System and method for converting whole tires to commodity products

Abstract

The present disclosure provides systems and methods for efficiently converting whole tires into various commodity products, such as crude oil (e.g., West Texas Intermediate crude oil) and carbon that can be used in industrial processes such as steel manufacturing or further processed (e.g., activated) to form activated carbon.

Description

Attorney Docket No. 81901 -8001 .WO00SYSTEM AND METHOD FOR CONVERTING WHOLE TIRES TO COMMODITY PRODUCTSPRIORITY CLAIM

[0001] This application claims priority to United States Provisional Patent Application Serial No. 63 / 713,798, filed on October 30, 2024, the entire contents of which are incorporated herein and relied upon.STATEMENT OF GOVERNMENT INTEREST

[0002] This invention was made with government support under grant nos. FA864920P0004, FA864920C0305, FA864921 P0731 , and FA864921 P1523, awarded by the United States Air Force AFWERX program. The government has certain rights in the invention.TECHNICAL FIELD

[0003] The present disclosure provides systems and methods for efficiently converting whole tires into various commodity products, such as crude oil and carbon that can be further processed to form activated carbon.BACKGROUND

[0004] Rubber tires, such as those for vehicles, are a source of environmental concern. There exist technologies which convert rubber tires into useful products, many of these technologies using some form of pyrolysis.

[0005] Pyrolysis is the thermal decomposition of materials in a non-oxidizing environment, i.e., without oxidizing agents such as air or oxygen. Pyrolysis processes for converting pre-processed rubber tires into finished products are known. However, these pyrolysis processes require laborious and expensive mechanical pretreatment of the rubber tires, e.g., shredding or chopping, before pyrolysis can be efficiently performed. Additionally, many of these processes require cumbersome and expensive processes for separating the desired pyrolysis products from undesirable steel and other metals present in the pre-processed rubber tire substrate material.

[0006] A need remains for improved pyrolysis processes for producing finished pyrolyzed products (e.g., carbon) from whole rubber tires (e.g., without first requiring pre-processing such as shredding or chopping of whole rubber tires before pyrolysis begins). A need also remains for improved pyrolysis processes for producing finished pyrolyzed products (e.g., carbon) without requiring a tedious separation of small steel and metal components from the pyrolysis product.Attorney Docket No. 81901 -8001 .WO00BRIEF DESCRIPTION OF THE FIGURES

[0007] FIG. 1 shows a flow diagram representative of a system and method of converting whole tires into commodity products such as carbon and crude oil according to one embodiment of the present disclosure.

[0008] FIG. 2A shows a system configured to convert tires (e.g., whole tires) into commodity products such as carbon and crude oil according to the embodiment of FIG. 1 .

[0009] FIG. 2B shows a representative embodiment of a reactor housing including a single reactor, wherein the reactor housing is configured to enable convenient loading and automatic orientation of whole tire rubber substrate into the reactor.

[0010] FIG. 2C shows a representative embodiment of an off-gas recycler configured to capture condensable and solid components of pyrolysis off-gases consistent with one embodiment of the present disclosure.

[0011] FIG. 3 is a photograph showing three reactors for pyrolyzing whole tires suitable for use in a system and method consistent with the embodiment of FIG. 1 .

[0012] FIG. 4 is a photograph showing four chambers of a reactor of FIG. 3.

[0013] FIG. 5 is a photograph showing a cross section of a chamber within the reactor of FIG. 3.

[0014] FIG. 6 is a photograph showing an enlarged portion of the chamber of FIG. 5.

[0015] FIG. 7 is a photograph showing an enlarged portion of the chamber of FIG. 5.

[0016] FIG. 8 is a photograph showing the chamber of FIG. 5 within the reactor of FIG. 3.

[0017] FIG. 9 is a photograph showing an enlarged portion of the exterior of the chamber of FIG. 5.

[0018] FIG. 10 is a photograph showing an enlarged portion of the interior of the chamber of FIG. 5.

[0019] FIG. 11 is a photograph showing a pyrolysis gas injection cap positioned at the end of the chamber of FIG. 5.

