Pyrolysis system and method for recovering carbon black and producing pyrolysis gases

Abstract

The invention refers to a pyrolysis system adapted for processing a feedstock comprising organic or carbon-rich materials comprising a first pyrolysis zone (100), a vapor thermal cracking zone (400), and a first outer housing (500), wherein said first pyrolysis zone (100) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees, and said vapor thermal cracking zone (400) is arranged longitudinally at an angle in the range of 0 degrees to 60 degrees in relation to the base of said pyrolysis system. The invention also refers to a method for producing recovered carbon black and pyrolysis gases. The pyrolysis system solves technical problems caused by fouling of trapped particles in the vapors products separation stages by incorporating the vapor thermal cracking zone (400) and solves the limitations associated with an improper quality of the obtained Recovered Carbon Black by developing a pyrolysis reactor configured to control the dwell time of the solid pyrolysis products.

Description

Pyrolysis System and Method for Recovering Carbon Black and Producing Pyrolysis Gases

[0001] The present application discloses a pyrolysis system adapted for processing a feedstock comprising organic or carbon-rich materials, which are converted to pyrolysis oil, pyrolysis gas, Recovered Carbon Black and other products.

[0002] Pyrolysis is a process of converting organic or carbon-rich materials into usable products, e.g. pyrolysis gas, pyrolysis oil, and recovered carbon black, by heating the material in the absence of oxygen. Pyrolysis reactors comprising screw conveyors are used to carry out this process. The screw conveyor system consists of a rotating spiral screw, which moves the waste material along a heated barrel or cylinder. The heat causes the polymers to break down into smaller molecules, which are vaporized and condensed into pyrolysis oil.

[0003] Recovering Carbon Black (rCB) through the pyrolysis of end-of-life tires is a sustainable and environmentally friendly way to recycle end-of-life tires and extract valuable materials. The process involves heating the tires or fragments thereof in a controlled environment to break down the rubber into its monomers or small chain oligomers, with the primary goal of recovering carbon black. The paper, drafted by Sebastião M. R. Costa et al, Production and Upgrading of Recovered Carbon Black from the Pyrolysis of End-of-Life Tires, Materials 2022, 15, 2030, presents a review on the prior art regarding the production of rCB.

[0004] The basic steps involved in obtaining rCB from end-of-life tires through pyrolysis comprise the collection and preparation of end-of-life tires, ensuring they are clean and free from contaminants like metal or large debris, and shredding the tires into smaller pieces to facilitate the pyrolysis process. After loading the shredded tires into a pyrolysis reactor, the tire feedstock is heated to a specific temperature range (typically between 300 °C to 800 °C) in the absence of oxygen in order to carry out thermal decomposition or pyrolysis of the polymers. As the tires heat up, the rubber material breaks down into its constituent molecules, releasing gases and liquids (pyrolysis oil) and leaving behind a solid residue containing carbon black.

[0005] The pyrolysis gases, which may include hydrocarbons and other volatile compounds, are collected and separated, wherein these gases can be further processed for energy recovery or other applications. The yield, properties, and quality of the products that can be obtained by the pyrolysis process depends on the type of raw material used and the reactor conditions. The main liquid or vapor products that can be produced by pyrolysis are: Heavy pyrolysis oil, which is a dark, viscous liquid comprising higher C-chain components in its composition, and that can be used as a fuel for heating or as a feedstock for further refining; Light pyrolysis oil, which is yellow orange color liquid comprising lower C-chain components in its composition; Pyrolysis gas, e.g. pyrolysis syngas, which comprises hydrogen, methane, carbon monoxide, carbon dioxide, light hydrocarbons, volatile organic compounds and other gases that can be used as a fuel for electricity generation or as a feedstock for chemical production. The light hydrocarbons comprise ethylene, propylene, and other light hydrocarbons.

[0006] The pyrolysis oil can be used for the manufacture of polymers, namely for the production of polymers that can be used for the formulation of new tires, contributing to a complete circular system.

[0007] Recovered Carbon Black (rCB) has a wide range of applications, and its use is growing due to its sustainability and cost-effectiveness compared to virgin Carbon Black. The uses of rCB can vary depending on its quality and characteristics, and high-purity rCB is particularly valuable for certain applications.

[0008] rCB is used in various rubber products, including conveyor belts, automotive parts, gaskets, and seals. rCB is used as a filler in plastic compounds to enhance their mechanical properties, such as tensile strength and impact resistance. rCB can be used as a pigment in paints and pigments to achieve black coloration. In the construction industry, rCB can be added to asphalt and concrete formulations to improve their performance and reduce costs. Nowadays, the production of rCB is one of the main goals of pyrolysis of feedstocks comprising tires, considering the sustainability goals imposed by the automotive industry.

[0009] As for high-purity Recovered Carbon Black, it is particularly valuable in applications where consistent quality, cleanliness, and low impurity levels are essential. High-purity rCB is used in printing inks and coatings for its pigmenting properties, providing black coloration while reducing the need for virgin carbon black. High-purity rCB is desirable for applications where product consistency and performance are critical. It is often chosen for high-end rubber and plastic compounds and specialty applications like the automotive industry. High-purity rCB is preferred in applications where the black color must be consistent and free of any unwanted tints or variations. Certain industries, such as food packaging and medical devices, require materials with minimal impurities and strict compliance with safety and regulatory standards. High-purity rCB can meet these requirements. In a first meaning, high-purity rCB refers to materials with low volatile content. In a second meaning, high-purity refers to low volatiles and low ash.

[0010] The solid residue, obtained according to the prior art pyrolysis systems, contains carbon black, among other materials, e.g. char and ash, wherein post-treatment processes are required to separate the Recovered Carbon Black from the char, ashes and volatile organic residues. Inorganic impurities can be removed by acid / base treatments. Volatiles organic residues can be removed by another high-temperature refining step or by a washing step with solvents, for example.

[0011] The international patent application WO2020057774A1, entitled “Pyrolysis Plant” of Germano Araújo Carreira and published on March 26th, 2020, discloses a pyrolysis plant, which is configured to process end-of-life tires and to recover Carbon Black, pyrolysis oil, and pyrolysis gas. The pyrolysis plant disclosed in this patent application comprises a pyrolysis reactor including two stages arranged in series and a vertical rotary screen cleaning tower connected to a frontal portion of the first pyrolysis stage. The pyrolysis reactor has outer housings that transfer heat through the side wall of the reactor tube to vaporize the material inside the reactor tubes as it is being conveyed. About 90 % of all the incoming tire crumb material will be vaporized in the first pyrolysis zone while the remaining 10% will be vaporized in the second pyrolysis zone, wherein the gases and liquids produced during the pyrolysis flow to the vertical rotary screen cleaning tower.

[0012] The pyrolysis plant disclosed in WO2020057774 is configured to produce pyrolysis oil and pyrolysis gas, wherein the vapors flow from the first pyrolysis zone into the rotary screen cleaning tower, which is arranged vertically in relation to the pyrolysis reactor and is configured to increase or decrease the dwell time of the vapors by changing the rotation velocity of their screen plates. The gaseous products comprise low-molecular-weight hydrocarbons, namely, C1–C5paraffins and olefins. Recovered Carbon Black is discharged from the second pyrolysis zone via a screw auger and through a gated airlock arrangement. The Recovered Carbon Black enters a combustion chamber, where hydrocarbons comprised in this product are incinerated along with any combustible material in the product.Technical Problems

[0013] The Recovered Carbon Black, obtained at the pyrolysis reactor outlet of the pyrolysis plant disclosed in WO2020057774, does not meet the required quality for a highly pure Recovered Carbon Black, which hinders its use in various fields, such as catalysts and supports, or pigments. To enhance its properties and purity level, the obtained Recovered Carbon Black must undergo further purification and upgrading processes. The incorporation of rCB in the manufacture of tires as an alternative to virgin CB is yet limited, considering the necessity of developing of processes for recovering Carbon Black in large scale and with proper quality levels.

[0014] The pyrolysis plant disclosed in WO2020057774 comprises a carbon refiner system to address the issue regarding the low purity of the Recovered Carbon Black. The carbon refiner system includes a combustion chamber configured to remove hydrocarbons from the product, a water bubbler configured to remove airborne particles and absorb chemicals like sulfur, and a separator tank to remove ashes and char from the product.

[0015] Another technical problem arising from the plant described in the patent application WO2020057774 pertains to the section responsible for producing gaseous products. The vertical rotary screen cleaning tower has a reduced capacity to separate gaseous products, primarily due to an improper thermal gradient and residence time along the rotary screen cleaning tower.

[0016] Moreover, fouling frequently develops at the inlet zone of the vertical rotary screen cleaning tower, caused by the condensation of vapors, wherein the condensate vapors trap solid particles flowing from the first pyrolysis zone, resulting in frequent obstructions at the inlet zone of the vertical rotary screen cleaning tower. These obstructions impair the proper gas flow along this device and increase the pressure inside the pyrolysis zone above desirable limits. Therefore, to remedy these drawbacks, routine interruptions of the pyrolysis plant are necessary to clean the inlet of the vertical rotary screen cleaning tower.

[0017] There is a need for a pyrolysis system that shall be configured to address properly these technical problems referred to the low quality of the Recovered Carbon Black obtained by means of the pyrolysis reactors known in the prior art. Indeed, it is deeply desired to develop a pyrolysis system to produce a High Purity Recovered Carbon Black, wherein this product presents a low volatile contamination, without a need to include a product refiner zone in said system.

[0018] There is also a need for a vapor thermal cracking zone configured to be connected to a pyrolysis zone of a pyrolysis reactor that provides more efficient use of the heat input in order to have an efficient thermal cracking of the pyrolysis products, namely producing lighter pyrolysis oils, and to properly control the desired dwell times, which are relevant for standardizing the yields of the pyrolysis process, avoiding the fouling observed in the entrance of the devices that are designed to receive and separate the vapor products outcoming from the pyrolysis reactor.Solution to Problem

[0019] The pyrolysis system comprises a new pyrolysis reactor designed to recover high-purity Carbon Black, eliminating the need for downstream equipment and unit operations to further refine this obtained product, wherein the new pyrolysis reactor comprises technical features configured to control the dwell time in the reactor. Controlling the residence time of the recovered Carbon Black is a key action to mitigate undesirable contaminants in this product.

