How to Build a 100,000 m² Tyre Recycling Line in Qatar?

How to Build a 100,000 m² Tyre Recycling Line in Qatar?

Building a tyre recycling plant in Qatar requires strict adherence to local regulations, including obtaining environmental permits, industrial licensing, and compliance with the GCC Standardization Organization (GSO) for emissions and safety. Qatar’s growing automotive sector generates over 2 million waste tyres annually, with most ending up in landfills. However, the government’s ‘National Vision 2030’ prioritizes sustainability, creating opportunities for tyre-to-fuel projects.

Recently, a Qatar client approached us with full certifications—including a Qatar Ministry of Municipality and Environment (MME) permit and GSO conformity certification—seeking to establish a 100,000 m² recycling facility. Below, we outline the key steps to design this tire recycling proposal.

Site Planning and Layout for a 100,000 m² Tyre Recycling Line

Tyre Storage Area (20,000 m²)

  1. Function: Store raw tyres (30,000 tons/year capacity).
  2. Requirements:
    Fire-resistant flooring and sprinkler systems (Qatar Civil Defence standards).
    Covered storage to prevent sand contamination in desert climates.

Tire Processing Area (50,000 m²)

  1. Function: Waste tires shredding, pyrolysis, and distillation equipment.
  2. Design:
    Segregate zones for dust-prone (shredding) and high-heat operations (pyrolysis).
    Install ventilation ducts to channel fumes to treatment systems.
Tire Processing Area (50,000 m²)

Final Product Storage (10,000 m²)

  1. Function: Store tire pyrolysis oil, carbon black, and steel wires.
  2. Safety:
    Explosion-proof tanks for diesel (API 650 standards).
    Silo storage for carbon black to prevent moisture absorption.

Auxiliary Facilities (20,000 m²)

  1. Administrative offices and worker facilities (Qatar Labour Ministry compliant).
  2. Maintenance workshops for equipment repairs.
  3. Wastewater treatment ponds and solar-powered lighting.

What Recycling Equipment You’ll Need in a Tyre Recycling Line

Usually, Qatar clients are extremely concerned about this question: What tire recycling equipment I’ll need in a tyre recycling line? A 10 – ton/hour line requires three core systems:

Comprehensive Size-Reduction System

  • Tire Shredder: Reduces tyres to 50–100 mm chips (e.g., YSX’s Giant Shredder).

  • Steel Separator: Extracts wires via magnetic belts (95% efficiency).

  • Granulator: Further crushes chips to 10–20 mm for pyrolysis.

  • Key Specs: 10 tons/hour capacity, 300–500 kW power consumption.

Pyrolysis Line

  • Continuous Pyrolysis Reactor: Converts rubber into oil, gas, and carbon black (450°C, oxygen-free).

  • Syngas Recycling System: Reuses gas to fuel the reactor, cutting energy costs by 40%.

  • Output: 45% pyrolysis oil, 35% carbon black, 15% steel, 5% syngas.

Distillation Line

  • Fractional Distillation Tower: Refines pyrolysis oil into diesel (ASTM D975 standards).

  • Catalytic Converter: Removes sulfur to meet Qatar’s Euro 5 diesel specs.

  • Yield: 1 ton of rubber chips ≈ 450 liters of diesel.

Budgetary Considerations for a Qatar 100,000 m² Tyre Recycling Line

Equipment Costs

Component Cost Range (USD)
Size – Reduction System $150,000 – $250,000
Pyrolysis Line $400,000 – $600,000
Distillation Line $80,000 – $120,000
Total $630,000 – $970,000

Installation and Setup Costs

Site Preparation

$10,000 (desert land leveling and foundation).

Utilities

$150,000 (grid connection, water pipelines).

Safety Systems

$100,000 (fire suppression, gas detectors).

Operating Costs

Maintenance

$200,000/year (high-grade steel reactors last 10–15 years).

Labor

$500,000/year (30 workers, including expat engineers).

Energy

$300,000/year (syngas recycling reduces power needs).

Building a 100,000 m² tyre recycling line in Qatar demands meticulous planning, robust equipment, and proactive risk management. With the right certifications and a well-designed layout, investors can achieve a 3–4 year ROI while supporting Qatar’s sustainability goals. For a customized quote, contact us today.

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