[0020] FIG. 12 is a photograph showing the interior portion of the pyrolysis gas injection cap of FIG.11.

[0021] FIG. 13 is a photograph showing an enlarged portion of the view of FIG. 12.

[0022] FIG. 14A is a photograph showing an enlarged portion of the exterior of the pyrolysis gas injection cap of FIG. 11.

[0023] FIG. 14B is a photograph showing an alignment blade subsystem configured to properly align the pyrolysis gas injection cap and the cylindrical body.

[0024] FIG. 15 is a photograph showing the pyrolysis gas injection manifold retracted from the chambers.

[0025] FIG. 16 is a photograph showing a chamber rotation subsystem.Attorney Docket No. 81901 -8001 .WO00

[0026] FIG. 17 is a photograph showing a cutaway view of the chamber rotation system engaged with a chamber.

[0027] FIG. 18 is a photograph showing the exhaust cap retracted from the end of a chamber.

[0028] FIG. 19 is a photograph showing an actuator for retracting the pyrolysis gas manifold from the chambers.

[0029] FIG. 20 is a photograph showing a locking mechanism for ensuring the pyrolysis injection cap manifold remains engaged with the chambers during pyrolysis.

[0030] FIG. 21 is a photograph showing a disassembled portion of the exhaust gas duct.

[0031] FIG. 22 is a photograph showing a partially disassembled portion of the exhaust gas duct.

[0032] FIG. 23 is a photograph showing an enlarged portion of the off-gas duct.

[0033] FIG. 24 is a photograph showing an enlarged portion of the off-gas duct.

[0034] FIG. 25 is a photograph showing a safety system for maintaining a sealed reactor during emergency condition or power outage.

[0035] FIG. 26 is a photograph of an exhaust manifold and associated off-gas ducts.

[0036] FIG. 27 is a functional representative view of a controller suitable for use in a system of the present disclosure.

[0037] FIG. 28 is a flow diagram illustrating a pyrolysis process for converting whole rubber tires into pyrolysis products by a method consistent with the present disclosure.

[0038] FIG. 29 is a perspective view of a system configured to convert tires (e.g., whole tires) into commodity products such as carbon and crude oil including a dust mitigation enclosure and a metal waste handling subsystem, consistent with another embodiment of the present disclosure.DETAILED DESCRIPTION

[0039] Provided herein is an improved system and method for pyrolyzing whole tires that overcomes the limitations of the prior art. Without being bound by theory, applicants believe that their technologies, which allows whole rubber tires to be pyrolyzed without mechanical or chemical pretreatment, allows for a decreased residence time in the pyrolysis reaction, and also does not require a cumbersome process for separating the finished products (e.g., carbon) from the metal in the whole tire substrate.

[0040] Referring now to FIG. 1 , a block flow diagram of a system 10 for pyrolyzing raw substrate 100 is illustrated. The system 10 may be controlled, operated, and monitored by a control unit 1000, as described in more detail herein. In general, the system 10 may include any number of components, devices, systems, apparatuses, or any combination thereof, that, alone or in combination, can carry out steps in accordance with the present disclosure. The system 10 may include, be part of, orAttorney Docket No. 81901 -8001 .WO00 cooperate with, various computers, systems, machines, mainframes, networks, servers, databases, portable devices, and so forth. The system 10 may be designed to integrate a variety of hardware, software, and firmware with various capabilities and functionalities.

[0041] As shown in FIG. 1 , the system 10 includes at least one reactor housing 300. Three reactor housings 300 are shown in FIG. 1 , however, any different number of reactor housings 300 could be employed in the system 10. Each reactor housing 300 houses a plurality of reactors 400, as discussed in more detail herein.

[0042] Reactor housing 300 and their included reactors 400 are in operative communication with a source of raw substrate 100 via a material feed system 310. In operation, raw substrate 100 may be conveyed to reactor housing 300 to be loaded into reactors 400 via the material feed system 310. After raw substrate 100 has been loaded into reactors 400, reactors 400 may be sealed, as discussed in more detail herein.