[0020] The present invention solves the problems caused by fouling of trapped particles in the vapors products separation zone by connecting a vapor thermal cracking zone, which is arranged longitudinally at an angle in the range of 0 degrees to 60 degrees in relation to the base of said pyrolysis system, wherein the vapor thermal cracking zone comprises a screw conveyor driven by a driven subsystem, wherein said screw conveyor is driven in the opposite direction of the flow to retain solid particles. The arrangement of the vapor thermal cracking zone prevents particles leaving the pyrolysis zone from being trapped by condensing vapors in the vapor thermal cracking zone. Furthermore, the controlled spinning of the screw conveyor allows the setup of a desired dwell time inside the vapor thermal cracking zone, contributing to proper separation of the vapor products, making it possible that dust particles to drop out of the vapor stream and go back to the pyrolysis zone.

[0021] The present invention solves the limitations associated with an improper quality of the obtained Recovered Carbon Black by developing a pyrolysis reactor configured to control the dwell time of the solid pyrolysis products. In the preferred embodiments according to the invention pyrolysis system comprises at least three pyrolysis zones arranged in series, being possible to obtain a high-purity Recovered Carbon Black, eliminating the need for downstream equipment and unit operations to further refine this obtained product.Advantageous Effects of Invention

[0022] The static pyrolysis zone solves the technical problems referred to the building-up of raw materials in the pyrolysis zone. The shredded raw materials, e.g. rubber or elastomer materials, are fed into the static pyrolysis zone and present several void spaces among the raw materials portions and fragments, wherein the melting of raw materials results in its volume decreasing. The first expansion frustum cone is used to displace the loss in volume, making it possible that the material flow rate along the static pyrolysis zone to be similar to the feeding rate. This zone also contributes to increased pressure inside it in relation to the pressure of the pyrolysis zone, resulting in higher cracking conversions in the pyrolysis zone, leading to lighter pyrolysis oils.

[0023] The horizontal or inclined arrangement of the pyrolysis zones and the vapor thermal cracking zone contributes to proper control of the dwell time in a heated environment to have an efficient thermal cracking of the hydrocarbons, producing lighter pyrolysis oils, besides improving the quality of the obtained Recovered Carbon Black.

[0024] A further advantage of the pyrolysis reactor is referred to the preferred embodiments that comprise a first raw material feeder subsystem, which further comprises an outer housing with closed ends, surrounding a tubular zone with a screw conveyor, and further comprising a heating fluid inlet and a heating fluid outlet. This preferred first raw material feeder subsystem assures that the feedstock being fed into the first pyrolysis zone substantially as a slurry instead of granules of rubber, avoiding that portions of feedstock melt and stick at the entrance of the first pyrolysis zone.

[0025] To promote an understanding of the principles by the embodiments of the present invention, reference will be made to the embodiments illustrated in the figures and to the language used to describe the same. Anyway, it must be understood that there is no intention of limiting the scope of the present invention to the contents of the figures. Any alterations or later changes of the inventive features illustrated herein, and any additional application of the principles and embodiments of the invention shown, which would occur normally for one skilled in the art when reading this description, are considered as being within the scope of the claimed invention.Fig.1

[0026] illustrates a first side view of a pyrolysis system according to the invention.Fig.2

[0027] illustrates a second side view of a pyrolysis system according to the invention.Fig.3

[0028] illustrates a perspective view of a pyrolysis system according to the invention.Fig.4

[0029] illustrates a first embodiment of a second raw material feeder subsystem connected to an airlock feeder subsystem, wherein this latter is connected to a first raw material feeder subsystem.Fig.5

[0030] illustrates a side view of a static pyrolysis zone connected to a pyrolysis system.Fig.6

[0031] illustrates a first set of components comprised in a static pyrolysis zone.Fig.7

[0032] illustrates a second set of components comprised in a static pyrolysis zone.Fig.8

[0033] illustrates a third set of components comprised in a static pyrolysis zone.Fig.9

[0034] illustrates a side view of a first embodiment of a single-stage pyrolysis zone connected to a vapor thermal cracking zone.Fig.10

[0035] illustrates a side view of a second embodiment of a single-stage pyrolysis zone connected to a vapor thermal cracking zone.Fig.11

[0036] illustrates a perspective view of a first raw material feeder subsystem comprising an outer housing.Fig.12

[0037] illustrates an internal view of a first raw material feeder subsystem comprising an outer housing.Fig.13

[0038] illustrates a second embodiment of a second raw material feeder subsystem connected to an airlock feeder subsystem, wherein this latter is connected to a first raw material feeder subsystem.Fig.14

[0039] illustrates an airlock discharger subsystem connected to the product outlet of a pyrolysis zone.Fig.15

[0040] illustrates a perspective view of an airlock feeder subsystem.Fig.16

[0041] illustrates a schematic block diagram of a method for recovering Carbon Black, light pyrolysis oil, and pyrolysis gas.

[0042] Pyrolysis is a process in which organic or carbon-rich materials, such as polymers, e.g. elastomers or rubbers, are heated in the absence of oxygen to break down into smaller molecules and a solid fraction. The smaller molecules are removed from the reactor and further separated to produce pyrolysis oil and pyrolysis gas. The Recovered Carbon Black corresponds to the solid fraction that is obtained after the thermal cracking and vaporization of the organic or carbon-rich materials. The heating fluid used in pyrolysis reactors is typically a gas or a liquid that is circulated through the reactor to transfer heat to the material being processed.

[0043] The present invention refers, in a first aspect, to a pyrolysis system adapted for processing a feedstock comprising organic or carbon-rich materials comprising a first pyrolysis zone (100), a vapor thermal cracking zone (400), and a first outer housing (500), wherein

[0044] the first pyrolysis zone (100) comprises a first raw material inlet (101), a first tubular zone with a screw conveyor (102), a first drive subsystem (103), a gas and particulates outlet (104), and a first product outlet (105), and wherein said gas and particulates outlet (104) is connected to said first tubular zone with a screw conveyor (102), and wherein said first product outlet (105) is arranged at an end portion of said first tubular zone with a screw conveyor (102), and wherein the first tubular zone with a screw conveyor (102) is connected to said first raw material inlet (101) and its screw conveyor is driven by the first drive subsystem (103); and

[0045] the vapor thermal cracking zone (400) is connected to the first pyrolysis zone (100); and wherein

[0046] said vapor thermal cracking zone (400) comprises a gas and particulates inlet (401), a fourth tubular zone with a screw conveyor (402), a fourth drive subsystem (403), a first cracked gas outlet (404); and wherein said gas and particulates inlet (401) is connected to said fourth tubular zone with a screw conveyor (402) and to said gas and particulates outlet (104) of the first pyrolysis zone (100), and wherein said first cracked gas outlet (404) is arranged at an end portion of said fourth tubular zone with a screw conveyor (402), and wherein the fourth tubular zone with a screw conveyor (402) is connected to said gas and particulates inlet (401) and its screw conveyor is driven by the fourth drive subsystem (403); and wherein

[0047] the first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), and the fourth tubular zone with a screw conveyor (402); and wherein

[0048] said first pyrolysis zone (100) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system, and wherein said vapor thermal cracking zone (400) is arranged longitudinally at an angle in the range of 0 degrees to 60 degrees in relation to the base of said pyrolysis system.

[0049] The arrangement of the vapor thermal cracking zone prevents solid particles leaving the pyrolysis zone from being trapped by condensing vapors in the vapor thermal cracking zone, wherein the screw conveyor of the is configured to be driven in the opposite direction of the flow to retain solid particles. Furthermore, the controlled spinning of the screw conveyor allows the setup of a desired dwell time inside the vapor thermal cracking zone, contributing to proper separation of the vapor products, making it possible that dust particles to drop out of the vapor stream and go back to the pyrolysis zone (100).

[0050] Preferably, the vapor thermal cracking zone (400) is arranged longitudinally at an angle in the range of 0 degrees to 30 degrees in relation to the base of said pyrolysis system, more preferably is arranged longitudinally and substantially horizontally in relation to a base of said pyrolysis system.

[0051] The gas and particulates outlet (104) can be arranged within the entire length of the first pyrolysis zone (100). Preferably, the gas and particulates outlet (104) is arranged at a portion of said first tubular zone with a screw conveyor (102) within the initial half of the length of the first tubular zone with a screw conveyor (102), more preferably within the initial one-third of the length of the first tubular zone with a screw conveyor (102). Even more preferably, the gas and particulates outlet (104) is arranged at a frontal portion of said first tubular zone with a screw conveyor (102).

[0052] The first cracked gas outlet (404) can be arranged within the entire length of the vapor thermal cracking zone (400). Preferably, the first cracked gas outlet (404) is arranged at a portion of said fourth tubular zone with a screw conveyor (402) within the initial half of the length of the fourth tubular zone with a screw conveyor (402), more preferably within the initial one-third of the length of the fourth tubular zone with a screw conveyor (402). More preferably, the first cracked gas outlet (404) is arranged at a frontal portion of said fourth tubular zone with a screw conveyor (402).

[0053] A feedstock comprising organic or carbon-rich materials comprises end-of-life tires, plastic wastes, rubber wastes, elastomer wastes, biomass, or mixtures thereof, wherein said feedstock comprises the raw materials that are introduced into the pyrolysis system to undergo the pyrolysis process. In the preferred embodiments according to the present invention, said feedstock comprises end-of-life tires, for example, scrap tires. Biomass comprises organic materials like wood or agricultural residues.

