Fabhind Private Limited

A continuous waste tyre pyrolysis plant offers a sustainable and efficient solution for recycling discarded tyres, converting them into valuable resources: pyrolysis oil, carbon black, steel wire, and combustible gas. 

Advantages of continuous pyrolysis plants

Environmental Friendliness: Compared to traditional disposal methods like landfilling or incineration, continuous pyrolysis significantly reduces waste and minimizes harmful emissions. The process is conducted in a sealed environment, eliminating gas leakage and dust release. Modern plants often include advanced exhaust gas treatment systems (desulfurization and denitrification, electrostatic precipitator, and activated carbon dust collectors) to meet stringent emission standards like those in the EU.

High Efficiency & Capacity: These plants are designed for uninterrupted, 24-hour operation with high processing capacities, making them suitable for large-scale waste tyre recycling.

Automation: Continuous pyrolysis plants utilize PLC control systems for automatic feeding, temperature control, and discharge, requiring minimal labor.

yrolysis Oil: Can be used as fuel in industries, for power generation (refined into diesel), or sold directly.

Carbon Black: Can be used as a raw material for rubber products, coatings, and inks, or further processed into higher-quality recovered carbon black (rCB).

Steel Wire: Can be sold as scrap metal for recycling.

Combustible Gas (Syngas): Recycled back into the plant to fuel the pyrolysis reactor, making the process energy self-sufficient. 

Typical working process

Tyre Collection: Waste tyres of various sizes are collected.

Shredding & Steel Wire Removal: Tyres are shredded into small pieces (e.g., 3-5 cm or <15 mm) and steel wires are extracted, crucial for the continuous operation and purity of the rubber material.

Feeding: Shredded tyre chips are transported to a sealed silo and then continuously fed into the pyrolysis reactor using screw conveyors. An inert gas (like nitrogen) system can be used to displace air in the feeding system, enhancing safety and process stability.

Pyrolysis: The reactor is heated (e.g., by burning fuel oil, LPG, natural gas). As the reactor rotates and heats up to around 300°C, the tyres undergo pyrolysis, decomposing into oil gas. Hot flue gases can be recycled to improve thermal efficiency.

Oil & Gas Collection: The hot oil gas enters a manifold system to separate heavy impurities. The condensable components are cooled in a multi-stage condensing system using circulating water, resulting in liquid pyrolysis oil, which is collected in storage tanks. Non-condensable components, mainly syngas, are piped to the combustion system to fuel the burner, achieving energy self-sufficiency.

Waste Flue Gas Treatment: Flue gases from the heating process undergo a series of treatments, including heat exchangers for cooling, a chemical tower for desulfurization and denitrification, and electrostatic precipitators and activated carbon dust collectors for purification, ensuring compliance with environmental standards before discharge.

In India, the Central Pollution Control Board (CPCB) has introduced Standard Operating Procedures (SOPs) for the recycling of waste tyre scrap, emphasizing the use of the Advanced Batch Automated Process (ABAP) and continuous pyrolysis processes. For capacities exceeding 60 tonnes per day (TPD), only continuous pyrolysis plants are permitted. These plants are subject to strict monitoring and adherence to CPCB guidelines for safe and environmentally sound operation. Regulations specify requirements such as minimum land area, treatment of outputs (TPO and charcoal), waste gas treatment systems, wastewater treatment systems, and hazardous waste management authorization.