A tyre pyrolysis plant heats scrap tires in an oxygen-free reactor to break down rubber polymers into valuable reusable resources. It converts waste tires into roughly 40% pyrolysis oil, 30% recovered carbon black, 20% steel wire, and 10% combustible syngas. It provides an eco-friendly circular economy solution for tire recycling.
A waste tyre pyrolysis plant recycles waste tyres into pyrolysis oil, carbon black, steel wire, and syngas. (Credit: Beston Group)
Tyre Pyrolysis Plant Models & Specifications: Fully Continuous & Batch
💡 Beston Engineer Tips: Having overseen 40+ installations globally, I recommend the BLJ-16 as the essential entry-level solution for those prioritizing lower initial risk. In contrast, the BLL-30 represents the inevitable industry trend for large-scale industrial expansion, offering the high-efficiency, continuous operation required to dominate the market in 2026.
Model
Blackgold P30
BLJ-20
BLJ-16 Standard
BLJ-16 ULTRA
Manufacturer
BESTON
BESTON
BESTON
BESTON
Time to Market
2026
2025
2013
2022
Motor Brand
Chinese brand
Chinese brand
Chinese brand
ABB Explosion-proof
Suitable Raw Materials
Waste plastics; Tires; Oil sludge
Waste plastics; Tires; Oil sludge
Whole tire Tire blocks Oil soil with liquid content
How Tyre Pyrolysis Process Works: Step-by-Step Breakdown
Step 1: Feedstock Pre-treatment
Tires are either loaded whole (for batch systems) or shredded into small chips (20–50 mm) and cleared of heavy steel wires (for continuous systems).
Step 2: Sealed Feeding
Whole tires or pre-shredded tire chips are loaded into the reactor through a sealed feeding system, preventing air from entering and ensuring a fully oxygen-free environment. The reactor is then gradually preheated to prepare for the pyrolysis reaction.
Step 3: Thermal Decomposition
Under heating conditions (180℃–450℃) and micro-negative pressure (＜20kPa), rubber polymers crack into oil gas. Lighter oil gases ascend to condensers, while heavy oil is re-fed by the screw into the reactor for re-pyrolysis.
Step 4: Oil Gas Condensation
Oil condensation: Hot oil vapors pass through cooling pipes and condensers, turning into liquid pyrolysis oil, which is collected in storage tanks.
Syngas recycling: Uncondensable gases are cleaned and often recycled back to fuel the reactor’s burners.
Step 5: Solid Residue Recovery
After pyrolysis completes, carbon black is safely discharged via a water-cooled screw conveyor at stable, low temperatures. For batch systems, steel wires are extracted post-cooling for direct scrap recycling.
Step 6: Exhaust Gas Treatment
Exhaust gas undergoes a multi-step dedusting and scrubbing process (e.g., water spray) to ensure compliance with stringent global emission standards (such as EU or EPA).
Tyre Pyrolysis Products: Yields & Market Applications
Tyre Pyrolysis Oil (TPO) | Yield: 40% – 45%
Our tyre to oil plant yields high-value light oil and non-standard diesel, serving a wide range of industrial needs.
Industrial Fuel: High-caloric energy source for steel mills, cement plants, and glass factories.
Refinery Feedstock: Can be refined into higher-grade fuel.
Deep Upgrading: Used as a blending component to produce commercial-grade gasoline and diesel.
Recovered Carbon Black (rCB) | Yield: 30% – 35%
Tyre Pyrolysis Carbon Black (rCB) serves as a cost-effective substitute for virgin carbon black across multiple industries:
Industrial Manufacturing: Used as a functional filler and pigment in rubber, plastics, inks, and coatings.
Construction: Added to asphalt, concrete, and carbon bricks to boost structural strength.
High-Value Upgrades: Deep-processed into high-purity grades like N550/N660, boosting market value by up to 5x.
Steel Wire Scrap | Yield: 12% – 15%
Steel wire can be sold to steel mills or recycling companies, where to be reused in tire production or reprocessed into other metal products.
Combustible Syngas | Yield: 5% – 7%
This non-condensable syngas is a key factor in lowering your OpEx. It is recycled to heat the reactor, achieving energy self-sufficiency.
