For the disposal of scrap tyres, continuous waste 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, continuous equipment adopts the latest fully automatic design. This design enables the machine to achieve uninterrupted production 24 hours a day. With the growing demand for tyre recycling, continuous tyre pyrolysis plant is gradually replacing batch type.
Turning Point in Tyre Pyrolysis: From Batch to Continuous
Global demand for waste tyre recycling is growing rapidly. Compared with the traditional batch pyrolysis process, continuous tyre pyrolysis plant is gradually becoming dominant with higher efficiency, automation and environmental performance. Various driving forces are promoting the transformation of tire pyrolysis plant from “Batch” to “Continuous“. It is mainly reflected in the following aspects:
Expansion of Tyre Recycling Market
Recently, the global annual production of waste tires has reached 1 billion. This undoubtedly drives the rapid expansion of the recycling market. As a result, the traditional intermittent pyrolysis recycling method is difficult to meet the needs of large-scale recycling. Continuous waste tyre pyrolysis plant has higher processing efficiency and production capacity to help companies cope with the challenges of market expansion.
Emergence of Cutting-edge Technology
Industrial automation and intelligent technology have driven the progress of tire pyrolysis recycling. The equipment with continuous operation mode can be seamlessly connected with various automation equipment. Thus, this realizes automatic control and monitoring of the entire operation process. The introduction of these technologies not only reduces labor costs. Also, it improves production efficiency and controllability.
Promotion of Environmental Policies
Countries are paying more and more attention to the ecological impact of industrial production. As a result, the introduction of a series of environmental policies has made the emission standards of pyrolysis projects higher. Continuous equipment adopts more advanced exhaust gas treatment and pollution control systems. This can reduce harmful emissions and meet the requirements of environmental regulations.
Parameters of Fully Continuous Tyre Pyrolysis Plant
BLL-30 pyrolysis machine integrates the advanced technology and R&D achievements of Beston Group. Different from traditional batch production, this machine can realize simultaneous feeding and discharging. In addition, the processing capacity of this continuous waste tyre pyrolysis plant is also the largest in the product line. The following are the specific parameters for your reference:
| 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 Continuous Tyre Pyrolysis Plant
Main Components
A Side
B Side
Optional Components
Tyre Shredder
The feed size is critical for the uninterrupted operation of continuous tyre to oil plant. It determines whether the tyres can undergo a complete and uniform reaction in the pyrolysis reactor. Therefore, the tyre shredder is critical. It can not only evenly crush the tires to the optimal feed size (<15mm). In addition, it can remove the steel wire in the waste tyre and ensure the purity of the tire rubber powder.
Oil Distillation Equipment
Tyre pyrolysis oil produced by the machine can be further processed by distillation. The distillation equipment can separate the oil products of different components according to the different boiling points of the oil products for collection. After the processing of the oil distillation equipment, customers can get non-standard diesel and non-standard gasoline, which hava higher utilization value.
Working Flow of Continuous Waste Tyre Pyrolysis Plant
01Feeding
- High-angle belt conveyor transports tyre particles to the sealed silo. In the silo, nitrogen protection system exhausts the excess air in tyre particles.
- Tyre particles in the sealed silo enters the weigh toometer for weighing through the first screw feeder.
- Weighed tyre particles enter the main furnace of continuous waste tire pyrolysis plant through the second screw feeder.
02Tyre Pyrolysis
- Turn on the burner (fuel can be diesel, natural gas, LPG, etc.). The hot air generated by the burner enters the combustion chamber, thereby preheating the tire pyrolysis reactor.
- After the reactor heats up, the raw materials enter the main furnace for reaction. Under the action of high-temperature hot air, the molecular bonds of long-chain hydrocarbons in tyre particles are broken. As a result, they are decomposed into short-chain hydrocarbons, which exist in the form of oil gas.
- The hot flue gas after heat exchange with the reactor returns to the combustion chamber. Then, it mixes with the high-temperature hot air generated by the burner to provide heat, thereby improving thermal efficiency.
03Pyrolysis Oil Collection
- High-temperature oil gas first enters the manifold system to separate heavy impurities. The heavy oil components fall into the residual oil tank under the action of gravity.
- The condensable components in the oil gas enter the condensation system. After passing through two condensers, the oil gas fully forms tyre pyrolysis oil under the action of cooling water. The oil enters the oil storage tank.
- The non-condensable components in the oil gas pass through the vacuum system and water seal to form syngas. Syngas enters the combustion system through the pipeline as fuel for the burner. Thus, it provides energy for the entire continuous tyre pyrolysis plant.