[0054] In the preferred embodiments according to the present invention, the pyrolysis system further comprises a second pyrolysis zone (200), wherein

[0055] the second pyrolysis zone (200) comprises a first intermediate products inlet (201), a second tubular zone with a screw conveyor (202), a second drive subsystem (203), and a second product outlet (204), wherein said first intermediate products inlet (201) is connected to said first product outlet (105), wherein said first intermediate products inlet (201) is arranged at a frontal portion of said second tubular zone with a screw conveyor (202) and said second product outlet (204) is arranged at an end portion of said second tubular zone with a screw conveyor (202), and wherein the second tubular zone with a screw conveyor (202) is connected to said first intermediate products inlet (201) and its screw conveyor is driven by the second drive subsystem (203); and

[0056] the first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), and the fourth tubular zone with a screw conveyor (402); and wherein

[0057] said second pyrolysis zone (200) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system.

[0058]

[0059] In the most preferred embodiments according to the present invention, as illustrated in Figures 1 or 2, the pyrolysis system further comprises a second pyrolysis zone (200) and a third pyrolysis zone (300), wherein

[0060] the third pyrolysis zone (300) comprises a second intermediate products inlet (301), a third tubular zone with a screw conveyor (302), a third drive subsystem (303), and a third products outlet (304), wherein said second intermediate products inlet (301) is connected to said second product outlet (204), wherein said second intermediate products inlet (301) is arranged at a frontal portion of said third tubular zone with a screw conveyor (302) and said third products outlet (304) is arranged at an end portion of said third tubular zone with a screw conveyor (302), and wherein the third tubular zone with a screw conveyor (302) is connected to said second intermediate products inlet (301) and its screw conveyor is driven by the third drive subsystem (303); and wherein

[0061] the first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302), and the fourth tubular zone with a screw conveyor (402); and wherein

[0062] said third pyrolysis zone (300) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system.

[0063]

[0064] In the most preferred embodiments, the first pyrolysis zone (100), the second pyrolysis zone (200) and the third pyrolysis zone (300) are arranged longitudinally and substantially horizontally in relation to the base of said pyrolysis system.

[0065] In some embodiments according to the invention, the first outer housing (500) and / or the second outer housing (503) are closed heating subsystems, for instance boilers or an electrical heater, wherein a thermal oil is heated by an electrical heating source. In these embodiments, the burners or the heating sources are preferably arranged at a bottom portion of the first outer housing (500) and of the second outer housing (503).

[0066] In the preferred embodiments according to the invention, the first outer housing (500) comprises connected a first heating fluid inlet (501) and a first heating fluid outlet (502) for circulating a heating fluid, e.g. steam or a thermal oil. In other preferred embodiments according to the invention, the second outer housing (503) comprises connected a second heating fluid inlet (504) and a second heating fluid outlet (505) for circulating a heating fluid, e.g. steam or a thermal oil. In these embodiments, the first heating fluid inlet (501) is preferably arranged at a bottom portion of the first outer housing (500) and the first heating fluid outlet (502) is preferably arranged at a top portion of the first outer housing (500); and the second heating fluid inlet (504) is preferably arranged at a bottom portion of the second outer housing (503). and the second heating fluid outlet (505) is preferably arranged at a top portion of the second outer housing (503).

[0067] The pyrolysis system includes a pyrolysis reactor comprising at least one reactional stage, wherein said at least one reactional stage is the first pyrolysis zone (100), as illustrated in Figures 9 or 10. In other embodiments, the pyrolysis system includes a pyrolysis reactor comprising two reactional stages, wherein said two reactional stages are the first pyrolysis zone (100) and the second pyrolysis zone (200). In other embodiments, as illustrated in Figures 1 or 2, the pyrolysis system includes a pyrolysis reactor comprising three reactional stages, wherein said three reactional stages are the first pyrolysis zone (100), the second pyrolysis zone (200), and the third pyrolysis zone (300). In the embodiments according to the invention, when the pyrolysis reactor comprises two or more reactional stages, said stages are arranged in series.

[0068] Concerning the embodiments of the present invention comprising a first pyrolysis zone (100), and a vapor thermal cracking zone (400), each one of these zones has a ratio Length / Diameter in the range of 10:1 to 100:1. Concerning the embodiments of the present invention comprising a first pyrolysis zone (100), a second pyrolysis zone (200), and a vapor thermal cracking zone (400), each one of these zones has a ratio Length / Diameter in the range of 10:1 to 100:1, preferably in the range of 10:1 to 50:1. Concerning the embodiments of the present invention comprising a first pyrolysis zone (100), a second pyrolysis zone (200), a third pyrolysis zone (300), and a vapor thermal cracking zone (400), each one of these zones has a ratio Length / Diameter in the range of 10:1 to 100:1, preferably in the range of 10:1 to 50:1, more preferably 10:1 to 30:1.

[0069] The pyrolysis zone is considered to be the location inside the pyrolysis reactor delimited by the interior walls of the tubular zone with a screw conveyor, the inlet of reactants in said tubular zone with a screw conveyor, and the outlet of products from said tubular zone with a screw conveyor.

[0070] The first outer housing (500) or the second outer housing (503) delimit a heating zone and surround at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302), and the fourth tubular zone with a screw conveyor (402). The first outer housing (500) can comprise at least a first heating fluid inlet (501) and a first heating fluid outlet (502). The first outer housing (500) can comprise at least a second heating fluid inlet (504) and a second heating fluid outlet (505). In the most preferred embodiments according to the present invention, the heating fluid inlets are arranged at a bottom portion of the respective outer housing, and the heating fluids outlets are arranged at a top portion of the respective outer housing. Common heating fluids for pyrolysis reactors include gases such as nitrogen, carbon dioxide, or steam, mixtures thereof, and liquids such as hot oil or molten salt. The choice of heating fluid depends on the specific requirements of the pyrolysis process, such as the desired temperature range, heat transfer efficiency, and the properties of the materials being processed.

[0071] Preferably, the first outer housing (500) and / or the second outer housing (503) can be heated by at least a burner, wherein said burner is configured to burn, for example, an exhaust gas, a fuel gas, or a pyrolysis gas as a heating fluid. In these embodiments, said burner is arranged inside the first outer housing (500) and / or the second outer housing (503) and the gas to be burned is fed respectively by the first heating fluid inlet (501) and by the second heating fluid inlet (504). The combustion gases leave the first outer housing (500) and / or the second outer housing (503) by the first heating fluid outlet (502) and the second heating fluid outlet (505). The burners are preferably arranged at a bottom portion of the first outer housing (500) and / or the second outer housing (503).

[0072] Preferably, the pyrolysis system comprises a second outer housing (503), wherein said second outer housing (503) delimits a heating zone and surrounds at least one of the group consisting of a second portion of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302), and the fourth tubular zone with a screw conveyor (402), and further comprises connected a second heating fluid inlet (504) and a second heating fluid outlet (505).

[0073] As illustrated in, a single first outer housing (500) surrounds substantially the overall length of the first tubular zone with a screw conveyor (102) and the fourth tubular zone with a screw conveyor (402). In other embodiments, a single first outer housing (500) surrounds substantially the overall length of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), and the fourth tubular zone with a screw conveyor (402). In other embodiments, a single first outer housing (500) surrounds substantially the overall length of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302), and the fourth tubular zone with a screw conveyor (402).

[0074] As illustrated in, a first outer housing (500) surrounds a first portion of the first tubular zone with a screw conveyor (102) and a first portion of the fourth tubular zone with a screw conveyor (402), and a second outer housing (503) surrounds a second portion of the first tubular zone with a screw conveyor (102) and a second portion of the fourth tubular zone with a screw conveyor (402). In other embodiments, a first outer housing (500) surrounds a first portion of the first tubular zone with a screw conveyor (102), a first portion of the second tubular zone with a screw conveyor (202) and a first portion of the fourth tubular zone with a screw conveyor (402), and a second outer housing (503) surrounds a second portion of the first tubular zone with a screw conveyor (102), a first portion of the second tubular zone with a screw conveyor (202), and a second portion of the fourth tubular zone with a screw conveyor (402). As illustrated in Figures 1 or 2, a first outer housing (500) surrounds a first portion of the first tubular zone with a screw conveyor (102), a first portion of the second tubular zone with a screw conveyor (202), a first portion of the third tubular zone with a screw conveyor (302), and a first portion of the fourth tubular zone with a screw conveyor (402), and a second outer housing (503) surrounds a second portion of the first tubular zone with a screw conveyor (102), a second portion of the second tubular zone with a screw conveyor (202), a second portion of the third tubular zone with a screw conveyor (302), and a second portion of the fourth tubular zone with a screw conveyor (402). In the preferred embodiments, wherein the pyrolysis system comprises a first outer housing (500) and a second outer housing (503), the first portion of a tubular zone with a screw conveyor refers to a range of 30 to 70 % of the entire length of the respective tubular zone with a screw conveyor, and the second portion of a tubular zone with a screw conveyor refers to the remaining length of said tubular zone with a screw conveyor.

[0075] Preferably, in the first outer housing (500) and in the second outer housing (503), respectively at least one first heating fluid inlet (501) and at least one second heating fluid inlet (504) are arranged tangentially at a bottom portion of a cross section of said first outer housing (500) and said second outer housing (503).

[0076] More preferably, the first outer housing (500) and the second outer housing (503) are two independent modules, as illustrated in, wherein each one of the modules can be heated by two independent burners, and wherein they are separated by an air gap between the second end of the first module and the first end of the second module. A plurality of baffles can be arranged in the first outer housing (500) and in the second outer housing (503) to increase the heat transfer rate of the heating fluid to the pyrolysis zones, wherein said baffles contribute to the increasing to alterations in the direction of the flow of a heating fluid, increasing the convective heat transfer rates from the heating fluid to the respective tubular zones enclosed in each outer housing.

[0077] In the preferred embodiments according to the present invention, as illustrated in, the first cracked gas outlet (404) is connected to the fourth tubular zone with a screw conveyor (402) and is projected through the first outer housing (500).

