Tyre pyrolysis plant is an innovative tyre treatment solution. It is designed to recycle waste tyres into valuable products such as carbon black, pyrolysis oil and gas. In recent years, the number of waste tyres has been increasing worldwide. Pyrolysis technology provides an environmentally friendly way to reduce landfill waste while producing usable resources. Tire pyrolysis plant can effectively convert waste tyres into reusable materials, contributing to the sustainable closed loop of tyre recycling.
Tyre Pyrolysis Plant: Turning Waste into Valuable Resources
Tyre pyrolysis reaction occurs under high temperature and anoxic conditions. Under the action of heat, the rubber components in waste tyre undergo thermal decomposition reaction, thereby converting into solid, liquid and gaseous products. The main stages of pyrolysis are as follows:
- Initial Stage: The long-chain structure of the polymer breaks down to generate smaller hydrocarbon molecules.
- Mid-term Stage: Further pyrolysis generates more gaseous light hydrocarbons and aromatic compounds.
- Final Stage: Stable carbon black forms, along with some smaller gas molecules.
As the carrier of this technology, tyre pyrolysis plant can not only realizes waste resource utilization, but also provides an effective way for energy substitution.
Pyrolysis Oil
Tyre pyrolysis oil is mainly composed of hydrocarbon compounds and has a high energy density. The components of these liquids include aromatic hydrocarbons, aliphatic hydrocarbons, and other olefinic substances. Pyrolysis oil can serve as fuel or be further distilled to produce high-quality oil products.
Carbon Black
About 30%-40% of the tyre is carbon black. This is a black powder with high stability. During the pyrolysis process, carbon black is directly left behind due to its non-volatility, mainly as a solid product. This product holds high commercial value and serves as an industrial filler, rubber recycling material, and more.
Syngas
During the pyrolysis process, some organic matter decomposes into light gases, mainly including carbon monoxide (CO), carbon dioxide (CO₂), hydrogen (H₂), methane (CH₄), and various light hydrocarbon gases. Proper treatment and purification can make these gases usable for energy supply in tire pytolysis plant.
Overview of the Key Components in Tire Pyrolysis Plant
Feeding System
The feeding system includes manual feeding, hydraulic feeding, and screw feeding. Manual feeding can reduce your pyrolysis plant cost. Hydraulic feeding and screw feeding are suitable for automation and large-scale production. They can stably and evenly feed tyres into the reactor.
Reactor
The reactor mainly includes the main furnace, drive system, and burner. The drive system promotes uniform heating of materials by rotating the main furnace. The burner provides a heat source. The whole reactor adopts thermal insulation and sealing design to ensure the stable operation of tyre pyrolysis plant.
Manifold
The manifold can collect and separate the heavy oil impurities produced by pyrolysis. It pushes the heavy oil impurities back to the reactor through the spiral device for secondary pyrolysis. Therefore, the manifold can improve energy utilization and reduce resource waste.
Condensation System
The condensation system is used to convert high-temperature oil gas into liquid pyrolysis oil. The cooling water in the condenser cools down the condensable components in the oil gas and condenses them into liquid. The oil product enters the oil storage tank under the action of gravity.
Discharge System
The water-cooled screw conveyor of the discharge system discharges the carbon black generated during the reaction. If you want a lower exhaust temperature, you can set up multiple water-cooled conveyors. This ensures safe operation of waste tyre pyrolysis plant and prevents overheating.
Exhaust Gas Treatment System
Pyrolysis exhaust gas can be discharged after being cooled and dust-removed. If your local emission standards are high, we recommend you choose a high-end treatment system (standard for continuous pyrolysis plant), and the exhaust gas treated by the system can reach EU emission standards.