04Waste Flue Gas Treatment
- Firstly, the waste flue gas after fully participating in the reaction enters the air-to-air heat exchanger. The air obtains heat from waste flue gas. Next, it enters the closed combustion chamber to provide oxygen for the burner.
- Waste flue gas then enters the air-water heat exchanger for further cooling.
- The cooled waste flue gas enters the chemical tower for desulfurization and denitrification.
- Subsequently, the waste flue gas enters the electrostatic precipitator and activated carbon dust collector for further purification.
- Finally, the treated waste flue gas which meets EU emission standards is discharged through the chimney.
05Carbon Black Discharging
- First, the screw extractor at the end of the reactor discharges the carbon black. It enters the water-cooled carbon black storage tank.
- Then, the carbon black in the storage tank enters the water-cooled discharge system. Three screw extractors quickly reduce the temperature of the carbon black.
- Finally, a container is used to collect the finished carbon black.
Application of End Products of Continuous Tyre Pyrolysis Plant
Pyrolysis Oil
- Energy Supply: High calorific value tyre pyrolysis oil can be used as a fuel substitute in boilers, industrial furnaces, power plants, etc.;
- Power Generation: The non-standard diesel components obtained after distillation can be used for heavy oil generator sets to generate electricity.
Carbon Black
- Further Processing: Carbon black can be further processed to obtain higher quality rCB. This is a good filler for rubber products, especially tyre.
- Coatings: Carbon black is widely used in the coating and ink industries, such as automotive coatings, home appliance coatings, and printing inks.
Steel Wire
The steel wire separated after pyrolysis can be sold directly to steel mills. It is re-smelted as scrap steel material to obtain steel products.
Syngas
The continuous waste tyre pyrolysis plant can directly use syngas to provide energy for the continuous pyrolysis reactor. Thus, it achieves energy self-sufficiency.
Technological Innovation of Continuous Waste Tyre Pyrolysis Plant
Inert Gas Protection
Beston Group continuous waste tyre pyrolysis plant uses inert gas (nitrogen) to replace the air in the feeding system. This not only maintains the oxygen-poor environment in the reactor, but also ensures the safety and stability of the pyrolysis process.
Precise Feeding with Real-time Monitoring
The machine uses a double screw conveyor and a high-precision weighing system. They control the continuity and accuracy of the feeding. In addition, this realizes real-time monitoring and stage statistics to ensure stable production.
Hot Air Heating
The induced draft fan reintroduces the high-temperature exhaust gas in the furnace into the combustion chamber. The chamber mixes it with the high-temperature hot air from the burner to heat the reactor and achieve precise temperature control.
Intelligent Control
Based on the PLC system and the Internet of Things technology, the tyre recycling pyrolysis plant realizes centralized system control and remote monitoring. This ensures the automation and intelligent management of the production process.
Triple Anti-coking
The fully automatic tyre pyrolysis plant integrates hot smoke recycling, catalyst anti-coking, and physical decoking technologies. They minimize coking on the inner wall of the reactor, ensuring production continuity and extending equipment life.
3-level Self-cleaning Condensor
The machine adopts a 3-level condensation structure. It can separate impurities and improve oil recovery. Automatic circulating hot oil cleaning of the condenser tube prevents condenser blockage, ensuring efficient operation.
Sealed Discharging with Real-time Sampling
The discharge system adopts a high-temperature sealed design. This ensures continuous slag discharge while maintaining gas sealing. The sampling device monitors the state of pyrolysis residue in real-time to optimize pyrolysis parameters.
High-end Waste Gas Treatment
The system treats high-temperature waste gas through desulfurization and denitrification. It then removes dust with an electrostatic precipitator and activated carbon dust collector. This ensures that exhaust gas emissions meet EU environmental standards.
Global Cases of Beston Pyrolysis Project
Beston Group understands the critical role that exceptional customer service plays. That’s why we provide seamless pre-sales and after-sales support. From project initiation to completion, our dedicated project consultants and expert technical engineers are with you every step of the way. It ensures comprehensive assistance. This commitment to service is why so many customers choose Beston Group for their pyrolysis recycling projects, such as tyre, plastic, oil sludge,etc. Below are some of our successful cases for your reference.
Choose to Invest in Beston Fully Automatic Tyre Pyrolysis Plant
As a leading manufacturer of continuous waste tyre pyrolysis plant, Beston Group has invested a lot of efforts in R&D. We take pride in delivering impeccable after-sales service to all our customers. The recycling 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.