[0078] In the preferred embodiments according to the present invention, as illustrated in, at least one of the group consisting of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302) or the fourth tubular zone with a screw conveyor (402) comprises a pair of screw conveyors.

[0079] A single or a first pair of screw conveyors can be designed to have a large cross area to reduce the velocity of the flowing vapors inside a tubular zone with a screw conveyor, wherein a slower velocity will allow for particles, e.g. dust and ash particles to sediment out of the vapor stream. Moreover, in the embodiments comprising a pair of screw conveyors in the fourth tubular zone with a screw conveyor (402), they can be operated in a counter flow screw flight, wherein his mode of operation allows the dust and ash particles to be collected and delivered back to the first pyrolysis zone (100). The counter flow screw speed can be increased or decreased to cause the vapor path to be longer or shorter because the vapors must flow around the flights to vent out of the vapor thermal cracking zone (400). The screw rotation forces the vapor to travel longer or shorter paths, which changes the dwell time, and consequently, the time exposed to heat and therefore submitted to thermal cracking reactions.

[0080] As illustrated in, the pyrolysis system further comprises a vent port (405), which is connected to the fourth tubular zone with a screw conveyor (402) and is projected through one of the group consisting of the first outer housing (500) or the second outer housing (503). The vent port (405) is configured to vent vapors, when it is not necessary to carry out a vapor treatment, wherein said vent can change the dwell time for a similar heat transfer rate into the fourth tubular zone with a screw conveyor (402).

[0081] In the preferred embodiments according to the present invention, at least one of the group consisting of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302) or the fourth tubular zone with a screw conveyor (402) comprises a gap formed between an end of a twist of the respective screw conveyor and the respective internal surface of the tubular zone with a screw conveyor, wherein said gap is in the range of 0.93 to 0.99 of the ratio between the diameter of the screw and the internal diameter of the tubular zone with a screw conveyor, preferably in the range of 0.95 to 0.99.

[0082] In the preferred embodiments according to the present invention, as illustrated in, said pyrolysis system further comprises a static pyrolysis zone (900), which is illustrated in Figures 6 to 8; and wherein

[0083] said static pyrolysis zone (900) comprises a second raw material inlet (901), a first expansion frustum cone (902), a first static tube (903), a depletion frustum cone (906), a fourth product outlet (907), an inner housing (908), and a first outer housing (909); and wherein

[0084] the second raw material inlet (901) is configured to be connected to a source of a raw material and to the first expansion frustum cone (902); and wherein

[0085] the first expansion frustum cone (902) comprises a first section having a first diameter and a second section having a second diameter greater than the first diameter and said second section is connected to the first static tube (903); and wherein

[0086] the first static tube (903) is connected to the depletion frustum cone (906); and wherein

[0087] the depletion frustum cone (906) comprises a first section having a first diameter and a second section having a second diameter smaller than the first diameter and said second section is connected to the fourth product outlet (907); and wherein

[0088] the inner housing (908) comprises closed ends and surrounds said first expansion frustum cone (902), said first static tube (903) and said depletion frustum cone (906); and wherein

[0089] the first outer housing (909) comprises closed ends, surrounds said inner housing (908), and further comprises connected a third heating fluid inlet (910) and a third heating fluid outlet (911); and wherein

[0090] said fourth product outlet (907) is connected to the first raw material inlet (101) comprised in the first pyrolysis zone (100).

[0091]

[0092] In the most preferred embodiments, as illustrated in Figures 6 to 8, the static pyrolysis zone (900) comprises a second expansion frustum cone (904), and a second static tube (905); and wherein the second expansion frustum cone (904) is connected to the first static tube (903) and to the second static tube (905); and wherein the second static tube (905) is connected to the depletion frustum cone (906); and wherein the inner housing (908) comprises closed ends and surrounds said first expansion frustum cone (902), said first static tube (903), said second expansion frustum cone (904), said second static tube (905), and said depletion frustum cone (906).

[0093] The feedstock comprising organic or carbon-rich materials enters the static pyrolysis zone (900) through the second raw material inlet (901) and are further displaced into a flowing zone arranged among the outer surface of the first expansion frustum cone (902), the first static tube (903), and the inner housing (908). This flowing zone is configured to promote a higher heat transfer rate into the shredded feedstock, resulting in a more effective changing phase from the solid state into the molten state. At the outer surrounding of the first static tube (903), the melting raw materials begin to be formed, as the outer surface of said static tube (903) is closer to the inner housing (908). The melting raw materials are vaporized among the outer surfaces of the static tube (903), the depletion frustum cone (906), and the inner housing (908). As a result of this process, a stream of raw materials comprising a vapor and a liquid phase is introduced into the screw reactor of the first pyrolysis zone (100).

[0094] The static pyrolysis zone (900) contributes to better heating of the raw material since, due to the expansion of the first expansion frustum cone (902) and / or second expansion frustum cone (904), it promotes the transport of a thin layer of raw material that is in contact with the outer walls of the static tube (903), the depletion frustum cone (906), and the inner housing (908). Thus, not only is it easier to reach the set-point temperature, but the raw material is heated uniformly. This aspect is particularly critical in the case of raw materials with low thermal conduction, such as tire rubber.

[0095] More preferably, as illustrated in, an even higher heat transfer is promoted when said static pyrolysis zone (900) further comprises a second expansion frustum cone (904), and a second static tube (905). In these preferred embodiments, a proper combination of the size of the first static tube (903) and its connection to the second expansion frustum cone (904) results in the raw materials melting occurring mainly between the outer surface the of second expansion frustum cone (904) and the inner housing (908), and the vaporization of raw material will take place mainly among the outer surfaces of the second static tube (905), the depletion frustum cone (906) and the inner housing (908). Therefore, the configuration of the static pyrolysis zone (900) promotes the flow of melted raw materials along the outer surfaces of the static tubes and expansion frustum cones, whereas the residual solid materials sediment due to their higher density. Considering that the density of the melted raw materials is lower, phase separation occurs along said static pyrolysis zone (900), which contributes to a more efficient thermal cracking of the raw material along said static pyrolysis zone (900). As the elastomer raw material is vaporized, the vapor stream flows over the liquid phase, resulting in a further phase separation inside the static pyrolysis zone (900), wherein the vapor stream is forced out from the static pyrolysis zone (900) through the expansion form between the outer surface of the depletion frustum cone (906) and the inner housing (908).

[0096] The static pyrolysis zone (900) avoids the building-up of raw materials in the pyrolysis zone. The shredded raw materials are fed into the static pyrolysis zone (900) and present several air spaces among the portions and fragments of raw materials, wherein90 the raw materials melting results in their volume decreasing. The first expansion frustum cone (902) is used to displace the loss in volume, making possible that the material flow rate along the static pyrolysis zone (900) be similar to the feeding rate.

[0097] The static pyrolysis zone (900) configuration also contributes to obtaining an increased pressure inside it in relation to the pressure of the first pyrolysis zone (100), because of compacting the incoming feedstock. The pressure gradient formed in the static pyrolysis zone (900) contributes to higher cracking conversions in the first pyrolysis zone (100), resulting in the production of lighter pyrolysis oils and pyrolysis gas.

[0098] Preferably, the first expansion frustum cone (902) has a ratio between its diameter outlet section and its diameter inlet section in the range of 20:1 to 70:1, more preferably in the range of 30:1 to 60:1. Preferably, the second expansion frustum cone (904) has a ration between its diameter outlet section and its diameter inlet section in the range of 20:1 to 60:1, more preferably in the range of 30:1 to 40:1.

[0099] The closed ends of the inner housing (908), namely flanged ends, are configured to retain the static pyrolysis zone (900), allowing its thermal expansion or retraction, but avoiding its rotating as the plastic material flows along it. Preferably, the static pyrolysis zone (900) is made of high-temperature resistance stainless steel, and welded flanged ends are proper to easily replace a static pyrolysis zone (900), if needed.

[0100] Preferably, as illustrated in, a slip seal collar (916) is arranged at each flanged end of the inner housing (908), in order to allow the expansion of said inner housing (908). The terminals slip seal collars (916) fit inside a ring, for instance, a U-shaped ring, where a high-temperature rope packing is fitted tightly inside, wherein a clip is arranged next to the respective seal collar to keep it centered. The sealing material contacts the metallic structure of the flanged end, preventing any metal-to-metal contact. Similarly, further slip seal collars can be arranged at least one of each flanged end of the first outer housing (500) or the second outer housing (503), wherein a respective clip is arranged next to the respective seal collar to keep it centered. The clips are arranged on slide plates, which are configured to slide according to the thermal expansion or thermal retraction of the respective outer housings to which said clips are connected.

[0101] Preferably, as illustrated in, a first thermal insulating layer (917), namely a ceramic fiber board, is connected to the interior walls of the said inner housing (908), in order to avoid loss of heat to the surrounding ambient. Moreover, a second thermal insulating layer (918) can be connected to the interior walls of each flanged end of the inner housing (908).

[0102] The inner housing (908) presents a tube-shaped form, and is preferably made of a metal or a metallic alloy, wherein its tube shape configuration is proper for the heating fluid flow around the outer surface of the static pyrolysis zone (900).

[0103] Preferably, said static pyrolysis zone (900) further comprises a support shaft, which is arranged longitudinally from the second raw material inlet (901) to the connection between the fourth product outlet (907) and the first tubular zone with a screw conveyor (102).

[0104] As illustrated in, in the preferred embodiments according to the invention, at least one of the group selected of an anterior spacer plate (913) or a rear spacer plate (914) connect respectively the first expansion frustum cone (902) and the inner housing (908) or the depletion frustum cone (906) and the inner housing (908). As additional optional features, the first outer housing (909) delimits a tubular heating zone, wherein at least one third heating fluid inlet (910) is arranged tangentially at a bottom portion of a cross section of said first outer housing (909).