SGS Test Reports: Tyre Pyrolysis Oil & Carbon Black Analysis
Tyre Pyrolysis Oil: SGS Report Analysis
High calorific value, low viscosity, and low ash content—tyre pyrolysis oil produced by our machine is a premium alternative fuel for industries.
The pyrolysis carbon black has a fair carbon content (76.26%) but relatively high ash content (20.91%). It is suitable for use as filler in low-end rubber products, partially replacing virgin carbon black and helping reduce carbon footprint.
Feedstock & Oil Yield Analysis: How Different Tires Impact Output
💡 Tip: “Based on our actual project experience in regions like South Africa and Brazil, we find that tires with high natural rubber content and low steel/cord impurities—such as OTR and large truck tires—are the gold feedstocks for pyrolysis. If you have a stable supply of these premium tires, pyrolysis often delivers a higher ROI than traditional mechanical recycling (producing low-margin rubber powder).”
Raw Material
Types
Tyre Pyrolysis Oil (TPO)
Recovered Carbon Black (rCB)
Steel Wire
Combustible Gas
Tyre
Truck Tires
45%-50%
30%
15%-20%
5%-10%
Car Tires
40%-45%
40%
10%-15%
5%-10%
Bicycle/motorcycle Tires
30%-35%
10%
5%-10%
5%-10%
Rubber Products
Rubber Cable
25%-35%
Shoes Sole
25%-35%
Mixed Sole
20%-30%
Sneakers
20%-30%
Waste Fiber Carpet
30%
PMMA
40%
Note: Data based on internal laboratory tests. Actual yields may vary slightly depending on the moisture content and rubber purity of the feedstock.
How We Verify Yield Rates: In-House Test Records Disclosed
To ensure the yield data we share is verifiable, our lab engineers run repeated small-batch tests on tyre feedstock from different sources and conditions — and we publish the raw records as-is: sample weight, reaction time, temperature curve, and unedited photos. Below are three of our most recent test records.
Material: Shredded TiresEnd Product: Pyrolysis OilEnd Product: Carbon Black
Global Project Cases: Proven Success Across 30+ Countries
Tyre Pyrolysis Project in South Africa
As a leading metal and integrated waste recycler in South Africa, the client faced a dual challenge: ① their recovery network generated thousands of tons of waste tires and plastics annually requiring reduction, while ② their metal smelting operations struggled with soaring fuel costs. This pyrolysis project successfully transformed a “waste dumping ground” into a “low-cost energy hub.”
Pyrolysis Oil Use: Fuel for aluminum melting and heavy-duty trucks
Project Timeline: 631-day full lifecycle
Start Date: June 7, 2023
Operation Date: Feb 26, 2025
Final Acceptance Date: March 12, 2025
Project Status
The tyre pyolysis plants has been successfully installed and commissioned. It is now fully operational, maintaining stable daily output.
Operational Results: The produced pyrolysis oil is consumed internally, significantly offsetting fuel costs for the client’s smelting furnaces.
Open for Site Visit: This project serves as a benchmark reference site in the region. Prospective clients with active project needs are welcome to witness the equipment in full operation by appointment.
BLJ-16 Tire to Oil Plant in South Africa
Tire Waste Feedstock to Recycle Oil
Tire Pyrolysis Oil Produced On-site
Tyre to Oil Pyrolysis Project in South Africa
Tyre Pyrolysis Project in West Africa
The client is a waste recycling company based in West Africa, currently expanding its resource recovery portfolio by developing pyrolysis capabilities. The primary objective of this initial waste tire project is to gain operational expertise and develop a skilled technical team, providing a foundation for the future integration of plastic and oil sludge pyrolysis operations.
Annual Capacity: 6,000 tons of waste tires
Equipment Configuration: BLJ-16 model with a dual-system setup (Manifold + Catalytic Tower), engineered to support future processing of waste plastics and oil sludge for feedstock diversification.
Launch Date: June 2024
Pyrolyis Oil Use: sold as fuel
Project Status: Installation and commissioning have been successfully completed. The system is currently in stable operation.
Zero Clogging & Less Coking: 30 Days Continuous Operation
Blackgold P30 utilizes steam heating with co-current self-cleaning to prevent wax clogging, and mechanical gravity-friction with uniform hot-air heating to mitigate coking. These ensure 300 days of annual operation and boost profitability.
