Continuous Screw Pyrolysis Plant
Detailed Introduction
- The world's first unique continuous screw running model pyrolysis technology.
- Automatic and stable operation for more than10 years.
- Anti-coking design and two cooling system. The pyrolysis line can run more than 100 days continuously.
- Large processing capacity: 10000 tons / year waste tire.
- Can be designed according to clients need.
- 27 meters long reactor, can get high quality recovered carbon black with low volatiles.
Working Process of an Industrial Continuous Waste Tyre Pyrolysis Plant
To maintain the efficiency of the continuous feeding and discharge system, waste tyres must be reduced to a small, uniform size. Therefore, before entering the pyrolysis reactor, the tyres are first shredded into smaller pieces.
To prevent steel wires from mixing with the carbon black produced during pyrolysis — which would be difficult to separate — it is recommended to remove the steel reinforcement from the tyres in advance.
Continuous Waste Tyre Pyrolysis Plant Process Description
1. Sorting and Shredding
The incoming waste tyres are sorted into three categories: OTR (Off-The-Road) tyres, truck tyres, and passenger car tyres.
Each tyre type is fed into a dedicated shredder designed for its specific thickness and structure. This protects the equipment and ensures efficient shredding. During this stage, thick tread wires are removed and collected. The output is tyre blocks measuring approximately 10–15 cm in size.
2. Crushing to Powder
The tyre blocks are then conveyed to a crushing system, where they are ground into powder ranging from 10 mesh to 2 mm in particle size. Any remaining fine steel wires are separated and recovered using magnetic separation equipment.
This step effectively removes most metallic impurities, reducing wear on the subsequent pyrolysis equipment.
3. Continuous Pyrolysis
The tyre powder is fed into a continuous pyrolysis reactor system. Inside multiple interconnected reactors, the powder undergoes high-temperature decomposition in an oxygen-free environment, producing a mixture of oil vapor and gas.
The (oil vapor) is cooled in a condensing system to form liquid fuel oil, which is collected for storage. Solid residues (carbon black) are discharged via a screw conveyor into the carbon black treatment line.
4. Carbon Black Refining
The raw carbon black from the pyrolysis process is in the form of crude char, which cannot be directly used in tyre manufacturing. It must undergo refinement.
First, it is milled into a fine powder of 300–1000 mesh. The powder is then pelletized into RCB (Recycled Carbon Black) pellets, which are dried to remove moisture. The final product is high-quality carbon black suitable for the rubber industry.
Continuous Waste Tyre Pyrolysis Plant – Key Advantages
1. Screw-Type Reactor Design
Compared with drum-type reactors, our screw-driven reactor operates continuously for longer periods thanks to its built-in coking cleaning system. This ensures stable performance and minimal downtime.
2. Advanced Sealing System
Traditional drum reactors require weekly replacement of sealing materials, preventing true continuous operation. Our screw-type reactor uses an advanced liquid film seal that eliminates oil and gas leakage, ensuring safe and uninterrupted production.
3. Fully Automatic Operation with Low Labor Costs
The entire plant is controlled by a PLC system with automatic feeding and discharge. Only 1–2 operators are needed, significantly reducing labor expenses.
4. Complete Pyrolysis for High Oil Yield
The screw reactor design ensures thorough pyrolysis of tyre powder, maximizing oil output compared to conventional systems.
5. Large Processing Capacity
Continuous feeding and discharge, combined with a unique multi-reactor configuration, enable the plant to process 10 to 100 tons of waste tyres per day, meeting both small and large-scale production needs.
6. Time and Energy Efficiency
Continuous operation eliminates the need for repeated startup and shutdown cycles, saving both time and energy.
7. Long Service Life
The reactor uses indirect hot air heating, minimizing wear and extending equipment lifespan. Additionally, steel wires are completely removed before pyrolysis, preventing mechanical damage to the reactor.
Applications of Fully Continuous Waste Tyre Pyrolysis Plant
Our fully continuous waste tyre pyrolysis plant can process all types of waste tyres, including:
- Bicycle tyres
- Motorcycle tyres
- Passenger car tyres
- Truck tyres
- OTR (Off-The-Road) tyres
In the first stage of the pretreatment process, steel wires are completely extracted from the tyres. The main end products from the pyrolysis process are:
- Fuel oil (used as an industrial fuel or further refined into higher-value products)
- Carbon black (which can be refined into high-quality RCB pellets for the rubber industry)
This makes the plant ideal for waste tyre recycling facilities, renewable energy projects, and industrial operations seeking to convert waste into valuable resources.
End‑Product Applications
After completing the entire pyrolysis process, the system yields three main products, each with valuable applications:
1. Pyrolysis Oil
Can be used as fuel in a wide range of industries:
- Steel and iron manufacturing
- Boiler operations
- Ceramic production
- Power generation
- Chemical processing
- Hotels and restaurants for heating or cooking
- Fuel for generators to produce electricity
2. Carbon Black
Has multiple practical uses:
- Mixed with clay to produce construction bricks
- Used as an industrial fuel source
- Further refined into high‑grade RCB pellets for the rubber industry
3. Steel Wire
- Can be sold directly as scrap metal
- Recycled to manufacture new steel products
If you want, I can also create a visual product‑flow diagram showing the input tyres and all possible output uses — it’s very persuasive for presentations.