For the disposal of scrap tyres, continuous tyre pyrolysis plant provides a sustainable solution for resource recycling. Through pyrolysis technology, the machine can convert waste tires into pyrolysis oil, carbon black, steel wire, and combustible gas. Unlike other equipment, this kind of machine adopts the latest fully automatic design. This design enables the machine to achieve uninterrupted production 24 hours a day.
Raw Materials Suitable for Continuous Waste Tyre Pyrolysis Plant
The main raw material of the machine is waste tyres. They can be divided into several main categories, which are usually based on factors such as the tire’s purpose, model, size, etc. In addition, the machine can also process waste rubber. The following are some common raw materials.
Waste Tyre
- Motorbike tyres: from all types of motorcycles and bicycles. They are smaller and lighter.
- Car tyres: this is a common type of scrap tire that comes from a variety of passenger vehicles.
- Truck tyres: tires used on commercial vehicles such as trucks, usually larger than car tires.
Waste Rubber
- Rubber products: they include insoles, sneakers, rubber gloves, and other rubber products.
- Rubber cables: rubber from discarded cables and wires. Their insulation is usually rubber.
- Rubber scraps: cutting waste, trimming waste, etc. from the rubber production process.
Application of End Products of Fully Continuous Tyre Pyrolysis Plant
After processing waste tires in a tire pyrolysis plant, four end products are produced. They include pyrolysis oil, carbon black, steel wire, and syngas. Their applications are spread across various fields.
Pyrolysis Oil
- Industrial fuel: Pyrolysis oil can be used in combustion equipment in glass factories, steel factories, power plants, ceramic factories, cement factories, etc. to generate heat.
- Engine fuel: Deep processing can convert pyrolysis oil into non-standard diesel. It can be used in internal combustion engines of industrial machinery, ships, and so on.
Carbon Black
- Rubber industry: Carbon black is an important additive for rubber products, which is used to improve the strength, wear resistance, and aging resistance of rubber.
- Road construction: Carbon black can be used to improve the texture and durability of asphalt. In road construction, it can increase the performance of the road.
Steel Wire
Collect steel wire from tires and resell it to smelters.
Syngas
Recycle syngas from the pyrolysis process and use it as fuel for the reactor.
Semi-continuous Vs. Continuous Tyre Pyrolysis Plant
Based on customer needs, Beston Group provides two types of continuous equipment. One of these models, the BLL-16, is of semi-continuous design. Besides, the other is the BLL-30 fully automatic pyrolysis plant. Below are their detailed parameters for your reference.
BLL-16 Semi-continuous Tyre Pyrolysis Plant
Semi-continuous Type
In fact, semi-continuous equipment is batch equipment with some accessories. These accessories include automatic screw feeding and three-pass water-cooled slag discharge system. Unlike batch type, tires need to be pre-treated to the state of rubber powder in advance. There should be no steel wire in the raw material when feeding, otherwise, it will block the slag outlet. In addition, the unique water-cooled slag discharge design can accelerate the cooling of carbon black. In particular, the slagging system reduces the carbon black temperature by 90-120°C.
| Model | BLL-16 | |
|---|---|---|
| Capacity | 8t/d (only for rubber powder) | |
| Working Process | Semi-continuous | |
| Reactor Size | φ2800*7100mm | |
| Reactor Material | Q345R | |
| Drive System | 500 reducer+7.5kw drive motor | |
| Land (L*W*H) | 33m*13m*8m | |
| Power | 55.6kw | |
| Burner | 2*400,000 kcal | |
| Total Weight of Shipped Materials | About 34.5t | |
| Number of Containers | 1*40FR+2*40HQ | |
| Noise (dB) | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | |
| Condensing System | Vertical Condenser | φ820*3600 Single piece condensing area 35.6m2 |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
|
BLL-30 Continuous Tyre Pyrolysis Plant
Fully Continuous Type
Unlike other models, the BLL-30 model adopts Beston Group’s latest design. The throughput of the machine is the largest of all models. In addition, it uses a unique hot air heating method. Not only that, the machine can truly realize continuous feeding and slag discharge. This mode of operation allows it to produce 24 hours without interruption. For the sake of environmental protection, the machine also has a high exhaust gas treatment.
| Model | BLL-30 | |
|---|---|---|
| Capacity | 30-35t/d | |
| Working Process | Fully continuous | |
| Reactor Size | φ1800*18500mm | |
| Reactor Material | 310S stainless steel | |
| Drive System | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 70m*20m*10m | |
| Power | 256kw | |
| Burner | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 150t | |
| Number of Containers | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | |
| Condensing System | Vertical Condenser | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
|
Components of Fully Continuous Tyre Pyrolysis Plant
Main Components
A Side
B Side
Optional Components
The main function of the machine is to extract steel wire from waste tires. Scrap tires often contain steel wire curtains and wire edges that require separation and extraction for subsequent processing and recycling.
Beston pyrolysis plant with continuous design has strict requirements on feed size. This machine can further refine the cut rubber particles into rubber powder, ensuring that the size and quality of the particles meet specific requirements.
Its main function is to pass the original pyrolysis oil through distillation and separation process. Afterward, the pyrolysis oil is transformed into high-quality non-standard diesel. This makes the final product more versatile.
