through pumps.
2.2.9 The removal of carbon should be through a mechanised system
and it should be ensured that no spillage takes place during the
collection of the carbon in the bags. Moreover an air-lock should
be provided to ensure no entry of air into the reactor.
2.2.10 Adequate number of sensors along with alarm system should be
provided at suitable locations throughout the plant to detect any
leakage of flammable vapors from the system.
2.2.11 Adequate fire-fighting system like sprinklers and fire hydrant
with necessary pumping system and water storage should be
provided.
2.2.12 The plot size should be adequate for storage of crumb or cut
tyres, oil and carbon black in addition to the pyrolysis plant and
accessories as well as enough space for movement of fire tender
in case of any emergency. A minimum indicative size of small
plant is about 3000 square metres.
2.2.13 The plant shall possess clearance certificates issued by
concerned departments.
2.2.14 The carbon black and the oil obtained from the process should
be supplied only to actual users/processors.
2.2.15 The waste water generated in the process from condensers or
any scrubbers should be properly treated in an effluent
treatement plant and the sludge generated should be sent to
TSDF.
2.2.16 Oil containing water condensate should be treated in suitable
ETP. Oily sludge/residues should be disposed through TSDF.