[0105] Heat is applied into the static pyrolysis zone (900) by feeding a heating fluid through a third heating fluid inlet (910), wherein the heating fluid flows along the interior of first outer housing (909) and heat is transferred to the walls of the static pyrolysis zone (900). As illustrated in, in the preferred embodiments according to the invention, the third heating fluid inlet (910) is arranged next to the depletion frustum cone (906) and the third heating fluid outlet (911) is arranged next to the first expansion frustum cone (902), which makes a counter-current heat transfer apparatus, resulting in a progressive heat increase along the flow of organic or carbon-rich raw materials in the static pyrolysis zone (900). Further advantages of this preferred embodiment are its contribution to a lower thermal shock, a lower material cracking, increased yields of pyrolysis oils, and lower yields of pyrolysis gas.

[0106] In the preferred embodiments, as illustrated in, the third heating fluid inlet (910) is arranged on an angle and mounted tangentially in relation to the outer wall of the first outer housing (909) in order to push the heating fluid, preferably hot air, in a spiral flow around the static pyrolysis zone (900). The third heating fluid outlet (911) is arranged at the opposite end of the first outer housing (909).

[0107] In the preferred embodiments, as illustrated in, the anterior spacer plate (913) or rear spacer plate (914) are configured to keep the static pyrolysis zone (900) arranged in a centered position in relation to the inner housing (908), making possible that centered gaps formed in relation to the inner housing (908) be formed in order to make way to the raw material flow.

[0108] Preferably, the support shaft is configured to act as an anchor point for the first tubular zone with a screw conveyor (102), stabilizing said screw and keeping a smooth area for the material to flow through. The first tubular zone with a screw conveyor (102) is maintained in a centered position by a bushing bearing for a speed screw (915), which is retained by the support shaft. The bushing bearing for a speed screw (915) reduces friction and allows a proper expansion due to the thermal expansion.

[0109] The first pyrolysis zone (100) and said vapor thermal cracking zone (400) are arranged longitudinally and substantially horizontally in relation to a base of said pyrolysis system, wherein said base can be arranged on a plane, which is parallel to the bottom of any one of the first outer housing (500) or the second outer housing (503).

[0110] The vapor thermal cracking zone (400) is arranged longitudinally at an angle in the range of 0 degrees to 60 degrees in relation to the first pyrolysis zone (100), making it possible for fine dust carbon particles to drop out from the vapor stream and go back to the pyrolysis zone (100), avoiding the contamination of the pyrolysis oil condensed further in the process with solid particles. Moreover, the addition of a vapor thermal cracking zone (400) results in an increased exposure time of vapors to high temperature, i.e., allows to achieve a proper dwell time in a heated environment to have a more efficient thermal cracking of the hydrocarbons produced during the pyrolysis, producing lighter pyrolysis oils. Therefore, the vapor thermal cracking zone (400) allows that gaseous intermediate products originated in the first pyrolysis zone (100) undergo further cracking reactions in the vapor thermal cracking zone (400).

[0111] The vent port (405) is configured to vent vapors, if needed when there is not a necessity of carrying out a vapor treatment, wherein said vent can change the dwell time for a similar heat transfer rate into the fourth tubular zone with a screw conveyor (402).

[0112] The fourth tubular zone with a screw conveyor (402) can comprise a single screw conveyor or a pair of screw conveyors. A single or a first pair of screw conveyors can be designed to have a large cross area to reduce the velocity of the leaving vapors, wherein a slower velocity will allow for dust and ash particles to drop out of the vapor stream. Moreover, in the embodiments comprising a first pair of screw conveyors, they can be operated in a counter flow screw flight, wherein his mode of operation allows the dust particles to be collected and delivered back to the first pyrolysis zone (100). The counter flow screw speed can be increased or decreased to cause the vapor path to be longer or shorter because the vapors must flow around the flights to vent out of the vapor thermal cracking zone (400). The rotation forces the vapor to travel longer or shorter paths, which changes the dwell time, and consequently the time exposed to the thermal cracking.

[0113] As illustrated in, the pyrolysis system further comprises a first raw material feeder subsystem (600) connected to the first pyrolysis zone (100) or to the static pyrolysis zone (900); and wherein said first raw material feeder subsystem (600) comprises a third raw material inlet (601), a fifth tubular zone with a screw conveyor (602), a fifth drive subsystem (603), and a second raw material outlet (604), and wherein said third raw material inlet (601) is arranged at a frontal portion of said fifth tubular zone with a screw conveyor (602), and wherein said second raw material outlet (604) is arranged at an end portion of said fifth tubular zone with a screw conveyor (602), and wherein the screw conveyor of said fifth tubular zone with a screw conveyor (602) is driven by the fifth drive subsystem (603).

[0114] In the most preferred embodiments, as illustrated in, the first raw material feeder subsystem (600) further comprises a third outer housing (605); and wherein said third outer housing (605) comprises closed ends, surrounds said fifth tubular zone with a screw conveyor (602), and further comprises connected a third heating fluid inlet (606) and a third heating fluid outlet (607). This preferred first raw material feeder subsystem (600) assures that the raw materials being fed into the first pyrolysis zone (100) substantially as a slurry instead of granules of rubber, avoiding that portions of rubber melt and stick at the entrance of the first pyrolysis zone (100), wherein these undesirable sticked rubber led to frequent interruptions of the pyrolysis process in order to clean the first tubular zone with a screw conveyor (102). The third outer housing (605) delimits a tubular heating zone, wherein at least one third heating fluid inlet (606) and a third heating fluid outlet (607) are arranged tangentially, and in opposite ends, at the third outer housing (605). Even more preferably, said fifth tubular zone with a screw conveyor (602) comprises a first pair of screw conveyors (608).

[0115] In other preferred embodiments, the third raw material inlet (601) is arranged vertically at a frontal portion of said fifth tubular zone with a screw conveyor (602), wherein this position allows that feedstock can be fed to the first raw material feeder subsystem (600) by the action of the gravitational force.

[0116] Common heating fluids for the first raw material feeder subsystem (600) include gases such as nitrogen, carbon dioxide, or steam, mixtures thereof, and liquids such as hot oil or molten salt. The choice of heating fluid depends on the specific requirements of the pyrolysis process, such as the desired temperature range, heat transfer efficiency, and the properties of the materials being processed.

[0117] In the preferred embodiments, the first raw material feeder subsystem (600) is connected to a first pyrolysis zone (100) or to a static pyrolysis zone (900).

[0118] As illustrated in, a plurality of baffles can be arranged in the third outer housing (605) to increase the heat transfer rate of the heating fluid to the fifth tubular zone with a screw conveyor (602).

[0119] The first raw material feeder subsystem (600) solves the problems caused by the fouling of portions of melted raw materials at the entrance of the pyrolysis zone by heating raw materials inside the tubular zone with a screw conveyor of the raw material feeder system by means of a heating fluid, wherein the raw materials are transformed in a slurry at the feeder. Therefore, the first raw material feeder subsystem (600) avoids the undesirable effects of sticked raw materials at the internal walls of the pyrolysis reactor, avoiding frequent interruptions of the pyrolysis process to clean the tubular zones with a screw conveyor of a pyrolysis system

[0120] As illustrated in Figures 14 or 15, the pyrolysis system further comprises an airlock feeder subsystem (700) connected to the first raw material feeder subsystem (600); and wherein said airlock feeder subsystem (700) comprises a first airlock chamber (701), a fourth raw material inlet (702), a first valve (703), a second valve (704), a second raw material outlet (705), a first inert gas inlet (706), a third valve (707), a first gas outlet (708), and a fourth valve (709); and wherein the first airlock chamber (701) is configured to maintain raw materials in contact with an inert gas, and wherein the first valve (703) is connected between the fourth raw material inlet (702) and the inlet of said first airlock chamber (701) and the second valve (704) is connected between the outlet of said first airlock chamber (701) and the second raw material outlet (705), and wherein the first inert gas inlet (706) comprising the third valve (707) and the first gas outlet (708) comprising the fourth valve (709) are further connected to the first airlock chamber (701); and wherein the second raw material outlet (705) is connected to the third raw material inlet (601) of the first raw material feeder subsystem (600).

[0121] In pyrolysis processes, inert gases are often used for safety reasons to prevent the risk of fire or explosion, besides avoiding the entrance of oxygen in the pyrolysis reactor, which could compromise yield, conversion and the quality of the desired products. Common industrial gases used as inert gases include Nitrogen, Argon, Carbon Dioxide, or mixtures thereof.

[0122] The airlock feeder subsystem (700) is also configured to avoid that gases, obtained in the first pyrolysis zone (100), leak to the raw material feeder subsystem, avoiding that products be lost or avoiding that inflammable vapors enter the feedstock zone.

[0123] As illustrated in, the pyrolysis system further comprises a second raw material feeder subsystem (800) connected to the airlock feeder subsystem (700); and wherein said second raw material feeder subsystem (800) comprises a hopper (801), a sixth tubular zone with a screw conveyor (802), a sixth drive subsystem (803), and a third raw material outlet (808); and wherein the hopper (801) is connected to a frontal portion of the sixth tubular zone with a screw conveyor (802) and the third raw material outlet (808) is arranged at an end portion of the sixth tubular zone with a screw conveyor (802); and wherein the sixth tubular zone with a screw conveyor (802) is driven by the sixth drive subsystem (803); and wherein the third raw material outlet (808) is further connected to the fourth raw material inlet (702) of the airlock feeder subsystem (700).

[0124] Alternatively, to the embodiment illustrated in, as illustrated in, the pyrolysis system further comprises a second raw material feeder subsystem (800) connected to the airlock feeder subsystem (700); and wherein said second raw material feeder subsystem (800) comprises a hopper (801), a sixth tubular zone with a screw conveyor (802), a sixth drive subsystem (803), a fourth raw material outlet (804), a fifth raw material inlet (805), a seventh tubular zone with a screw conveyor (806), a seventh drive subsystem (807), and a third raw material outlet (808); and wherein the hopper (801) is connected to a frontal portion of the sixth tubular zone with a screw conveyor (802) and the fourth raw material outlet (804) is arranged at an end portion of the sixth tubular zone with a screw conveyor (802); and wherein the sixth tubular zone with a screw conveyor (802) is driven by the sixth drive subsystem (803); and wherein the fourth raw material outlet (804) is further arranged at a frontal portion of the seventh tubular zone with a screw conveyor (806) and the third raw material outlet (808) is arranged at an end portion of the seventh tubular zone with a screw conveyor (806); and wherein the seventh tubular zone with a screw conveyor (806) is driven by the seventh drive subsystem (807); and wherein the third raw material outlet (808) is further connected to the fourth raw material inlet (702) of the airlock feeder subsystem (700).

