genburg feasibility report for Re-Born fuel plant
- 1. GENBURG ENERGY Energizing the Future… Report on Feasibility study of setting up a Waste plastic to fuel Plant May 2022 All Rights reserved
- 2. GENBURG ENERGY LTD 2 Global waste Scenario P. 3 Plastic Pollution P. 6 The Challenge P. 9 The Solution P. 14 Plant Components P. 20 Advantages & Benefits P. 21 Financial Analysis P. 22 About Us P. 35 Our Products P. 36 Agenda
- 3. GENBURG ENERGY LTD 3 Solid waste management affects everyone; however, those most affected by the negative impacts of poorly managed waste are largely society’s most vulnerable—losing their lives and homes from landslides of waste dumps, working in unsafe waste-picking conditions, and suffering profound health repercussions. As you will see in this report, the world is on a trajectory where waste generation will drastically outpace population growth by more than double by 2050. Although we are seeing improvements and innovations in solid waste management globally, it is a complex issue and one that we need to take urgent action on. Solid waste management is a critical—yet often overlooked—piece for planning sustainable, healthy, and inclusive cities and communities for all. However, waste management can be the single highest budget item for many local administrations Global Waste Scenario
- 4. GENBURG ENERGY LTD 4 Solid Waste Management Global Projected Waste Generation
- 5. GENBURG ENERGY LTD 5 Solid Waste Management Global Waste Composition Global Waste treatment and Disposal
- 6. GENBURG ENERGY LTD 6 Plastic Pollution Plastic Pollution Take a moment and look around, you will realize how dependent we are on plastics. It has become an unavoidable part of our lives in the past three decades or so. According to a report, the world produces 400 million ton single-use plastic (SUP) waste annually (47 per cent of the total plastic waste). It is estimated that only 9 per cent of the plastic is getting recycled worldwide. Globally to date, there is about 8.3 billion tons of plastic in the world – some 6.3 billion tons of that is trash In 1950, we created 2 million tons a year, which increased 200-fold by 2015.
- 7. GENBURG ENERGY LTD 7 Plastic Pollution 1950 1976 1989 2002 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 0 50 100 150 200 250 300 350 400 Production of Plastics Worldwide From 1950 to 2018 Year Production Volume ( In million metric Tons)
- 8. GENBURG ENERGY LTD 8 Plastic Pollution United States European Union India Japan Sweeden Norway 0 20 40 60 80 100 120 28.9 58.2 80 84.8 85 97 Plastic Bottle Recycling - Different countries 2017 & 2018 Recycling Rate
- 9. GENBURG ENERGY LTD 9 Plastic Pollution The Challenge While plastic has many valuable uses, we have become addicted to single-use plastic products — with severe environmental, social, economic and health consequences. Around the world, one million plastic bottles are purchased every minute, while up to five trillion plastic bags are used worldwide every year. In total, half of all plastic produced is designed for single-use purposes – used just once and then thrown away. Plastics including microplastics are now ubiquitous in our natural environment. They are becoming part of the Earth's fossil record and a marker of the Anthropocene, our current geological era. They have even given their name to a new marine microbial habitat called the "plastisphere". Our planet is chocking with Plastics.
