The process of pyrolysis of rubber involves heating rubber, typically from waste tires, in an oxygen-free environment to break down its molecular structure into simpler compounds.
This process yields several valuable by-products including fuel oil, combustible gas, carbon black, and steel wire.
The pyrolysis occurs in stages within an indirect kiln, where the rubber first becomes brittle and separates from the steel, then releases oil and gas, and finally transforms into a carbon black-like substance.
5 Key Stages of Rubber Pyrolysis Explained
1. Initiation of Pyrolysis
The process begins when the temperature in the reactor reaches approximately 180 degrees Celsius.
At this point, the rubber starts to break down, releasing oil gas.
This stage is crucial as it sets the foundation for the subsequent stages of the pyrolysis process.
2. Oil Gas Cooling
The oil gas generated in the reactor is then cooled down using a condenser.
This cooling process transforms the gas into a liquid state, yielding fuel oil.
This oil can be used directly as a fuel source in various industries or further processed into non-standard diesel oil or fuel oil.
3. Recycling Combustible Gas
During the pyrolysis, some combustible gases are produced that cannot be condensed into oil.
These gases are processed through a recycling system, which includes a manifold, condensers, and a hydroseal.
The treated gas is then used as a fuel to provide heat for the reactor, thereby conserving energy and reducing costs.
4. Stages in the Kiln
The rubber chips undergo three distinct stages in the indirect kiln:
First Stage
The rubber becomes brittle and separates from the embedded steel, forming what is referred to as rubber char.
Second Stage
The char releases oil and gas, which are then swept out of the kiln.
Third Stage
The char is fully processed into a substance similar to carbon black and is separated from the steel wires.
5. Processing of By-products
Char Processing
The char is cooled and then sent to a grinding, pelletizing, and bagging system where it is prepared for transport.
The final product, resembling carbon black, can be used in various industries such as tire manufacturing or ink production.
Steel Processing
The steel wires are also cooled, compacted, and made ready for transport to a steel recycler or processing furnace.
Utilization of Final Products
Pyrolysis Oil
Used as a fuel in various industries or for electricity generation.
Carbon Black
Can be formed into carbon black balls for direct combustion or ground for use in manufacturing and ink production.
Combustible Gas
Used to heat the reactor or stored for other uses.
This pyrolysis process is not only environmentally friendly by recycling waste rubber but also economically beneficial by producing valuable by-products.
The advanced technology used in modern rubber pyrolysis plants ensures high efficiency and minimal environmental impact.
Continue Exploring, Consult Our Experts
Discover how KINTEK SOLUTION's cutting-edge pyrolysis technology is revolutionizing the recycling industry!
Our advanced indirect kilns and specialized processing systems optimize the conversion of waste rubber into high-value by-products, including fuel oil, carbon black, and steel wire.
Elevate your sustainability initiatives and increase your economic returns with KINTEK SOLUTION – where environmental responsibility meets efficiency.
Contact us today to explore how our innovative pyrolysis solutions can transform your waste rubber into a profitable resource!