[0043] Reactors 400 are configured to house and pyrolyze the raw substrate 100. In some embodiments, the raw substrate 100 comprise, consist essentially of, or consist of whole rubber tires. Once the reactors 400 are sealed, the raw substrate 100 may be pyrolyzed by a pyrolysis gas supplied to the reactors 400 from a heat module 200 in in operative communication with reactors 400, as discussed in more detail herein.

[0044] As shown in FIG. 1 , the pyrolysis reaction may produce finished products 800 and off-gases 410. In some embodiments, the finished pyrolysis products 800 (e.g., carbon) may be collected into a finished products storage vessel 900 in operative communication with reactors 400. The storage vessel 900 may store finished pyrolysis products 800 for sale or for optional further processing. In some embodiments, finished pyrolysis products 800 may include activated carbon, as discussed in more detail herein.

[0045] As discussed in more detail herein, at least a fraction of off-gases gases 410 may be sent to heat module 200 for combustion to generate additional pyrolysis gases / heat. Without being bound by theory, off-gases 410 may contain a combustible (e.g., non-condensable) gas fraction 412, which can be recycled back into heat module 200 to reduce energy consumption in the system 10. The remainder of off-gases 414 which are not recycled into heat module 200 may be sent to chiller 500. In some embodiments, the chiller 500 may be a water chiller. In chiller 500, the non-combustible (condensable) off-gases 414 may be cooled and converted into crude oil 510 and flue gas 520. Flue gas 520 may be conveyed to an exhaust stack 700 in operative communication with chiller 500 before being vented into the atmosphere, as discussed in more detail below. The crude oil 510 may be conveyed to a crude oil collector 600 for storage, disposal, and / or further processing. In some embodiments, crude oil 510 may be West Texas Intermediate grade oil.Attorney Docket No. 81901 -8001 .WO00Material feed system

[0046] The material feed system 310 includes one or more components configured to enable a user to load raw substrate (whole tires) 100 into the reactors 400. As shown in FIG. 1 , in some embodiments, for each reactor housing 300, there may be a corresponding material feed system 310 in operative communication with each reactor 400. In other embodiments, there may be one material feed system 310 in operative communication with each reactor 400. Some non-limiting examples of such one or more components of material feed system 310 include ladders, steps, catwalks, platforms, chutes, conveyers, cranes, belts, pulleys, and so forth. The material feed system 310 may be automated or semi-automated. Alternatively, the material feed system 310 may be operated manually, for example by one or more users.

[0047] In one non-limiting example shown in FIG. 3, material feed system 310 includes an elevated catwalk from which the raw substrate 100 (whole tires) is loaded into each of the reactors 400. In some embodiments, such as those generally consistent with the embodiment shown representatively in FIG. 2B, the reactor housing 300 is configured such that one end can be elevated by an angle 301 relative to its other end (e.g., pivots) to align at least one reactor 400 with the material feed system 310. In such embodiments, the whole tires 1 10 may be rolled on its tread surface 1 12 into the aligned reactor 400 (e.g., one tire at a time) such that each tire 110 adopts (e.g., automatically adopts) an orientation where its sidewall 114 is adjacent to or in direct contact with a sidewall 114 of the next tire 1 10. In some embodiments, the angle 301 is not less than about 5° and not greater than about 75°, for example about 5°, about 6°, about 7°, about 8°, about 9°, about 10°, about 11 °, about 12°, about 13°, about 14°, about 15°, about 16°, about 17°, about 18°, about 19°, about 20°, about 21 °, about22°, about 23°, about 24°, about 25°, about 26°, about 27°, about 28°, about 29°, about 30°, about31°, about 32°, about 33°, about 34°, about 35°, about 36°, about 37°, about 38°, about 39°, about40°, about 41°, about 42°, about 43°, about 44°, about 45°, about 46°, about 47°, about 48°, about49°, about 50°, about 51 °, about 52°, about 53°, about 54°, about 55°, about 56°, about 57°, about58°, about 59°, about 60°, about 61 °, about 62°, about 63°, about 64°, about 65°, about 66°, about67°, about 68°, about 69°, about 70°, about 71 °, about 72°, about 73°, about 74°, or about 75°.

