PACS Series 1

IRR Waste 2 Energy

1

Contact Details

1.1

IRR Waste 2 Energy
Head Office: Blyth Road Worksop, Nottinghamshire, UK, S81 0TP
Telephone: 01909 540000
Email: info@irrwaste2energy.com

About IRR

1.2
The Pyrolysis plant at Worksop UK

The last decade was a game-changer in terms of technological advancements for dealing with hard to recycle material. With the circular economy concept and sustainability high on the agenda of businesses across the globe. Many have started to review their procedures and business practices which includes exploring ways to minimise their carbon footprint, increase their recycling and generate their own power.

IRR Manufacturing traded for over 14 years in South Africa and has operated a half tonne per hour continuous pyrolysis kiln since 2013. The kiln outputs were pyrolysis oil which was used as a fuel in the marine industry and a carbon char which was briquetted and used as a solid fuel. The pyrolysis plant ran for 6 years delivering both products continuously during that time.

To facilitate independent power generation for business, Carlton Forest Group invested in not only the technology of a pyrolysis process but the entire South African company – IRR Manufacturing, such was its belief that it had the potential to revolutionise power generation through a cyclical process. The acquisition was completed in 2018 and its visionary approach to the potential that this technology had was evident from the outset. In 2019 a fully functioning kiln was installed at the business headquarters in the UK.

Carlton Forest Group has established the UK subsidiary IRR Waste 2 Energy and this will serve as the main distribution and sales function for the pyrolysis kiln within the Group. It provides a platform to promote the technology in the UK and beyond and allows businesses to fully appreciate how such technology can be integrated into existing business operations to great effect.

The Pyrolysis plant at Worksop UK

Carlton Forest Renewable Holdings Ltd is the overarching company of IRR Manufacturing and IRR Waste 2 Energy and is a company dedicated to investing in a green future. It is committed to developing renewable energy solutions that provide alternative sources of energy. These alternatives sources can be utilised in the local environment by contributing to local heat projects for both domestic and commercial benefits.

Carlton Forest Renewable Holdings Ltd is committed to establishing tangible, viable alternatives that not only replace the carbon sources, but also provide ecologically friendly and aesthetically acceptable solutions via investment in solar power, wind power and waste to energy (biofuels) projects. These are all “green” alternatives to the current over utilised and rapidly depleting carbon energy sources that are commonplace in both domestic and commercial use. In order to achieve these goals, Carlton Forest Renewable Holdings Ltd is working with a worldwide team of both recognised and renowned experts in their respective fields to develop and deliver solutions to benefit the planet collectively.

The manufacturing base has been retained in South Africa and has been developed to cope with increased capacity by partnering with a manufacturing company who can provide a solid manufacturing base to achieve initial expected kiln sales.

Carlton Forest Board

1.3
Mark Pepper Photo

Mark Pepper

Chief Executive Officer
Scott Robson Photo

Scott Robson

Group Finance Director
Diane Ward Photo

Diane Ward

Group Operational Director
Graham White Photo

Graham White

Group Commercial Director

IRR Waste 2 Energy Delivery Team

1.4
Rory Huges Photo

Rory Hughes

Technical Director

Rory is considered globally, as one of the world’s leading pyrolysis and thermal engineers.

Rory commented: "The news that Carlton Forest’s pyrolysis oil has been approved by a third-party engine manufacturer adds great credibility to the massive impact such systems can have."

Adriaan Odendaal Photo

Adriaan Odendaal

SA Technical Director

Adriaan started his career at Chrysler South Africa working his way up to manager. As part of his training he visited Hiroshima in Japan, to pioneer the use of BAR coding and just in time supplies. Adriaan joined BMW South Africa in 1982 and later became Operations Director (one of the youngest directors at BMW).

After owning a successful construction company, in 2005 Adriaan invested in IRR Manufacturing and the research and development of pyrolysis to recycle used tyres. Working with the IRR team together they created a successful pilot plant and by 2010 the first continuous plant was constructed. In 2019 Adriaan sold IRR Manufacturing to The Carlton Forest Group and was made Technical Director South Africa.

Mick Hayes Photo

Mick Hayes

Technical Operations Manager

Highly experienced Operations Manager with an extensive background in manufacturing, including 13 years in FMCG at one of the UK’s largest manufacturing sites. Recognised as a strong and capable leader, developing high-performing teams, delivering major cost reductions and increased profitability via restructures and process efficiency initiatives.

Mick commented: "Delivering projects that integrate into day to day business operations is an area of expertise and my transferrable skills ensure that our technical operations will be efficient and process driven."

Alex Matthias Photo

Alex Matthias

Divisional Commercial Director

Alex Matthias has over 20 years experience handling compliance in both engineering and energy sectors.  He has worked at a senior board level with organisations helping them improve the energy efficiency of their property portfolios. Energy from waste is a sector that he has had specialist knowledge in over the past ten years supporting the development of a number of capital projects with their planning and licensing requirements. 

Alex commented: "The very fact that our oil meets the stringent standards required by engine manufacturers is an incredible development for us and unlocks the potential for more businesses to be able to enjoy the benefits of producing power from waste tyres with ease."

