Tech Team · Kintek Solution

The pyrolysis process of scrap tires involves breaking down the rubber into smaller molecules through thermal decomposition in an oxygen-free environment. This process transforms waste tires into valuable products such as pyrolysis oil, syngas, and carbon black. The key steps include feeding shredded or whole tires into a reactor, heating them to high temperatures (200-900°C), vaporizing the rubber, and condensing the vapors into liquid oil. The process is influenced by factors like temperature, residence time, and particle size, and it ensures the safe and efficient conversion of waste tires into reusable resources. Below is a detailed explanation of the process.

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Key Points Explained:

1. Preparation of Scrap Tires:

   • Shredding and Pre-Treatment: Scrap tires are first shredded into smaller pieces to facilitate easier handling and faster thermal decomposition. Pre-treatment may involve removing impurities like steel wires and other non-rubber components.
   • Magnetic Separation: Steel wires and other metallic components are separated using magnetic techniques, as they can interfere with the pyrolysis process and damage equipment.

2. Loading into the Pyrolysis Reactor:

   • The shredded or pre-treated tires are loaded into a pyrolysis reactor. The reactor is designed to operate in an oxygen-free environment to prevent combustion and ensure safe thermal decomposition.
   • The reactor can handle whole, halved, or shredded tires, depending on the design and capacity.

3. Heating and Thermal Decomposition:

   • Temperature Control: The reactor is heated to temperatures ranging from 200°C to 900°C. At these temperatures, the rubber softens and breaks down into smaller hydrocarbon molecules.
   • Vaporization: The rubber disintegrates into vapors, which exit the reactor. These vapors consist of a mixture of gases and condensable hydrocarbons.

4. Condensation and Product Collection:

   • Pyrolysis Oil: The vaporized hydrocarbons are passed through a condenser, where they are cooled and converted into liquid pyrolysis oil. This oil has a high calorific value and can be used as fuel or further refined.
   • Syngas: Non-condensable gases, such as methane and hydrogen, are collected and can be used as fuel for the pyrolysis process or other applications.
   • Carbon Black: Solid residues, primarily carbon black, are collected from the reactor. Carbon black is a valuable material used in manufacturing tires, inks, and other industrial products.

5. Factors Influencing the Pyrolysis Process:

   • Temperature: Higher temperatures favor the production of non-condensable gases, while lower temperatures produce more solid residues and high-quality pyrolysis oil.
   • Residence Time: The time the material spends in the reactor affects the degree of thermal decomposition. Longer residence times can lead to more complete breakdown of the rubber.
   • Particle Size: Smaller tire particles decompose more quickly and efficiently, leading to higher yields of pyrolysis oil.
   • Catalyst Use: Catalysts can be added to the reactor to enhance the breakdown of rubber molecules and improve the quality of the end products.

6. Applications of Pyrolysis Products:

   • Pyrolysis Oil: Used as a fuel in industrial boilers, furnaces, and engines. It can also be refined into diesel or gasoline.
   • Syngas: Used as a fuel for power generation or to provide heat for the pyrolysis process itself.
   • Carbon Black: Used in the production of new tires, rubber products, and as a pigment in inks and paints.
   • Steel Wire: Recovered steel wires can be recycled and reused in various industries.

7. Environmental and Safety Considerations:

   • The pyrolysis process is conducted in an oxygen-free environment, minimizing the risk of combustion and ensuring safe operation.
   • The process converts waste tires into valuable resources, reducing landfill waste and environmental pollution.
   • Emissions from the process are controlled, and the use of syngas as a fuel reduces the need for external energy sources.

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In summary, the pyrolysis process of scrap tires is a highly efficient and environmentally friendly method of converting waste into valuable resources. By carefully controlling factors like temperature, residence time, and particle size, the process maximizes the yield of useful products such as pyrolysis oil, syngas, and carbon black. This not only addresses the problem of tire waste but also provides sustainable alternatives to traditional fuels and raw materials.

Summary Table:

Step	Details
Preparation	Shredding, pre-treatment, and magnetic separation of scrap tires.
Loading into Reactor	Tires are loaded into an oxygen-free reactor for thermal decomposition.
Heating & Decomposition	Rubber breaks down at 200-900°C, producing hydrocarbon vapors.
Condensation & Collection	Vapors are condensed into pyrolysis oil; syngas and carbon black are collected.
Key Factors	Temperature, residence time, particle size, and catalyst use influence yield.
Applications	Pyrolysis oil for fuel, syngas for energy, carbon black for manufacturing.
Environmental Benefits	Reduces landfill waste, controls emissions, and provides sustainable resources.

Discover how pyrolysis can transform your waste tires into valuable resources—contact us today to learn more!