- 10. GENBURG ENERGY LTD 10 Plastic Pollution Primary Plastic Production by industrial sector Plastic waste generation per person
- 11. GENBURG ENERGY LTD 11 Plastic Pollution Probability of mismanaged plastics emitted to Ocean Share of Global mismanaged plastic waste 2019
- 12. GENBURG ENERGY LTD 12 Plastic Pollution
- 13. GENBURG ENERGY LTD 13 Plastic Pollution
- 14. GENBURG ENERGY LTD 14 The Solution The Solution Plastic recycling refers to the process of recovering waste or scrap plastic and reprocessing the materials into functional and useful products. This activity is known as the plastic recycling process. The goal of recycling plastic is to reduce high rates of plastic pollution while putting less pressure on virgin materials to produce brand new plastic products. This approach helps to conserve resources and diverts plastics from landfills or unintended destinations such as oceans. Currently, there are three types of plastic waste recycling: mechanical recycling, incineration, and chemical recycling .Mechanical recycling is the most widely used recycling option, and it involves mechanically grinding or compounding plastic waste for re-use in similar products. However, this process will result in poorer plastic quality, and thus these recycled products are not widely used by industries. Incineration can convert plastic waste into heat and electricity, but the process may result in the emission of toxic pollutants such as acid gases and heavy metals. Therefore, the last option, chemical recycling, where plastics are converted to fuels, is considered to be the most promising plastic waste recycling process with the least adverse effects. Plastic Recycling
- 15. GENBURG ENERGY LTD 15 The Solution Plastic recycling reduces the amount of trash that ends up in the oceans. Plastic recycling creates new jobs. Plastic recycling creates additional revenue for the government and private organizations. Recycling plastic reduces the release of carbon dioxide and harmful gases into the environment. Plastic recycling conserves the space used as landfills. It makes it possible to use those landfills for other purposes. Recycling saves petroleum that producers may use to make new plastics. Plastic recycling lessens the energy that manufacturers consume in creating new products. Plastic recycling prevents global warming. Plastic recycling reduces the emergence of all forms of pollution. Plastic recycling provides income for volunteers who collect plastic waste. Plastic recycling helps reduce activities like deforestation that happen when making new plastic. Encourages a Sustainable Lifestyle among People. Benefits of Recycling
- 16. GENBURG ENERGY LTD 16 The Solution The Solution Waste plastic disposal and excessive use of fossil fuels have caused environment concerns in the world. Both plastics and petroleum derived fuels are hydrocarbons that contain the elements of carbon and hydrogen. The difference between them is that plastic molecules have longer carbon chains than those in LPG, petrol, and diesel fuels. Therefore, it is possible to convert waste plastic into fuels The technology helps to save land resources by utilizing waste plastics to generate valuable energy. Currently, a majority of the waste plastic is land filled and it is not sustainable because waste plastic takes very long time to decay Re-Born Fuel
- 17. GENBURG ENERGY LTD 17 The Solution Re-Born Fuel (RBF) Pyrolysis is a process of thermal degradation of a material in the absence of oxygen. Plastic is fed into a cylindrical chamber. The pyrolytic gases are condensed in a specially designed condenser system, to yield a hydrocarbon distillate comprising straight and branched chain aliphatic, cyclic aliphatic, and aromatic hydrocarbons, and liquid is separated using fractional distillation to produce the liquid fuel products. The plastic is pyrolysed at 370°C– 450°C. The essential steps in the pyrolysis of plastics involve (1) evenly heating the plastic to a narrow temperature range without excessive temperature variations, (2) purging oxygen from pyrolysis chamber, (3)managing the carbonaceous char by-product before it acts as a thermal insulator and lowers the heat transfer to the plastic, (4)careful condensation and fractionation of the pyrolysis vapors to produce distillate of good quality and consistency
- 18. GENBURG ENERGY LTD 18 The Solution Re-Born Fuel (RBF) Re-Born Fuel is based on a century old Pyrolysis technology with a proprietary design to chemically breakdown the plastics to a molecular level to produce liquid and gaseous fuel. RBF process is a unique Non-Catalytic Thermal depolymerization technology that is used to recover energy from trash while carbon emissions, resulting in a beneficial environmental impact. Thus, Re-born Fuel process can be considered as another non-conventional energy source RBF process also helps to lessening the pressure on landfills and hence lowering Green House Emission
- 19. GENBURG ENERGY LTD 19 The Solution Plastic Waste becomes a valuable energy Source ( Fuel) Crushed Plastic Waste Re-Born Fuels
- 20. GENBURG ENERGY LTD 20 The Solution Plant Components (RBF) Material Shredding and Feeding If the input material is too coarse it can be shredded to a suitable size with an optional shredder. SILO and Material Conveyor In the Silo the small sized waste plastic material is stored and conveyed to the feeding system through a conveyor. Feeding System The material is partially melted and fed to the reactor in an airtight manner. Pyrolysis Reactor In the reactor Polymer waste is heated upto 500 deg C. At this temperature de-polymerization occurs. The plastic is cracked to small chain hydrocarbon gases and residue Char. Char Collection bin The residue is collected automatically in a bin from the reactor and manually removed from the bin. Staged Condensation In the Several boiling point of the condensable vapours are collected as wax and oil. Cooling System By means of cooling water the condensation is done even to collect low boiling point components. Flare system The non condensable permanent gases can be either used to run gas engine or can be used for any heating application or burnt out safely. Control Panel The entire system is controlled by PLC and Power electronics components that can be easily monitored and controlled by the operator.