Light & Heavy Oil Fractional Distillation System
Collect Light Oil & Non-Standard Diesel
Blackgold P30 uses an oil-gas spray technology to fractionate light oil and non-standard diesel, collecting 8 tons more light oil per day than before. (Extra revenue: 8 tons × 320 RMB/ton = 2,560 RMB/day → 2,560 × 300 days = 768,000 RMB/year)
Automatic Technology
High Automation & Min Manual Labor
Blackgold P30 features automatic reactor temperature control (±10°C precision), automated weighing and feeding, and automatic fractional condensation. Together, these boost efficiency by 60% and reduce labor costs by the equivalent of 2 workers.
Self-adjusting Sealing Technology
Safety Upgrade & Compliant Operation
BlackGold P30 features automatic sealing based on variable thermal deformation and nitrogen sealing technology. Dynamic sealing withstands 3 kPa pressure.
BLJ-20 Technical Breakthrough
Fractional Distillation Technology
One Step to Get Light Oil & Non-standard Diesel
Energy saving & consumption reduction: Reduce heating and cooling loads.
Product optimization: High light component yield and sufficient heavy component recovery.
Investment optimization: Reduce intermediate equipment, resulting in lower floor space and capital expenditures.
Large-capacity Pyrolysis Reactor (ø2800*10000)
Increase Processing Capacity by 50%
Larger recycling scale: Improves processing capacity to 18-20 tons/day. Annual tire treatment capacity up to 6,000 tons, ideal for medium to large projects.
Better Economic Return: Improved equipment utilization and generated more revenue from oil products.
Engineering Excellence: Key Advantages of Beston Tyre Pyrolysis Plant
Operational Efficiency: Lowering Your OPEX
Syngas Self-Sufficiency: The system recycles non-condensable gases back to the furnace as fuel. This Syngas Recycling System dramatically reduces external energy costs and lowers overall emissions.
Advanced Heat Retention: Our tyre pyrolysis reactor is wrapped in high-density insulation casing, ensuring maximum thermal efficiency and less energy cost.
Safety First: Proactive Risk Mitigation
Nitrogen Replacement:Before ignition and slag discharge, nitrogen is introduced to displace oxygen.This creates an inert environment, effectively preventing flash explosions
Overpressure Alarm & Automatic Pressure Relief: In the event of overpressure in the main furnace, the safety valve will be automatically opened for emergency pressure relief to ensure equipment safety and personal safety.
Multi-Point Monitoring: Multiple observation points provide real-time tracking of temperature, pressure, and liquid levels for total operational transparency.
Modular Dedusting: Various dedusting treatments (water washing, spraying, ceramic ring adsorption, and activated carbon adsorption) to ensure meeting EU emission standard or your local standard.
Zero-Discharge Cooling: Recycles 100% of cooling water to minimize resource consumption and prevent thermal pollution.
Enclosed Clean Operation: From feeding to carbon black discharging, the entire process is fully enclosed to eliminate dust pollution.
Intelligent Control: Precision Operations
PLC/DCS Automation: Our centralized control systems (available in PLC or DCS configurations) allow for remote monitoring and operation. This reduces on-site labor requirements by up to 40% while keeping operators at a safe distance from the heat zone.
IoT & Remote Diagnostics: With integrated IoT Technology, our engineers can provide remote technical support and real-time monitoring of your equipment’s health, ensuring maximum uptime and predictive maintenance.
Beyond Disposal: Why Pyrolysis Outperforms Traditional Tire Treatment
Environmental Benefits
Avoid Negative Environmental Impacts: Discarded tires take up significant space and degrade slowly in nature; long-term stockpiling can also pose environmental risks, such as mosquito breeding, fire hazards and water pollution.
Lower Lifecycle Carbon Footprint: Tire pyrolysis is conducted in an oxygen-deprived environment, reducing the generation of combustion-related emissions. Through resource recovery, this process also decreases reliance on virgin fossil resources and supports the use of low-carbon resources.
Economic Benefits
High-Value Product Sales: Pyrolysis generates key marketable outputs: fuel oil, steel wire, syngas, and raw carbon black. Driven by global sustainability mandates, the market demand for recovered Carbon Black (rCB) is surging, offering robust revenue potential.