Comparison of Different Tyre Pyrolysis Plant: Batch Vs. Continuous
There are two main types of tyre pyrolysis plant: batch and continuous. They each have different working principles, advantages, and applicable scenarios. Here is a comparison of the two types:
| Feature | Batch Plant | Continuous Plant |
|---|---|---|
| Operation Mode | Batch processing, requires stoppage for feeding | Continuous operation with automated production |
| Applicable Scale | Suitable for small to medium-scale production, flexible | Ideal for large-scale production, efficient handling of large amounts of waste tyres |
| Energy Efficiency | Lower efficiency, frequent heating and cooling required | Higher efficiency, consistent operation with lower energy consumption |
| Initial Investment | Lower cost, simpler equipment | Higher cost, more complex equipment |
| Production Efficiency | Lower, limited output | Higher, 24/7 continuous production |
| Flexibility | Offers diverse configuration options | Lower flexibility, suited for stable, long-term production |
| Adaptability | Handles various tyre types and size flexibly | Requires more fixed tyre size |
| Maintenance Requirements | Relatively simple maintenance of tyre pyrolysis plant | More complex equipment, higher maintenance demands |
Parameter table of Waste Tyre pyrolysis Plant
| Model | BLJ-16 | BLL-30 | |
| Capacity | 12-16t/d | 30-35t/d | |
| Working Process | Batch | Fully continuous | |
| Reactor Size | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | 310S stainless steel | |
| Drive System | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 33m*13m*8m | 70m*20m*10m | |
| Power | 55.6kw | 256kw | |
| Burner | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 34.5t | About 150t | |
| Number of Containers | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤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 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
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Transformative Solutions Enabled by Tyre Pyrolysis Plant
Efficient Tyre Handling
Tire pyrolysis machine decomposes waste tyres into carbon black, pyrolysis oil, and gas through a high-temperature and anoxic environment, significantly reducing the volume of waste tyres. Through the pyrolysis process, the volume of waste tyres can be reduced to 1/5 or less of its original size. Thus, this effectively solves the space pressure and processing burden caused by the accumulation of waste tyres.
Environmental Impact Reduction
Tyre pyrolysis plant can effectively reduce the pollution of air, water, and soil caused by inefficient disposal. The gas generated during the pyrolysis process can meet environmental protection emission standards after being treated by the exhaust gas treatment system. Compared with traditional incineration or landfill, pyrolysis technology reduces harmful gas emissions and optimizes resource utilization.
Alternative Energy Production
Tyre pyrolysis oil has high energy density and can be used as an alternative energy source for industrial boilers and power generation. Through the distillation process, different hydrocarbon components can be extracted. Especially non-standard diesel has more industrial energy application scenarios. Pyrolysis reduces dependence on traditional energy and forms a closed loop of resource recycling.
Industrial Materials Production
As an important industrial filler, carbon black is widely used in the rubber, plastics, and coatings industries. In addition, further processing into rCB (recovered Carbon Black) has higher utilization value. Meanwhile, recycled steel wire can serve as recycled metal materials. Therefore, it can enter the metallurgical industry or other fields. tire pyrolysis plant supports the production of sustainable materials and drives the development of a circular economy.
Operation Process of Tire Pyrolysis Plant
Tyre Feeding
01
Tyre Pyrolysis
02
Oil Gas Condensation
03
Gas Treatment
- Syngas Recovery: The non-condensable components in the high-temperature oil gas are purified to form syngas. The syngas is used to provide energy for tyre pyrolysis machine.
- Exhaust Gas Discharge: The remaining exhaust gas is cooled and dust removed through a condenser and spray tower, and then discharged through the chimney.
04
Carbon Black Discharge
05
Technical Advantages of Tyre Pyrolysis Plant
Inert Gas System
When the waste tyre pyrolysis machine is started and stopped, the system introduces inert gas (nitrogen) for gas replacement. Through nitrogen replacement, the residual combustible gas and air in the reaction furnace can be effectively removed. Thus, this prevents the flash explosion of the main furnace and ensures the safe operation of the equipment.
Hot Air Heating
Compared with burner heating, the hot air heating system provides more uniform heating and more precise temperature control. Most importantly, the hot air heating system can achieve waste heat recovery, saving 20-30% of energy consumption. Thus, this significantly improves energy efficiency and environmental benefits.
Floating Seal Technology
The floating seal technology uses a sealing method that combines carbon fiber and high-temperature soft filler. Compared with traditional graphite filler sealing technology, Beston‘s seal has stronger resistance to high-temperature corrosion and wear. Therefore, it can stably and long-term guarantee the sealing effect of the waste tyre pyrolysis plant.
Reliable Insulation Material
High-temperature ceramic wool is used for the internal insulation material of the equipment’s casing. You can choose to use Morgan brand high-temperature ceramic wool. This material does not pose a risk of cancer or lung infection to workers, and meets EU standards to ensure worker safety and environmental protection requirements.
Why Choose Beston Group as Your Tyre Pyrolysis Plant Manufacturer?
Two Models with Flexible Configuration
Beston Group offers two main models: batch type and continuous tyre pyrolysis plant. Especially, both models feature flexible configurations. You can adjust parts like materials, reactor door, feeder, PLC, and motor. These customizations improve operational efficiency and bring significant economic benefits. Let us know your requirements, so we’ll provide the perfect tyre pyrolysis equipment for you.