- 21. GENBURG ENERGY LTD 21 The Solution Advantages & Benefits The tasks in plastics recycling are as varied as the nature of the different raw materials. RBF is the first container-based, decentralised plant in India from the Enviro Janitors to process plastic waste or production residues that cannot be directly recycled into materials or energy- recyclable oils and waxes. The advantages of the process compared to conventional disposal are minimal logistics costs and a high local added value. Fully automated – Highly safety Low cost Short ROI No emission No further waste generated High yield Fully modular and scalable
- 22. GENBURG ENERGY LTD 22 Financial Office Equipments Furniture & Fittings Electrical Accessaries Transportation and Installation Generator 62.5 KVA Advances and Deposits Building RBF5000 Plastic Pyrolysis Plant 0 50000 100000 150000 200000 250000 300000 2500 2500 3000 5000 9000 10000 60800 249500 Cost of the Project Amount in USD Owner's Equity Bank Term Loan 0 50000 100000 150000 200000 250000 300000 Project Finance Amount in USD Financial Analysis
- 23. GENBURG ENERGY LTD 23 1 0 50000 100000 150000 200000 250000 30000 150000 198000 Project Annual Income Sale of Pyrolysis Oil By Extended Producer Responsibilty Sale of Carbon Black Insurance Repairs and Maintenance Raw material Transport Travel Staff Refreshment Raw Material Fuel for Generator Depreciation Salary & Remuneration 0 20000 40000 60000 80000 100000 Expenses Amount in USD Financial Analysis Financial
- 24. GENBURG ENERGY LTD 24 Year 1 Year 2 Year 3 Year 4 Year 5 0 50000 100000 150000 200000 250000 300000 350000 400000 450000 500000 Profitability Aanalysis Income Expenses Net Income Financial Analysis Financial
- 25. GENBURG ENERGY LTD 25 Sl.No. Amt in USD Total 1 Land Rental 2 Building 60,800 3 Office Equipments 2,500 4 RBF5000 Plastic Pyrolysis Plant 249,500 5 Furniture & Fittings 2,500 6 Electrical Accessaries 3,000 7 Generator 62.5 KVA 9,000 8 Advances and Deposits 10,000 9 Transportation and Installation 5,000 TOTAL 342,300 Sl.No. In USD 1 Owner's Equity 85,575 2 Bank Term Loan 256,725 TOTAL 342,300 COST OF PROJECT MEANS OF FINANCE Financial
- 26. GENBURG ENERGY LTD 26 Financial (Amount in USD) Sl. No. Name of the Asset Value Rate of I II III IV V Dep. 1 Land 0 0 0 0 0 0 0 2 Building 60,800 20% 12,160 12,160 12,160 12,160 12,160 3 Office Equipments 2,500 20% 500 500 500 500 500 4 RBF5000 - Plant 249,500 20% 49,900 49,900 49,900 49,900 49,900 4 Furniture & Fittings 2,500 20% 500 500 500 500 500 5 Electrical & Accessories 3,000 20% 600 600 600 600 600 6 Generator 10,000 20% 2,000 2,000 2,000 2,000 2,000 Total 328,300 65,660 65,660 65,660 65,660 65,660 DEPRECIATION SCHEDULE
- 27. GENBURG ENERGY LTD 27 Financial (Amount in USD) Sl. No. Name of the Asset Value Rate of I II III IV V Dep. 1 Land 0 0 0 0 0 0 0 2 Building 60,800 20% 12,160 12,160 12,160 12,160 12,160 3 Office Equipments 2,500 20% 500 500 500 500 500 4 RBF5000 - Plant 249,500 20% 49,900 49,900 49,900 49,900 49,900 4 Furniture & Fittings 2,500 20% 500 500 500 500 500 5 Electrical & Accessories 3,000 20% 600 600 600 600 600 6 Generator 10,000 20% 2,000 2,000 2,000 2,000 2,000 Total 328,300 65,660 65,660 65,660 65,660 65,660 DEPRECIATION SCHEDULE
