A continuous tyre pyrolysis plant is engineered for ongoing processing of end-of-life tires, distinguishing itself from batch processing methods. This continuous operation offers advantages such as higher efficiency and consistent product output. It caters to tyre recycling industry’s need for efficient large-scale tyre management. Beston Group has developed BLL-30 model. Welcome to contact us for expert consultation.
What Can Continuous Tyre Pyrolysis Plant Do?
Every year, the global production of end-of-life waste tires reaches 10 million tons. There is a need for large-scale processing capabilities within tyre recycling industry. Beston BLL-30 continuous tyre pyrolysis plant is capable to process 30-35 tons waste tyres per day and turn them into valuable pyrolsyis oil, carbon black, steel wire and syngas. Its continuous operation aligns with industry demands for large-scale tyre management and recycling, making it a highly favorable choice.
| Model | BLL-30 |
|---|---|
| Manufacturer | BESTON |
| Time to Market | 2024 |
| Motor Brand | Chinese brand |
| Suitable Raw Materials | Waste plastics; Tires; Oil sludge |
| Input Capacity (Max.) | Waste plastic pellets: 0.8-1.05t/h Rubber powder: 1.25-1.5t/h Oil sludge:1.8-2.3t/h |
| Working Method | Fully Continuous |
| Final Oil Quality | Pyrolysis oil Pyrolysis oil with wax or naphtha |
| Reactor Materil | 304/310S Stainless steel |
| Reactor Life Span (Years) | 5-8 |
| Guarantee (Months) | 12 |
| Delivery Time (Calendar Days) | 150 |
| Land Space Required (L*W*H*m) | 70*20*10 |
| Packing | 20*6*3m in bulk+13*40HQ |
| Installation Period (Calendar Days) | 90 |
Meaning of “Continuous” in Continuous Tyre Pyrolysis Plant
The key aspect of a continuous tyre pyrolysis plant is its ability to operate non-stop. Here compare batch working model to understang what is continuous operation.
| Working Model | Batch | Continuous |
| Process | feeding-preheating-pyrolysis-discharging-cooling-repreheating-pyrolysis-discharging | feeding-preheating-pyrolysis-discharging&refeeding-pyrolysis-discharging&refeeding |
| Description | After completing a batch pyrolysis, the system requires cooling time before starting the next batch. It also needs to re-preheat the reactor for the next batch. Its feeding and discharging processare not simultaneous. | Once a batch of pyrolysis is completed, it immediately feeds in the next batch of waste tires. Simultaneously, it can discharge the products from the previous batch. There’s no need for cooling time or re-preheating the reactor between batches. By this way, it realizes non-stop operation. |
Advantages of Continuous Operation by Continuous Tyre Pyrolysis Plant
Maintaining a continuous process flow in tyre pyrolysis plant offers some benefits, making it an attractive solution for large-scale tire recycling.
BLL-30 continuous pyrolysis plant can process a larger volume of tires compared to batch systems. The non-stop operation maximizes the efficiency and optimizes the use of energy and resources.
Continuous systems provide a steady and uniform output of pyrolysis products, such as pyrolysis oil, carbon black, and steel wire. This consistency is beneficial for downstream processing and commercialization.
By eliminating the need for cooling and reheating cycles inherent in batch processes, continuous plants minimize downtime, resulting in higher overall productivity.
Continuous tyre pyrolysis plant feature advanced PLC control and IOT systems.This enhance the stability and reliability of the process, reducing the risk of operational disruptions.
Advanced Configurations of Continuous Tyre Pyrolysis Plant
Nitrogen is introduced for replacement before ignition and slag discharge to prevent flash explosions in the main furnace and ensure safe and stable operation of the equipment.
Compared with direct heating by traditional burner, the hot air heating method is safer, more uniform in heating, and more precise in temperature control. Additionally, it enables waste heat recycling, which saves 20-30% of energy consumption, thereby enhancing energy efficiency and reducing emissions.
The main furnace uses a combination of floating sealing technology with combination between carbon fiber and high-temperature soft filler. This technology surpasses traditional graphene packing seals in high-temperature resistance, corrosion resistance, and wear resistance.
High-end exhaust gas treatment system, combined with the higher exhaust gas treatment and wastewater discharge requirements of European clients, can provide semi-dry or fully dry desulfurization, denitrification and de-dusting system to meet European emission standards.
In case of overpressure in the main furnace, an automatic safety valve activates for emergency pressure relief, ensuring the safety of both equipment and personnel.
This system efficiently separates heavy impurities and collects pyrolysis oil, enhancing the overall efficiency of the pyrolysis process.
Pyrolysis Principle of Continuous Tyre Pyrolysis Plant
- Feeding: Automatic feeder will push waste tyres to the furnace.
- Preheating: Combustion chamber burns the fuel to provide hot air to heat the furnace.
- Oil Gas Generation: When the interior temperature of the reactor reaches 180℃, oil gas will be generated and then go to the manifold. After that, the heavy particles of the oil gas will be collected into the oil sludge tank while the light oil gas travel to the condenser and then liquefied into the pyrolysis oil. Finally, it will be stored in the oil tank, and that is oil you can get.
- Slag Discharging and Gas Emission: Tyre pyrolysis carbon black is discharged through the sealed water-cooling discharging system. All flue gas will be discharged safely after going through de-dusting, water spraying and cleansing, activated carbon absorption and ceramic ring absorption. And we promise all the emissions of our pyrolysis units to meet the EU environmental emission standard.
Economic Benefit Source of Continuous Tyre Pyrolysis Plant
The economic benefits of a continuous tyre pyrolysis plant primarily stem from the sale of its products:
Tyre pyrolysis oil can be sold as fuel to high-energy-consuming industries or refined into high-quality fuels such as non-standard diesel, commercial diesel, or gasoline.
Carbon black, a byproduct of tyre pyrolysis, is valuable in various industries such as rubber manufacturing, coatings, and printing inks.
The steel wire recoveved from waste tyres can be sold to steel manufacturing plants to make rolled steel.
Key Considerations for Continuous Tyre Pyrolysis Plant Operation
Continuous pyrolysis operation typically require a tyre shredder to reduce the size of waste tyres. Specifically, tyre waste should be in the form of rubber powder with particle sizes ranging from 1 to 5 millimeters. This size reduction is crucial for efficiently feeding small tyre pieces into the continuous reactor, ensuring smooth operation and high-quality end products.
The temperature of tyre pyrolysis process can be adjustable based on the raw material and desired output. For tyre pyrolysis, the optimal temperature is between 280-350°C, with the pyrolysis vapor temperature controlled between 280-320°C. To maximize tyre pyrolysis oil yield, a relatively “low and slow” heating approach is recommended. Customers can remotely adjust temperature parameters through PLC control and IoT systems.
The entire system is designed for fault-free continuous operation for no less than 21 days. Scheduled downtime for maintenance is arranged 4-8 days per month. During normal production, safety inspections should be conducted at least every 2 hours. Major maintenance is planned 1-2 times per year, lasting 10-15 days each time, focusing on replacing worn parts. It involves high-temperature soft filler of feed inlet and discharge outlet, drive gears correction, and replenishing various oils and fluids, etc.
Cooperate with Beston Group – Your Reliable Partner
Considering implementing a continuous tyre pyrolysis plant for large-scale recycling? Partnering with Beston Group ensures expertise and support to optimize your operations. We offer a comprehensive range of services including technical consultation, material testing, customized solution design, information sharing, on-site installation, and operational training. Contact us now for maximum convenience and efficiency in your recycling initiatives.