Fast Delivery & Short Lead Time
We keep some machines in stock. Therefore, once you sign the contract, we can quickly check and ship these machines. For new orders, production usually takes 30-45 days. After that, we perform a final inspection before shipment. With our years of export experience, we ensure smooth processing and find the best shipping route for you. Get in touch for more details.
Installation & Training Services
We has shipped many Beston tyre pyrolysis plant to countries all over the world. Beston Group managed everything, from project design to installation and trial runs. We handled capacity planning, factory layout, and end-product applications. Our goal is to ensure a seamless experience for our clients. Additionally, we offer installation and training services, so you can operate your plant smoothly from day one.
ROI Analysis of Waste Tyre Pyrolysis Plant
| Return on Investment of BLJ-16 Tyre Pyrolysis Project in Europe | |||||||
| Introduction | According to the market data of Europe, the estimated ROI report, the various expenses are as follows: | ||||||
| Fixed Investment Cost | Item | Details | Unit | Unit Price/USD | Quantity | Amount/USD | Remark |
| Equipment | BLJ-16 | Set | 89000 | 1 | 89000 | ||
| Transportation | Seafreight | Set | 64600 | 1 | 64600 | ||
| From Port to Site | Set | 5800 | 1 | 5800 | |||
| Customs Tax | 0.15 | Set | 13350 | 1 | 13350 | ||
| Installation | Beston technician's salary | Day | 350 | 50 | 17500 | ||
| Round-trip aritickets | Ea | 3820 | 2 | 1640 | |||
| Visa | Ea | 750 | 1 | 750 | |||
| Local welder | Day | 120 | 100 | 12000 | 2 welders are needed | ||
| Local plumber | Day | 120 | 20 | 2400 | |||
| Local labor | Day | 108 | 50 | 5400 | |||
| Crane forklift | Day | 160 | 30 | 4800 | |||
| Materials | Installation materials ready | Set | 5200 | 1 | 5200 | Foundation, pipe, etc. | |
| Licenses | / | Ea | 2000 | 1 | 2000 | Environmental, firefighting, etc. | |
| Workshop | 500 | ㎡ | 380 | 500 | 190000 | ||
| Total Amount | $452440.00 | ||||||
| Operating Cost | Raw Materials | Waste tyre | Ton | 0 | 12 | 0 | |
| Water | / | m³ | 0.39 | 3 | 1.17 | ||
| Electricity | / | KWH | 0.2 | 864 | 172.8 | ||
| Fuel | Natural gas | Liter | 0.77 | 240 | 184.8 | ||
| Labor | / | People | 72 | 4 | 288 | ||
| Maintenance | / | Day | 85 | 1 | 85 | ||
| Depreciation | 8 years | Day | 175.18 | 1 | 175.18 | ||
| Tax | 5% | 0 | |||||
| Total Amount | $906.95 | ||||||
| End Products Price | Tyre oil | 45% | Ton | 5.4 | 433 | 2338.2 | 45% of input |
| Steel Wire | 15% | Ton | 1.8 | 216 | 388.8 | 15% of input | |
| Carbon black | 3% | Ton | 3.6 | 162 | 583.2 | 30% of input | |
| Subsidy | Ton | 100 | 12 | 1200 | |||
| Total Amount | $4510.2 | ||||||
| Daily Income | $3603.25 | ||||||
| Monthly Income | Working day | Day | 25 | $90081.17 | |||
| Yearly Income | Working day | Day | 300 | $1080974 | |||
Global Success Cases: Tyre Recycling Solutions Trusted Worldwide
Beston Group’s tyre recycling solutions have been successfully deployed around the world. Our tyre recycling pyrolysis plant is highly recognized for their efficiency and reliability. As a result, numerous customers from different countries choose Beston as their long-term partner. Thus, customers benefit from our advanced technology and sustainable practices in tyre pyrolysis. Below, explore the cases behind these successful collaborations. Find out how Beston Group is shaping the future of recycling, including plastic, oil sludge, waste tyre, etc.
Join Tyre Recycling Ranks with Beston Group’s Solution
In summary, tyre pyrolysis plant provides an efficient and eco-friendly method of recycling waste tires. It plays a key role in the circular economy by transforming tires into valuable materials and reducing waste. By investing in waste tyre pyrolysis plant, investors not only contribute to sustainable development. Also investors can unlock new business opportunities, ensuring long-term profitability and environmental responsibility. To get the latest news on tire recycling, follow us on LinkedIn.