[0125] In the preferred embodiments, as illustrated in, the pyrolysis system further comprises an airlock discharger subsystem (1000) connected to any one of the group consisting of the first pyrolysis zone (100), the second pyrolysis zone (200) or the third pyrolysis zone (300); and wherein said airlock discharger subsystem (1000) comprises a second airlock chamber (1001), a first product inlet (1002), a fifth valve (1003), a sixth valve (1004), a fifth product outlet (1005), a second inert gas inlet (1006), a seventh valve (1007), a second gas outlet (1008), and an eighth valve (1009); and wherein the second airlock chamber (1001) is configured to maintain the product in contact with an inert gas, and wherein the fifth valve (1003) is connected between the first product inlet (1002) and the inlet of said second airlock chamber (1001) and the sixth valve (1004) is connected between the outlet of said second airlock chamber (1001) and the fifth product outlet (1005), and wherein the second inert gas inlet (1006) comprising the seventh valve (1007) and the second gas outlet (1008) comprising eighth valve (1009) are further connected to the second airlock chamber (1001).

[0126]

[0127] The general process for obtaining Recovered Carbon Black, pyrolysis oil, and pyrolysis gas is illustrated in. Preferably, the feedstock comprising organic or carbon-rich materials, e.g. tire crumb or scrap tires, shall be shredded, cleaned, and / or washed in order to standardize the stream to be fed to the pyrolysis process, as well as standardize the obtained products.

[0128] The present invention refers, in a second aspect, to a method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in the first aspect, wherein said method comprises the following steps:

[0129] a) Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); and

[0130] b) Maintaining the temperature of the first pyrolysis zone (100) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; and

[0131] c) Keeping the residence time of the first pyrolysis zone (100) in the interval of 10 minutes to 40 minutes, more preferably of 15 minutes to 30 minutes; and

[0132] d) Maintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; and

[0133] e) Obtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); and

[0134] f) Obtaining Recovered Carbon Black at the first product outlet (105) of the first pyrolysis zone (100).

[0135]

[0136] The present invention refers, in a third aspect, to a method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in the first aspect, wherein said method comprises the following steps:

[0137] a) Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); and

[0138] b) Maintaining the temperature of the first pyrolysis zone (100) and the temperature of the second pyrolysis zone (200) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; and

[0139] c) Keeping the residence time of the first pyrolysis zone (100) and of the second pyrolysis zone (200), independently, in the interval of 1 minute to 20 minutes, more preferably of 3 minutes to 15 minutes; and

[0140] d) Maintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; and

[0141] e) Obtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); and

[0142] f) Obtaining Recovered Carbon Black at the second product outlet (204) of the second pyrolysis zone (200).

[0143]

[0144] In a preferred embodiment of the method according to third aspect of the invention, the temperatures of each the first pyrolysis zone (100) and the second pyrolysis zone (200) are substantially equal. In other preferred embodiments, a temperature gradient is defined between of each the first pyrolysis zone (100) and second pyrolysis zone (200), and the temperature of the first pyrolysis zone (100) is lower than the temperature of the second pyrolysis zone (200).

[0145] Preferably, the temperatures of the vapor thermal cracking zone (400) and of the first pyrolysis zone (100) are substantially equal.

[0146] In some embodiments, the residence time of each the first pyrolysis zone (100) and second pyrolysis zone (200) are substantially equal. In other preferred embodiments, each one of the first pyrolysis zone (100) and the second pyrolysis zone (200) have different residence times.

[0147]

[0148] The present invention refers, in a fourth aspect, to a method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in the first aspect, wherein said method comprises the following steps:

[0149] a) Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); and

[0150] b) Maintaining the temperature of the first pyrolysis zone (100), the temperature of the second pyrolysis zone (200) and the temperature of the third pyrolysis zone (300) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; and

[0151] c) Keeping the residence time of the first pyrolysis zone (100), of the second pyrolysis zone (200) and of the third pyrolysis zone (300), independently, in the interval of 1 minute to 20 minutes, more preferably of 3 minutes to 15 minutes; and

[0152] d) Maintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; and

[0153] e) Obtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); and

[0154] f) Obtaining Recovered Carbon Black at the third product outlet (304) of the third pyrolysis zone (300).

[0155]

[0156] The parameters of operation concerning the vapor thermal cracking zone (400) do not interfere with the parameters of operation of each one of the first pyrolysis zone (100), second pyrolysis zone (200) and third pyrolysis zone (300). The residence time of the gases in the vapor thermal cracking zone (400) is influenced by several variables, among them the flow of the gases fed to the vapor thermal cracking zone (400), the pressure of the pyrolysis system and qualitative and quantitative features of the feedstock comprising organic or carbon-rich materials. Preferably, the residence time in the vapor thermal cracking zone (400) is in the interval of few seconds to several minutes, more preferably of 5 seconds to 30 minutes.

[0157] In a preferred embodiment of the method according to the fourth aspect of the invention, a temperature gradient is defined between of each the first pyrolysis zone (100), second pyrolysis zone (200) and third pyrolysis zone (300), and the temperature of the first pyrolysis zone (100) is lower than the temperature of the second pyrolysis zone (200), and the temperature of the second pyrolysis zone (200) is lower than the temperature of the third pyrolysis zone (300).

[0158] In some embodiments, the residence time of each the first pyrolysis zone (100), second pyrolysis zone (200) and third pyrolysis zone (300) are substantially equal. In other preferred embodiments, each one of the first pyrolysis zone (100), the second pyrolysis zone (200), and the third pyrolysis zone (300) have different residence times.

[0159] In an embodiment, the pyrolysis system is maintained above atmospheric pressure. The upper pressure is limited to the maximum pressure allowed by the material used in the reactor construction.

[0160] In the preferred embodiments of the pyrolysis system, which comprise the static pyrolysis zone (900), the temperature of the static pyrolysis zone (900) is preferably in the range of 200 ºC to 500 °C, more preferably of 300 ºC to 400 °C.

[0161] Nevertheless, the temperature of the first pyrolysis zone (100), second pyrolysis zone (200), third pyrolysis zone (300) and vapor thermal cracking zone (400) are adjusted to the type of raw material. Furthermore, the residence time of each the first pyrolysis zone (100), second pyrolysis zone (200) and third pyrolysis zone (300) is adjusted to the type of raw material.

[0162] The vapor stream flowing from the first cracked gas outlet (404) shall be processed to remove additional traces of solid particles from this stream. The Solids removal step can be accomplished by using cyclones, filters, electrostatic precipitators, and other similar separation devices.

[0163] The separation between condensable pyrolysis oil and non-condensable pyrolysis gas may be accomplished in heat exchangers, distillation columns, cyclones and other similar devices.

[0164] Moreover, the solids may be removed from the vapor stream by the addition of a liquid phase, namely in spray towers, and further removed from the liquid by filtration and centrifugation.

[0165] In the preferred embodiments, the Recovered Carbon Black obtained at the outlet of the pyrolysis reactor, particularly at the fifth product outlet (1005), is sent to a rCB processing subsystem, wherein the processing of rCB can include at least one of the following steps: i) rCB cooling after being discharged from the pyrolysis reactor in cooling drums, cooling conveyors and other similar cooling devices; ii) grinding and milling in a hammer mill, a vibratory mill, a jet mill, and other similar particle size devices; iii) pelleting with or without the addition of a binding agent with the production of rCB pellets; or iv) packaging the obtained rCB.

[0166] The Recovered Carbon Black obtained according to the method of the present invention is a high-purity product, meaning presents low level of organic contamination.

[0167] In an embodiment, the obtained Recovered Carbon Black presents a toluene transmittance value of at least 90 %, preferably at least 95 %. The toluene transmittance is determined following the protocol defined in ASTM D1618.

[0168] In an embodiment, the obtained Recovered Carbon Black presents an organic volatile content below 2.0 % in weight, preferably below 1.5 % in weight, more preferably below 1.2 % in weight. The organic volatile content is determined following the protocol defined in ASTM D8474.

[0169] In an embodiment, the obtained Recovered Carbon Black presents a polycyclic aromatic hydrocarbon (PAH) content below 8 ppm, preferably below 5 ppm. The PAH content is determined following the protocol defined in ASTM D8143. The quantification of PAH is followed considering the list of 8 molecules identified by the European Union: benz(a)anthracene, chrysene, benzo(b)fluoranthene, benzo(j)fluoranthene, benzo(k)fluoranthene, benzo(e)pyrene, benzo(a)pyrene, and dibenz(a,h / a,c)anthracene.

[0170] The selection of materials for pyrolysis reactors is critical to ensure the safe and efficient operation of the process. Pyrolysis reactors are typically exposed to high temperatures, corrosive gases, and thermal stresses, which can cause materials to degrade or fail over time. Therefore, materials used in pyrolysis reactors must be able to withstand these conditions while maintaining their structural integrity.

[0171] The pyrolysis reactor according to the present invention can be made of stainless steel, nickel-based alloys, and refractory metals such as tungsten and molybdenum. These materials are known for their high-temperature resistance, corrosion resistance, and mechanical strength.

[0172] Stainless steel is a common material used in pyrolysis reactors because it is relatively inexpensive, readily available, and has good corrosion resistance. Nickel-based alloys, such as Inconel and Hastelloy, are used in pyrolysis reactors that require higher temperature and corrosion resistance. Refractory metals, such as tungsten and molybdenum, are used in reactors that require very high-temperature resistance.