Continuous Tyre Pyrolysis Plant Working Flow
Material Feeding
First, transport the pre-processed 3-5mm rubber powder to the sealed material silo via a conveyor. Then, a feed screw introduces the rubber powder from the sealed silo into the main furnace. The sealed silo maintains the rubber powder in a saturated state, acting as a material seal.
Pyrolysis – Decomposition of Waste Tyres
Burners and non-condensable combustible gas supply the necessary heat to the main furnace. Through a secondary combustion chamber, apply indirect heating to the main furnace. Thus, it ensures a more stable temperature increase. Therefore, it aids in precise temperature control. The machine recycles most of the high-temperature waste gases from the furnace chamber to reheat the main furnace. Besides, a small portion is directed to preheat the air, conserving energy. The pyrolysis reactor operates under slight negative pressure, with a reaction temperature below 450°C, and it’s carried out in a sealed oxygen-deficient environment.
Condensation – Production of Pyrolysis Oil
The three-stage condenser cools the pyrolysis oil and gas, utilizing circulating water as the cooling medium. This process yields liquefied tire oil, which we store in an oil tank. Simultaneously, the machine uses a vacuum pump to improve the fluidity of the pyrolysis gas, preventing excessive pressure inside the reactor and ensuring constant furnace pressure.
Exhaust Gas Treatment
Exhaust gases first pass through a supply air heat exchanger to preheat the air, then go through a flue gas condensation process to lower their temperature. Subsequently, they undergo adsorption with activated charcoal before entering a spray tower for treatment. The machine discharges the gases through a chimney once they meet emission standards.
Combustible Gas Treatment
The machine conveys combustible gases to the secondary combustion chamber for combustion, generating high-temperature gas to heat the main furnace. It directs any excess combustible gas to the exhaust gas combustion system or utilizes it to provide heat for other equipment.
Carbon Black Handling
The pyrolysis process produces carbon black, which the first slagging screw extracts. It then undergoes two stages of water cooling to eliminate slag. Subsequently, we transfer the carbon black into a storage tank, where we cool it using circulating water. Once the temperature falls below 60 degrees, the machine discharges it from the carbon black storage tank.
Beston Group – a Reliable Continuous Tyre Pyrolysis Plant Manufacturer
Beston Group has a rich experience in equipment design, manufacture, installation, and operation in the field of pyrolysis for many years. Therefore, we have designed and developed the latest fully automatic tire pyrolysis equipment. In addition, We incorporate advanced structures and processes into the design and development of equipment. At present, Beston Group has obtained 9 patents, including 1 invention patent. The following are some of the advantages of our equipment.
Unique Design of Beston Continuous Waste Tire Pyrolysis Plant
| Unique Design | |
| Exhaust Temperature Control | We use a stainless steel induced draft fan to reintroduce 400-450°C high-temperature exhaust gas into the combustion chamber. It mixes with the 1000-1300°C high-temperature hot air from the burner, ensuring precise reactor temperature control. Some of the flue gas enters the exhaust gas treatment system, saving fuel and meeting treatment standards. |
| Clean Condensing System | Our three-stage condensing system separates heavy impurities in the first stage with a double-plate structure and external insulation. Tube condensers in the second and third stages improve oil recovery, allowing the collection of different oil fractions. An innovative self-cleaning system prevents condensation pipe blockages. |
| Continuous Sealed Feeding | We use double-screw conveyors, sealed silos, and high-precision electronic weighing systems for precise feeding control, real-time monitoring, and stage statistics. |
| Real-time Sampling and Monitoring | Our high-temperature sealed slag discharge system with dynamic seals, water-cooled sealed slag box, and residue sampling structure ensures continuous slag discharge and gas outlet sealing. Real-time sampling monitors material pyrolysis in the furnace. |
| Inert Gas Protection | We use a nitrogen generator with over 95% purity to replace air in the sealed silo, maintaining an oxygen-poor environment and enhancing safety during pyrolysis. |
| Anti-Coking | Various technologies, including hot fume recycling, high-temperature catalysts, and physical coking prevention, minimize coking risks on the reactor’s inner wall. |
| Intelligent PLC Control | Our Siemens PLC core, Ethernet communication network, and 5G technology enable centralized control of system start-stop, temperature, pressure, material level, and other parameters. This allows remote real-time monitoring of the entire system’s operation. |
Global Cases of Beston Pyrolysis Project
Not only advanced equipment, but as an experienced manufacturer, Beston Group knows the importance of service to customers. Therefore, our pre-sales and after-sales services are integrated. From the beginning to the end, our project consultants and professional technical engineers will provide you with comprehensive assistance. This is why so many customers cooperate with Beston Group for pyrolysis projects. Below are some successful cases for your reference.
Choose to Invest in Beston Fully Automatic Tyre Pyrolysis Plant
As a leading manufacturer of continuous tyre pyrolysis plant, Beston has invested a lot of energy in research and development. We are committed to providing impeccable after-sales service to all of our customers. The waste-to-energy industry is developing rapidly. Furthermore, it has increasing official support from governments around the world. This presents a significant opportunity for potential investors. If you want to know more about our machine solutions, please feel free to leave us a message here. You can also get more information on our Facebook.