- 28. GENBURG ENERGY LTD 28 Financial Interest Schedule @ 14% per Annum No. of Months Principle EMI Closing Value Interest Total 1 256,725 4,279 252,446 2,995 2 252,446 4,279 248,168 2,945 3 248,168 4,279 243,889 2,895 4 243,889 4,279 239,610 2,845 5 239,610 4,279 235,331 2,795 6 235,331 4,279 231,053 2,746 7 231,053 4,279 226,774 2,696 8 226,774 4,279 222,495 2,646 9 222,495 4,279 218,216 2,596 10 218,216 4,279 213,938 2,546 11 213,938 4,279 209,659 2,496 12 209,659 4,279 205,380 2,446 32,647 Interest Schedule @ 14% per Annum No. of Months Principle EMI Closing Value Interest Total 13 205,380 4,279 201,101 2,396 14 201,101 4,279 196,823 2,346 15 196,823 4,279 192,544 2,296 16 192,544 4,279 188,265 2,246 17 188,265 4,279 183,986 2,196 18 183,986 4,279 179,708 2,147 19 179,708 4,279 175,429 2,097 20 175,429 4,279 171,150 2,047 21 171,150 4,279 166,871 1,997 22 166,871 4,279 162,593 1,947 23 162,593 4,279 158,314 1,897 24 158,314 4,279 154,035 1,847 25,459
- 29. GENBURG ENERGY LTD 29 Financial Interest Schedule @ 14% per Annum No. of Months Principle EMI Closing Value Interest Total 25 154,035 4,279 149,756 1,797 26 149,756 4,279 145,478 1,747 27 145,478 4,279 141,199 1,697 28 141,199 4,279 136,920 1,647 29 136,920 4,279 132,641 1,597 30 132,641 4,279 128,363 1,547 31 128,363 4,279 124,084 1,498 32 124,084 4,279 119,805 1,448 33 119,805 4,279 115,526 1,398 34 115,526 4,279 111,248 1,348 35 111,248 4,279 106,969 1,298 36 106,969 4,279 102,690 1,248 18,270 Interest Schedule @ 14% per Annum No. of Months Principle EMI Closing Value Interest Total 37 102,690 4,279 98,411 1,198 38 98,411 4,279 94,133 1,148 39 94,133 4,279 89,854 1,098 40 89,854 4,279 85,575 1,048 41 85,575 4,279 81,296 998 42 81,296 4,279 77,018 948 43 77,018 4,279 72,739 899 44 72,739 4,279 68,460 849 45 68,460 4,279 64,181 799 46 64,181 4,279 59,903 749 47 59,903 4,279 55,624 699 48 55,624 4,279 51,345 649 11,082
- 30. GENBURG ENERGY LTD 30 Financial Interest Schedule @ 14% per Annum No. of Months Principle EMI Closing Value Interest Total 49 51,345 4,279 47,066 599 50 47,066 4,279 42,788 549 51 42,788 4,279 38,509 499 52 38,509 4,279 34,230 449 53 34,230 4,279 29,951 399 54 29,951 4,279 25,673 349 55 25,673 4,279 21,394 300 56 21,394 4,279 17,115 250 57 17,115 4,279 12,836 200 58 12,836 4,279 8,558 150 59 8,558 4,279 4,279 100 60 4,279 4,279 0 50 3,894
- 31. GENBURG ENERGY LTD 31 Financial (Amount in USD) A) DETAILS OF INCOME Per Month Per Annum Sale of Pyrolysis Oil @ USD 0.33 per Kg x 2000Kg/day x 25 days 16,500 198,000 Sale of Carbon Black @ USD 0.10 per Kg x 1000Kg/day x 25 days 2,500 30,000 By Extended Producer Responsibilty @ USD 0.1 per Kg x 5000Kg x 25 days 12,500 150,000 TOTAL 31,500 378,000 B) DETAILS OF EXPENDITURE Per Month Per Annum Raw Material 1,250 15,000 Raw material Transport 250 3,000 Fuel for Generator 3,600 43,200 Repairs and Maintenance 200 2,400 Salary & Remuneration 7,500 90,000 Travel 500 6,000 Staff Refreshment 500 6,000 Insurance 100 1,200 Depreciation 5,472 65,660 Interest 2,721 32,647 TOTAL 22,092 265,107 Income & Expenses Statement