[0173] As used in this application, a negative angle is defined as an angle set in a clockwise direction. A positive angle is defined as an angle set in a counterclockwise direction.

[0174] As used in this description, the expression “substantially” means that the real value is within an interval of about 10 % of the desired value, variable or related limit, particularly within about 5 % of the desired value, variable or related limit or particularly within about 1 % of the desired value, variable or related limit.

[0175] Moreover, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B.

[0176] In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form.

[0177] Further, as used herein, the term “exemplary” is intended to mean serving as an illustration or example of something and is not intended to indicate a preference.

[0178] The subject matter described above is provided as an illustration of the present invention and must not be interpreted to limit it. The terminology used to describe specific embodiments, according to the present invention, must not be interpreted to limit the invention. As used in this description, the definite and indefinite articles, in their singular form, aim to include in the interpretation the plural forms, unless the context of the description explicitly indicates the contrary. It will be understood that the expressions “comprise” and “include” when used in this description, specify the presence of the characteristics, the elements, the components, the steps, and the related operations, but do not exclude the possibility of other characteristics, elements, components, steps, and operations from being also contemplated.

[0179] All modifications, providing that they do not modify the essential features of the following claims, must be considered within the scope of protection of the present invention.

[0180] The industrial applicability of a pyrolysis reactor is significant, as it offers several advantages over traditional methods of waste disposal and energy production. Here are some examples: Waste management: Pyrolysis can be used to process various types of waste, including plastic, rubber, and biomass. This process can reduce the volume of waste and produce useful products such as Recovered Carbon Black, pyrolysis oil, and pyrolysis gas. This process can also be used to produce gases like methane, which can be used for energy generation.

[0181] Overall, the industrial applicability of a pyrolysis reactor is vast, and this technology is being increasingly used as a sustainable and cost-effective way to manage waste, recovering Carbon Black, produce energy, and reduce greenhouse gas emissions.

[0182] 100  A first pyrolysis zone101  A first raw material inlet102  A first tubular zone with a screw conveyor103  A first drive subsystem104  A gas and particulates outlet105  A first product outlet200  A second pyrolysis zone201  A first intermediate product inlet202  A second tubular zone with a screw conveyor203  A second drive subsystem204  A second product outlet300  A third pyrolysis zone301  A second intermediate product inlet302  A third tubular zone with a screw conveyor303  A third drive subsystem304  A third product outlet400  A vapor thermal cracking zone401  A gas and particulates inlet402  A fourth tubular zone with a screw conveyor403  A fourth drive subsystem404  A first cracked gas outlet405  A vent port500  A first outer housing501  A first heating fluid inlet502  A first heating fluid outlet503  A second outer housing504  A second heating fluid inlet505  A second heating fluid outlet600  A raw material feeder system601  A raw material inlet of the feeder subsystem602  A tubular zone with a screw conveyor of the feeder subsystem603  A drive subsystem of the feeder subsystem604  A raw material outlet of the feeder subsystem605  An outer housing of the feeder subsystem606  A heating fluid inlet of the feeder subsystem607  A heating fluid outlet of the feeder subsystem608  A first pair of screw conveyors700  An airlock feeder subsystem701  An airlock chamber702  A fourth raw material inlet703  A first valve704  A second valve705  A second raw material outlet706  A first inert gas inlet707  A third valve708  A first gas outlet709  A fourth valve800  A second raw material feeder system801  A hopper802  A sixth tubular zone with a screw conveyor803  A sixth drive subsystem804  A fourth raw material outlet805  A fifth raw material inlet806  A seventh tubular zone with a screw conveyor807  A seventh drive subsystem808  A third raw material outlet900  A static pyrolysis zone901  A second raw material inlet902  A first expansion frustum cone903  A first static tube904  A second expansion frustum cone905  A second static tube906  A depletion frustum cone907  A fourth product outlet908  An inner housing909  A first outer housing910  A third heating fluid inlet911  A third heating fluid outlet912  A rear spacer stop913  An anterior spacer plate914  A rear spacer plate915  A bushing bearing for a feed screw916  A slip seal collar917  A first thermal insulating layer918  A second thermal insulating layer1000An airlock discharger subsystem1001A second airlock chamber1002A first product inlet1003A fifth valve1004A sixth valve1005A fifth product outlet1006A second inert gas inlet1007A seventh valve1008A second gas outlet1009An eighth valve

[0183] Citation List follows:

[0184] International patent application WO2020057774A1 entitled “Pyrolysis Plant” of Germano Araújo Carreira, and published on March 26th 2020

[0185] Sebastião M. R. Costa et al, Production and Upgrading of Recovered Carbon Black from the Pyrolysis of End-of-Life Tires, Materials 2022, 15, 2030