The Story So Far

1.5
 
 
 
 
Mar 2006

IRR Manufacturing established

May 2013

IRR South Africa producing oil

 
 
 
 
 
 
 
 
Jun 2015

Ongoing production of oil for the marine industry

Jan 2016

Ongoing production of low cost fuel

 
 
 
 
 
 
 
 
Carlton Forest Group Map
Jan 2018

Carlton Forest - IRR acquisition

Pyrolysis Kiln
Aug 2019

UK plant operational

 
 
 
 
 
 
 
 
Pyrolysis Oil
Sep 2019

UK oil production

PACS Series 1(Pyrocycle Advanced Conversion System)

2

Introducing the PACS Series 1

2.1
PACS Series 1

PACS Series 1 is a 1000kg per hour continuous pyrolysis plant which can be extended to satisfy the capacity requirements for each customer. IRR Waste 2 Energy’s competitive advantage is that the plants are designed as a modular system and therefore can be purchased incrementally and increased to meet capacity requirements. The modular aspect of the PACS Series 1 allows for multiple streams to be processed. The 1000kg per hour system requires 8mm–15mm tyre crumb which is 99% wire free and 85% fibre free.

The plant, which is operated through a PLC system, is designed to operate continuously for 8000 hours per annum and maintenance requirements are such that the plant will only need to shut down periodically for planned maintenance, major service every 3 months.

Process Flow

2.2
PACS Series 1 Process Flow
Download PDF

Technical Specification Table

2.3
Ref Component Specification
P1.1 Tyre crumb feed Crumb spec: 8–15mm tyre crumb @ 99% steel free, 85% fibre free.
P1.2 Rotating Kiln x 2 Operating temp 450–500°C. Throughput 500kg per hour per kiln.
P1.3 Carbon Char Storage Operating temp 20°C. 2 x 500kg bag stations. Discharge temp 20°C @ 350kg/h.
P1.4 Condensing Array X4 Water cooled condensers in series 7.3m high. Discharge oil at 30°C.
P1.5 Thermal oxidiser 6m long. 2.5m diameter. Refractory lined. Operating temp 850°C and 2 second residence time.
P1.6 Exhaust Gas Scrubbers (Ceramic) Ceramic type dry scrubber using sodium carbonate and powdered AC.
P1.7 Cooling Tower Wet-type cooling tower.
P1.8 Exhaust Stack 150mm Diameter. Height dependent on air dispersion modeling on each site. Output temp 110°C.
P1.9 Interim Oil Tank Capacity 1000ltr. Temperature 30°C at discharge into tank prefiltering.
P1.10 Oil Filtration Skid Filtering all metal from oil and reduces suspended particulates to sub 4 microns. Also incorporating vacuum dehydration for moisture removal.
P1.11 Bulk Oil Storage (Customer Supply) Mild steel 40,000ltrs with recirculating pumps placed on a bund with 110% capacity.
P1.12 Exhaust Fans 2 number exhaust fans, 1 primary and 1 back-up.
P1.13 Backup Generator Energy consumption 100kW/h.
P1.14 PLC PLC control and monitoring of all motors, fans and temperatures. Controlled through a SCADA system that controls safety and inputs.
P1.15 Heat Exchanger Operating Temperature 850°C input and 200°C output.
P1.16 Baghouse Filter Baghouse filter leading to exhaust fan.

Outputs

2.4

The outputs are detailed on the below diagram for a PACS Series 1. This system will operate for 8000 hours per annum.

Costs/Program of Works

2.5

PACS Series 1 £3,250,000 + VAT

Payment Terms

The following payment terms apply and will be invoiced in stage payments as set out below.

  1. 40% of the total contract sum to be invoiced on contract signature.
  2. 50% of the total contract sum to be invoiced prior to shipping (following factory acceptance testing).
  3. 10% after successful completion of acceptance testing.

Payments 1 & 2 due within 7 days and the final 10% payment within 28 days.

Due to currency fluctuations the above costs are valid for 14 days from the date of this offer. Finance can be arranged, and the above figure does not include any finance which will be separate and outside of this agreement.

Delivery

Delivery to be confirmed at time of order – but will be approximately 9 months from order placement to completion of commissioning. See Project Timeline.

Project Timeline

2.6

Indicative Timescale

Place order to machine build 6 Months
Packing 2 Weeks
Shipping 6 Weeks
Installation 4 Weeks
Commissioning 2 Weeks
Acceptance & performance testing 4 Weeks

A site visit and sign off prior to packing being commenced is required to ensure the build site is prepared to accept the equipment this is to include but is not limited to the following customer supplied facilities:

  • Concrete slab to accept all equipment including but not limited to two kilns and ancillary equipment.
  • 100 kVA power supply (single phase & 3 phase).
  • A suitable water supply for the cooling tower.
  • All the above services must be positioned ready to be connected to the plant.
  • Suitable staff facilities and sanitation are available.
  • A safe area for IRR staff to work that is fenced off from all other personnel/traffic (2.5 metre perimeter).
  • Adequate Liability Insurance is in place with a reputable insurer.
  • A suitable base for the cooling tower.
  • Watertight building – Doorway access min 3m wide, 4m high.

Support/Warranties

2.7
  • 5–year warranty on the stainless-steel kiln body
  • 2–year warranty on all mechanical components
  • 1–year warranty on electrical components
  • Essential parts and support pack available upon request

Certification

2.8
  • CE marked
  • Atex rated

Clarifications

2.9

The following are not included within our scope of supply.

  • Design, supply and erection of necessary buildings
  • Masonry, concrete and excavation work
  • Lightning protection system
  • Fire and explosion protection equipment, sufficient to provide structural and organisational fire protection
  • Water supply for plant
  • Main voltage distribution and cabling to switch cabinets and connection thereof
  • Building electrical supply and illumination including emergency lighting
  • Storage area for equipment during assembly
  • Any kind of insurance
  • Taxes, duties, customs charges, public charges etc.
  • Local certifications and requisite consents
  • Additional measures due to local regulations which are not yet known
  • Critical spare parts
  • Consumable materials
  • Crumb for testing, commissioning and 30 days acceptance testing
  • Exhaust stack
  • External oil tank
  • Routine maintenance of oils, lubrication and greases