- 32. GENBURG ENERGY LTD 32 Financial Particulars I Year II Year III Year IV Year 0.8 0.85 0.9 0.95 (A) INCOME Sale of Pyrolysis oil and Char, EPR 378,000 401,625 425,250 448,875 TOTAL 378,000 401,625 425,250 448,875 (B) EXPENDITURE Raw Material 15,000 15,938 16,875 17,813 Raw material Transport 3,000 3,188 3,375 3,563 Fuel for Generator 43,200 45,900 48,600 51,300 Repairs and Maintenance 2,400 2,550 2,700 2,850 Salary & Remuneration 90,000 95,625 101,250 106,875 Travel 6,000 6,375 6,750 7,125 Staff Refreshment 6,000 6,375 6,750 7,125 Insurance 1,200 1,275 1,350 1,425 Depreciation 65,660 65,660 65,660 65,660 Interest 32,647 25,459 18,270 11,082 TOTAL 265,107 268,344 271,580 274,817 (c) Net Income before Taxation 112,893 133,281 153,670 174,058 Provision for Taxation (Including Surcharge) 40,303 47,581 54,860 62,139 (d) Net Income after Taxation 72,590 85,700 98,810 111,919 (e) Depreciation 65,660 65,660 65,660 65,660 (f) Interest 32,647 25,459 18,270 11,082 (g) Repayment of Principle 51345 51345 51345 51345 (d+e+f)/(f+g) 2.03 2.30 2.62 3.02 DSCR 2.70 Profitability Statement Amount in USD
- 33. GENBURG ENERGY LTD 33 Financial PROJ E CTED BALANCE S HE ET (Amount in US D) Particulars IYear IIYear IIIYear IV Year V Year 0.8 0.85 0.9 0.95 1 LIABILITIE S Owner's E quity 85,575 85,575 85,575 85,575 85,575 Profit and Loss Account 72,590 158,290 257,100 369,019 494,048 Bank Term Loan 205,380 154,035 102,690 51,345 0 TOTAL 363,545 397,900 445,365 505,939 579,623 AS S E TS Fixed Assets 262,640 196,980 131,320 65,660 0 Advances & Deposits 10,000 10,000 10,000 10,000 10,000 Receivables 31,500 31,500 31,500 31,500 31,500 Cash and Bank Balances 59,405 159,420 272,545 398,779 538,123 TOTAL 363,545 397,900 445,365 505,939 579,623
- 34. GENBURG ENERGY LTD 34 Financial Particulars I Year II Year III Year IV Year V Year 0.8 0.85 0.9 0.95 1 SOURCES OF FUNDS Opening Balance 0 55,405 123,920 205,545 300,279 Owner's Equity 85,575 85,575 85,575 85,575 85,575 Profit and Loss Account 72,590 85,700 98,810 111,919 125,029 Bank Term Loan 256,725 256,725 256,725 256,725 256,725 Depreciation 65,660 65,660 65,660 65,660 65,660 TOTAL 480,550 549,065 630,690 725,424 833,268 APPLICATION OF FUNDS Fixed Assets 342,300 342,300 342,300 342,300 342,300 Decrease in Bank Term Loan 51,345 51,345 51,345 51,345 51,345 Receivables 31,500 31,500 31,500 31,500 31,500 Cash and Bank Balances 55,405 123,920 205,545 300,279 408,123 TOTAL 480,550 549,065 630,690 725,424 833,268 Projected Cash Flow Statement Amount in USD