Gate Fee / Waste Tonnage Income: By scaling operations up to industrial recycling hubs, operators can generate steady cash flow through gate fees (tipping fees) collected from tire manufacturers, waste management firms, and local municipalities for processing end-of-life tires (ELTs).
Technology
Usage & Features
Secondary Pollutants
Facility Investment
ROI & Value
Limitations
Landfill
Traditional dumping
Soil and water pollution
Low
Negative (Disposal fees)
Prohibited in most countries.
Retreading
For slightly worn tires
Minimal
Low
Moderate
Only applies to 10% of waste tires.
Incineration
Suitable for tires that cannot be reused
High CO2 & toxic emissions
Low
High
High environmental control costs
Shredding
Rubber granules/powder
Dust & Noise pollution
Low (Market saturation)
High
Limited market demand for recycled products; difficult to handle large volumes
Tire-Derived Fuel
Industrial fuel
Secondary solid (ash) and air (SO2, NOx, dioxins) pollutants
Moderate
High
High pollution control costs
Pyrolysis
Total Resource Recovery
Eco-friendly
High
Low
/
Lifecycle Services: Your Partner from Consultation to Commissioning
01 Professional Consultation & Site Planning
Technical Advisory: Expert consultation on technical Q&A, local emission standards compliance, and financial ROI estimation.
Customized Layouts: Tailored Process Flow Diagrams (PFD), 2D civil engineering drawings, and 3D site layout plans.
02 Manufacturing & Quality Control
Precision Manufacturing: Every system undergoes rigorous factory testing and quality inspections before shipment.
Logistics Support: Professional shipping coordination to ensure safe delivery to your global site.
03 Installation & Expert Commissioning
On-Site Guidance: Our senior technical team travels to your location to guide assembly and installation.
System Commissioning: Full trial runs and performance fine-tuning to ensure the system meets all operational benchmarks before handoff.
04 Personnel Training & Lifetime Support
Skill Transfer: We provide hands-on training for your local operators, covering safety protocols, maintenance, and PLC management.
24/7 Technical Response: With our IoT-enabled remote support, we provide real-time diagnostics and rapid spare parts delivery wherever you are.
FAQ of Tire Pyrolysis Machine
01 What are the operating temperature and pressure for tire pyrolysis?
The normal operating reaction temperature is 280–350°C. Oil begins to distill at 180°C, and peak oil output occurs between 280°C and 350°C.
The working pressure does not exceed 20 kPa.
02 What’s the feeding size requirement for waste tires?
Feeding size varies by equipment model (Batch vs. Fully Continuous) and feeding system:
1. Batch Pyrolysis Plant
Manual/Hydraulic Feeding: Whole tires ≤1200mm (1.2m) can feed directly. Tires larger than 1200 mm require shredding.
Shredding tires down to 10–15 mm achieves a 99% steel wire removal rate. Processing further to 1–5 mm is also acceptable, but significantly increases pre-treatment energy consumption.
03 Can your exhaust treatment pass EU standards? Do you have third-party test reports?
Yes. With our high-end flue gas dedusting system, the emissions easily meet strict EU standards. We also provide third-party SGS test reports.
SO₂ ≤ 50 mg/m³,
NOₓ ≤ 200 mg/m³
particulate matter ≤ 10 mg/m³
HCl ≤ 10 mg/m³
HF ≤ 1 mg/m³
04 What are the yield ratios of products from waste tire pyrolysis?
Note: Yield ratios vary slightly based on tire composition—passenger car tires yield slightly less oil, while heavy truck tires yield higher oil output and better quality carbon black due to higher natural rubber content.
05 What are the power, water and fuel consumption of tire pyrolysis machine?
Consumption varies by equipment model.
Fuel consumption: 40–50 L/h for Diesel/Heavy Oil, or 47–50 m³/h for Natural Gas (per 400,000 kcal burner)
Water consumption: 0.3–0.5 tons/day for BLJ-16 batch unit; 5–8 tons/day for BLL-30 continuous unit.
Power consumption: Exact figures depend on the specific equipment model.
Start Your Tyre Pyrolysis Project with Beston Group
Start your tyre pyrolysis project with Beston Group today and turn waste into profit while reducing tyre pollution. With our cutting-edge technology and full-service support, we ensure your project’s success from start to finish. Ready to learn more? Visit Linkedin for detailed information and expert guidance.