Claims

A pyrolysis system adapted for processing a feedstock comprising organic or carbon-rich materials comprising a first pyrolysis zone (100), a vapor thermal cracking zone (400), and a first outer housing (500), characterized in thatthe first pyrolysis zone (100) comprises a first raw material inlet (101), a first tubular zone with a screw conveyor (102), a first drive subsystem (103), a gas and particulates outlet (104), and a first product outlet (105), and wherein said gas and particulates outlet (104) is connected to said first tubular zone with a screw conveyor (102), and wherein said first product outlet (105) is arranged at an end portion of said first tubular zone with a screw conveyor (102), and wherein the first tubular zone with a screw conveyor (102) is connected to said first raw material inlet (101) and its screw conveyor is driven by the first drive subsystem (103); andthe vapor thermal cracking zone (400) is connected to the first pyrolysis zone (100); and whereinsaid vapor thermal cracking zone (400) comprises a gas and particulates inlet (401), a fourth tubular zone with a screw conveyor (402), a fourth drive subsystem (403), a first cracked gas outlet (404); and wherein said gas and particulates inlet (401) is connected to said fourth tubular zone with a screw conveyor (402) and to said gas and particulates outlet (104) of the first pyrolysis zone (100), and wherein said first cracked gas outlet (404) is arranged at an end portion of said fourth tubular zone with a screw conveyor (402), and wherein the fourth tubular zone with a screw conveyor (402) is connected to said gas and particulates inlet (401) and its screw conveyor is driven by the fourth drive subsystem (403); and whereinthe first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), and a first portion of the fourth tubular zone with a screw conveyor (402); and whereinsaid first pyrolysis zone (100) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system, and wherein said vapor thermal cracking zone (400) is arranged longitudinally at an angle in the range of 0 degrees to 60 degrees in relation to the base of said pyrolysis system.The pyrolysis system, according to the previous claim, wherein said pyrolysis system further comprises a second pyrolysis zone (200), whereinthe second pyrolysis zone (200) comprises a first intermediate products inlet (201), a second tubular zone with a screw conveyor (202), a second drive subsystem (203), and a second product outlet (204), wherein said first intermediate products inlet (201) is connected to said first product outlet (105), wherein said first intermediate products inlet (201) is arranged at a frontal portion of said second tubular zone with a screw conveyor (202) and said second product outlet (204) is arranged at an end portion of said second tubular zone with a screw conveyor (202), and wherein the second tubular zone with a screw conveyor (202) is connected to said first intermediate products inlet (201) and its screw conveyor is driven by the second drive subsystem (203); andthe first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), a first portion of the second tubular zone with a screw conveyor (202), and a first portion of the fourth tubular zone with a screw conveyor (402); and whereinsaid second pyrolysis zone (200) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system.The pyrolysis system, according to the previous claim, wherein said pyrolysis system further comprises a third pyrolysis zone (300), whereinthe third pyrolysis zone (300) comprises a second intermediate products (301), a third tubular zone with a screw conveyor (302), a third drive subsystem (303), and a third products outlet (304), wherein said second intermediate products inlet (301) is connected to said second product outlet (204), wherein said second intermediate products inlet (301) is arranged at a frontal portion of said third tubular zone with a screw conveyor (302) and said third products outlet (304) is arranged at an end portion of said third tubular zone with a screw conveyor (302), and wherein the third tubular zone with a screw conveyor (302) is connected to said second intermediate products inlet (301) and its screw conveyor is driven by the third drive subsystem (303); and whereinthe first outer housing (500) delimits a heating zone and surrounds at least one of the group consisting of a first portion of the first tubular zone with a screw conveyor (102), a first portion of the second tubular zone with a screw conveyor (202), a first portion of the third tubular zone with a screw conveyor (302), and a first portion of the fourth tubular zone with a screw conveyor (402); and whereinsaid third pyrolysis zone (300) is arranged longitudinally at an angle in the range of -30 degrees to +30 degrees in relation to a base of said pyrolysis system.The pyrolysis system, according to any of the previous claims, wherein the first cracked gas outlet (404) is connected to the fourth tubular zone with a screw conveyor (402) and is projected through the first outer housing (500).The pyrolysis system, according to any of the previous claims, wherein said pyrolysis system further comprises a second outer housing (503), wherein said second outer housing (503) delimits a heating zone and surrounds at least one of the group consisting of a second portion of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302), and the fourth tubular zone with a screw conveyor (402), and further comprises connected a second heating fluid inlet (504) and a second heating fluid outlet (505).The pyrolysis system, according to any of the previous claims, wherein at least one of the group consisting of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302) or the fourth tubular zone with a screw conveyor (402) comprises a pair of screw conveyors.The pyrolysis system, according to any of the previous claims, wherein said pyrolysis system further comprises a vent port (405), which is connected to the fourth tubular zone with a screw conveyor (402) and is projected through one of the group consisting of the first outer housing (500) or the second outer housing (503).The pyrolysis system, according to any of the previous claims, wherein at least one of the group consisting of the first tubular zone with a screw conveyor (102), the second tubular zone with a screw conveyor (202), the third tubular zone with a screw conveyor (302) or the fourth tubular zone with a screw conveyor (402) comprises a gap formed between an end of a twist of the respective screw conveyor and the respective internal surface of the tubular zone with a screw conveyor.The pyrolysis system, according to any of the previous claims, wherein said pyrolysis system further comprises a static pyrolysis zone (900); and whereinsaid static pyrolysis zone (900) comprises a second raw material inlet (901), a first expansion frustum cone (902), a first static tube (903), a depletion frustum cone (906), a fourth product outlet (907), an inner housing (908), and a first outer housing (909); and whereinthe second raw material inlet (901) is configured to be connected to a source of a raw material and to the first expansion frustum cone (902); and whereinthe first expansion frustum cone (902) comprises a first section having a first diameter and a second section having a second diameter greater than the first diameter and said second section is connected to the first static tube (903); and whereinthe first static tube (903) is connected to the depletion frustum cone (906); and whereinthe depletion frustum cone (906) comprises a first section having a first diameter and a second section having a second diameter smaller than the first diameter and said second section is connected to the fourth product outlet (907); and whereinthe inner housing (908) comprises closed ends and surrounds said first expansion frustum cone (902), said first static tube (903) and said depletion frustum cone (906); and whereinthe first outer housing (909) comprises closed ends, surrounds said inner housing (908), and further comprises connected a third heating fluid inlet (910) and a third heating fluid outlet (911); and whereinsaid fourth product outlet (907) is connected to the first raw material inlet (101) comprised in the first pyrolysis zone (100).The pyrolysis system, according to the previous claim, wherein said static pyrolysis zone (900) comprises a second expansion frustum cone (904), and a second static tube (905); and whereinthe second expansion frustum cone (904) is connected to the first static tube (903) and to the second static tube (905); and whereinthe second static tube (905) is connected to the depletion frustum cone (906); and whereinthe inner housing (908) comprises closed ends and surrounds said first expansion frustum cone (902), said first static tube (903), said second expansion frustum cone (904), said second static tube (905), and said depletion frustum cone (906).The pyrolysis system, according to any of the claims 9 to 10, wherein said static pyrolysis zone (900) comprises a support shaft, which is arranged longitudinally from the second raw material inlet (901) to the connection between the fourth product outlet (907) and the first tubular zone with a screw conveyor (102).The pyrolysis system, according to any of the claims 9 to 11, wherein at least one of the group selected of an anterior spacer plate (913) or a rear spacer plate (914) connect respectively the first expansion frustum cone (902) and the inner housing (908) or the depletion frustum cone (906) and the inner housing (908).The pyrolysis system, according to any of the claims 9 to 12, wherein the first outer housing (909) delimits a tubular heating zone, wherein at least one third heating fluid inlet (910) is arranged tangentially at a bottom portion of a cross section of said first outer housing (909).The pyrolysis system, according to any of the previous claims, wherein said pyrolysis system further comprises a first raw material feeder subsystem (600) connected to the first pyrolysis zone (100) or to the static pyrolysis zone (900); and whereinsaid first raw material feeder subsystem (600) comprises a third raw material inlet (601), a fifth tubular zone with a screw conveyor (602), a fifth drive subsystem (603), and a second raw material outlet (604), and wherein said third raw material inlet (601) is arranged at a frontal portion of said fifth tubular zone with a screw conveyor (602), and wherein said second raw material outlet (604) is arranged at an end portion of said fifth tubular zone with a screw conveyor (602), and wherein the screw conveyor of said fifth tubular zone with a screw conveyor (602) is driven by the fifth drive subsystem (603).The pyrolysis system, according to the previous claim, wherein said first raw material feeder subsystem (600) further comprises a third outer housing (605); and whereinsaid third outer housing (605) comprises closed ends, surrounds said fifth tubular zone with a screw conveyor (602), and further comprises connected a third heating fluid inlet (606) and a third heating fluid outlet 607).The pyrolysis system, according to the previous claim, wherein said fifth tubular zone with a screw conveyor (602) comprises a first pair of screw conveyors (608).The pyrolysis system, according to any of the claims 14 to 16, wherein said pyrolysis system further comprises an airlock feeder subsystem (700) connected to the first raw material feeder subsystem (600); and whereinsaid airlock feeder subsystem (700) comprises a first airlock chamber (701), a fourth raw material inlet (702), a first valve (703), a second valve (704), a second raw material outlet (705), a first inert gas inlet (706), a third valve (707), a first gas outlet (708), and a fourth valve (709); and whereinthe first airlock chamber (701) is configured to maintain raw materials in contact with an inert gas, and wherein the first valve (703) is connected between the fourth raw material inlet (702) and the inlet of said first airlock chamber (701) and the second valve (704) is connected between the outlet of said first airlock chamber (701) and the second raw material outlet (705), and wherein the first inert gas inlet (706) comprising the third valve (707) and the first gas outlet (708) comprising the fourth valve (709) are further connected to the first airlock chamber (701); and whereinthe second raw material outlet (705) is connected to the third raw material inlet (601) of the first raw material feeder subsystem (600).The pyrolysis system, according to the previous claim, wherein said pyrolysis system further comprises a second raw material feeder subsystem (800) connected to the airlock feeder subsystem (700); and whereinsaid second raw material feeder subsystem (800) comprises a hopper (801), a sixth tubular zone with a screw conveyor (802), a sixth drive subsystem (803), and a third raw material outlet (808); and whereinthe hopper (801) is connected to a frontal portion of the sixth tubular zone with a screw conveyor (802) and the third raw material outlet (808) is arranged at an end portion of the sixth tubular zone with a screw conveyor (802); and whereinthe sixth tubular zone with a screw conveyor (802) is driven by the sixth drive subsystem (803); and whereinthe third raw material outlet (808) is further connected to the fourth raw material inlet (702) of the airlock feeder subsystem (700).The pyrolysis system, according to the claim 17, wherein said pyrolysis system further comprises a second raw material feeder subsystem (800) connected to the airlock feeder subsystem (700); and whereinsaid second raw material feeder subsystem (800) comprises a hopper (801), a sixth tubular zone with a screw conveyor (802), a sixth drive subsystem (803), a fourth raw material outlet (804), a fifth raw material inlet (805), a seventh tubular zone with a screw conveyor (806), a seventh drive subsystem (807), and a third raw material outlet (808); and whereinthe hopper (801) is connected to a frontal portion of the sixth tubular zone with a screw conveyor (802) and the fourth raw material outlet (804) is arranged at an end portion of the sixth tubular zone with a screw conveyor (802); and whereinthe sixth tubular zone with a screw conveyor (802) is driven by the sixth drive subsystem (803); and whereinthe fourth raw material outlet (804) is further arranged at a frontal portion of the seventh tubular zone with a screw conveyor (806) and the third raw material outlet (808) is arranged at an end portion of the seventh tubular zone with a screw conveyor (806); and whereinthe seventh tubular zone with a screw conveyor (806) is driven by the seventh drive subsystem (807); and whereinthe third raw material outlet (808) is further connected to the fourth raw material inlet (702) of the airlock feeder subsystem (700).The pyrolysis system, according to any of the previous claims, wherein said pyrolysis system further comprises an airlock discharger subsystem (1000) connected to any one of the group consisting of the first pyrolysis zone (100), the second pyrolysis zone (200) or the third pyrolysis zone (300); and whereinsaid airlock discharger subsystem (1000) comprises a second airlock chamber (1001), a first product inlet (1002), a fifth valve (1003), a sixth valve (1004), a fifth product outlet (1005), a second inert gas inlet (1006), a seventh valve (1007), a second gas outlet (1008), and an eighth valve (1009); and whereinthe second airlock chamber (1001) is configured to maintain the product in contact with an inert gas, and wherein the fifth valve (1003) is connected between the first product inlet (1002) and the inlet of said second airlock chamber (1001) and the sixth valve (1004) is connected between the outlet of said second airlock chamber (1001) and the fifth product outlet (1005), and wherein the second inert gas inlet (1006) comprising the seventh valve (1007) and the second gas outlet (1008) comprising eighth valve (1009) are further connected to the second airlock chamber (1001).A method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in any one of the claims 1 and 9 to 19, wherein said method comprises the following steps:Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); andMaintaining the temperature of the first pyrolysis zone (100) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; andKeeping the residence time of the first pyrolysis zone (100) in the interval of 10 minutes to 40 minutes, more preferably of 15 minutes to 30 minutes; andMaintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; andObtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); andObtaining Recovered Carbon Black at the first product outlet (105) of the first pyrolysis zone (100).A method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in any one of the claims 2 and 9 to 19, wherein said method comprises the following steps:Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); andMaintaining the temperature of the first pyrolysis zone (100) and the temperature of the second pyrolysis zone (200) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; andKeeping the residence time of the first pyrolysis zone (100) and of the second pyrolysis zone (200), independently, in the interval of 1 minute to 20 minutes, more preferably of 3 minutes to 15 minutes; andMaintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; andObtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); andObtaining Recovered Carbon Black at the second product outlet (204) of the second pyrolysis zone (200).A method for recovering carbon black and pyrolysis gases using the pyrolysis system, as defined in any one of the claims 3 to 19, wherein said method comprises the following steps:Feeding an organic or a carbon-rich material into the first pyrolysis zone (100); andMaintaining the temperature of the first pyrolysis zone (100), the temperature of the second pyrolysis zone (200) and the temperature of the third pyrolysis zone (300) in the range of 400 ºC to 800 °C, more preferably of 500 ºC to 700 °C, and even more preferably of 550 ºC to 650 °C; andKeeping the residence time of the first pyrolysis zone (100), of the second pyrolysis zone (200) and of the third pyrolysis zone (300), independently, in the interval of 1 minute to 20 minutes, more preferably of 3 minutes to 15 minutes; andMaintaining the temperature of the vapor thermal cracking zone (400) in the range of 350 ºC to 800 °C, more preferably of 350 ºC to 600 °C, and even more preferably of 400 ºC to 550 °C; andObtaining pyrolysis gases at the first cracked gas outlet (404) of the vapor thermal cracking zone (400); andObtaining Recovered Carbon Black at the third product outlet (304) of the third pyrolysis zone (300).

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