- 35. GENBURG ENERGY LTD 35 Company Background About Us Genburg Energy, a leading waste management and energy recovery company from Chennai, India. Genburg Energy is focused on delivering integrated waste management and energy recovery solutions to meet national, regional and local needs for local authorities and private commercial companies. The Company operates facilities for the reception, recycling and disposal of waste. We manufacture and supply world’s best waste management and energy recovery equipment to several countries across the globe. Our products are tremendously owing to the great market demand, which has now become a brand name in itself .. Our vision is to play our part in the global mind shift towards industrial ecology. We understand the value of waste as a feedstock to create energy and the ever- increasing need for the sequestering of greenhouse gases via our technology of organic biomass, Plastic and utilization of Biochar agriculturally and beyond. Our aim is to support government, private, NGO's and commercial enterprises through offering, designing and implementing our system solution to a range of different applications
- 36. GENBURG ENERGY LTD 36 Our Services This technology involves the In-stitu decontamination of hydrocarbon oil contaminated soil using a novel microbial consortia at low retention time (30 days). The novelty of the process consists of production of the unique microbial consortia from the mother culture of Genburg using the waste wet hydrocarbon sludge or oil, as the carbon substrate, accumulated in the contaminated site. Bio- Remediation of Soil Genburg’s Anaerobic Soil Remediation Plant (ASRP) is an ex-situ, non-incineration technology designed to separate hydrocarbons from various matrices including oil field waste, soil, sludge, sand, filter-cake, tank and tanker bottoms, organic-based hazardous waste and contaminated soil in a non-oxidizing atmosphere without destroying the hydrocarbons. Rapid Anerobic Soil Remediation Plant Other Products
- 37. GENBURG ENERGY LTD 37 Gasification Is a Unique Process That Transforms a Carbon-based Material, Such As Combustible Solid Waste (CSW) Into Other Forms Of Energy Without Actually Burning It. Gasification Converts The Solid Waste Materials Into A Gas, By A Chemical Reaction. Result Is A Low Emission, Clean Fuel Called Producer Gas Or Synthesis Gas (Syngas). The Syngas can be fed to turbine or generator to produce electricity. Gasification The Domestic/ Industrial wastewater is characterized by dissolved natural and synthetic organics, a considerable concentration of suspended solids (mostly fecal materials) besides a wide spectrum of pathogenic and non- pathogenic organisms. The Domestic wastewater has been treated through many techniques. However, all the techniques have certain issues such as huge footprint area, emits malodorous gases, generate foam and produce huge amount of sludge. Wastewater Recovery Other Products
- 38. We offer complete sustainability and Waste management solutions. We can be where our customers need us to be – with team of professionals offering sustainability and environmental and project management experience to help them advance along the path toward sustainability. OUR SUSTAINABLITY COMMITMENT GENBURG ENERGY No: 49, Bavanandhiyar Street, Sembakkam, Chennai – 600 073 Tamilnadu, India Emai: [email protected] www. genburgenegy.com