The process of pyrolysis of tyres involves converting waste tyres into valuable products such as fuel oil, carbon black, steel wire, and gas through a controlled heating process in the absence of oxygen.
This technology is an effective method for recycling waste tyres, with a high recovery rate.
4 Key Steps in the Tyre Pyrolysis Process
1. Preparation and Feeding
Waste tyres are shredded into small pieces and then fed into a sealed pyrolysis reactor using a screw conveyor.
This process is automated and controlled by a PLC system, ensuring safety and environmental protection.
2. Heating
The reactor is heated using various fuels like fuel oil, natural gas, wood, or LPG.
As the temperature rises, the tyres undergo pyrolytic reactions, producing oil gas.
The temperature is precisely controlled to optimize the yield of oil.
3. Pyrolysis
At high temperatures (typically between 260°C and 280°C), the rubber polymers in the tyres break down into smaller molecules, which vaporize and exit the reactor.
This step requires maintaining the temperature for several hours to ensure complete pyrolysis.
4. Condensing and Separation
The vaporized gases are cooled in a condenser, turning into liquid fuel oil.
Some gases remain uncondensed and can be used as fuel.
The solid residue, which includes carbon black and steel wire, is also collected.
Detailed Explanation of Each Step
Preparation and Feeding
The initial step involves shredding the tyres into manageable pieces, typically 3-5 cm in size.
This facilitates the pyrolysis process by increasing the surface area exposed to heat.
The shredded tyres are then automatically fed into the reactor, which is sealed to prevent oxygen from entering and causing combustion.
The feeding system is designed to be continuous and highly automated, reducing labor and time costs.
Heating
The choice of fuel for heating the reactor depends on availability and efficiency.
The heating process is critical as it initiates the breakdown of tyre components.
The PLC system plays a crucial role in maintaining the optimal temperature range, ensuring that the pyrolysis reaction proceeds efficiently.
Pyrolysis
This is the core step where the actual decomposition of tyre materials occurs.
The temperature is gradually increased, and as it reaches the optimal range, the rubber polymers in the tyres start to break down into smaller molecules.
These molecules vaporize and are ready for the next stage of condensation.
Condensing and Separation
The vaporized gases, which include both condensable and non-condensable components, are directed to a condenser.
Here, the condensable gases are cooled and transformed into liquid fuel oil, while the non-condensable gases can be used as fuel for other processes.
The solid residues, including carbon black and steel wire, are also collected and can be further processed or sold.
This process is designed to be environmentally friendly, with minimal emissions or waste, making it a sustainable solution for managing waste tyres.
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