[0048] In other embodiments, the whole tires 110 adopt a non-uniform orientation relative to each other (e.g., not neatly stacked sidewall 114 to sidewall 1 14). In such embodiments, the continuous lumen 118 formed by the lumens 116 of each tire 110 has an irregular (e.g., non-linear) axial orientation. A non-uniform orientation of tires 1 10 may in some embodiments be advantageous at least because the flow of pyrolysis gas 305 through the reactor 400 is more turbulent as it passes through the continuous lumen 1 18 and may have a longer residence time within the reactor 400Attorney Docket No. 81901 -8001 .WO00 compared to a continuous lumen 118 formed by tires 112 strictly oriented sidewall 114 to sidewall 1 14.

[0049] In other embodiments, the whole tires 110 are loaded into each reactor 400 manually or with the assistance of a loading hoist (not shown) to ensure that each whole tire is oriented in the reactor 400 such that a sidewall 114 of one whole tire 110 is adjacent to or in direct contact with the sidewall 1 14 of the next whole tire 110.

[0050] In some embodiments, the loaded reactor 400 includes a plurality of whole tires 110 oriented such that the sidewall 1 14 of each tire 110 is adjacent to or in direct contact with the sidewall 114 of the next tire 1 10, and the tread surface 1 12 of each tire 110 is oriented to contact the inner wall of the reactor 400. In this orientation, the lumen 116 of each tire forms a continuous lumen 1 18 from one end of the reactor 400 to the opposite end of the reactor 400.Reactor Housing

[0051] FIG. 3 illustrates one embodiment of system 10 consistent with the present disclosure. As shown in FIG. 3, system 10 has three reactor housings 300 arranged in parallel relative to the heat module 200 (e.g., the heat module 200 is in direct fluid communication with each reactor housing 300). In other embodiments, multiple reactor housings 300 are arranged in sequence relative to the heat module 200. While FIG. 3 shows three reactor housings 300, any different number of reactor housings 300 may be used. In some embodiments, each reactor housing 300 includes a reactor housing body 360 having a first end and a second end. The reactor housing body 360 may be of any sufficient size and shape to house the desired number of reactors 400. For example, the reactor housing body 360 may be sized and shaped to accommodate one reactor 400, two reactors 400, three reactors 400, four reactors 400, five reactors 400, six reactors 400, seven reactors 400, eight reactors 400, or more than eight reactors 400. As shown in FIG. 3, in a non-limiting example, the reactor housing body 360 is rectangular in shape and is sized to accommodate four reactors 400. In some embodiments, the reactor housing body 360 is made of steel. For example, the reactor housing body 360 shown in the embodiment illustrated in FIG. 3 may be formed from a steel shipping container.

[0052] As shown in FIG. 3, the reactor housing 300 may include a first reactor housing frame 320. The first reactor housing frame 320 is configured to removably couple the off-gas duct 390 to the exhaust end of the reactor(s) 400. The first reactor housing frame 320 may be reversibly coupled to a first end of reactor housing body 360, for example in response to a change in state of an associated second reactor housing frame actuator 325 (e.g., a hydraulic piston) using one or more joints. Some non-limiting examples of suitable joints include a plane joint, a hinge joint, a saddle joint, a pivot joint,Attorney Docket No. 81901 -8001 .WO00 and a ball and socket joint. The one or more joints may reversibly the couple reactor housing body 360 to the first reactor housing frame 320 using one or more of a motor, an actuator, a piston, a pneumatic system, a hydraulic system, or the like.

[0053] As shown in FIG. 4, the reactor housing 300 may include a second reactor housing frame 330. The second reactor housing frame 330 is configured to removably couple the pyrolysis gas duct 220 to the inlet end of the reactor(s) 400, for example in response to a change in state of an associated second reactor housing frame actuator 335 (FIG. 19). The second reactor housing frame 330 may be reversibly coupled to a second, opposite end of reactor housing body 360, for example using one or more joints. Some non-limiting examples of suitable joints include a plane joint, a hinge joint, a saddle joint, a pivot joint, and a ball and socket joint. The one or more joints may reversibly the couple reactor housing body 360 to the second reactor housing frame 330 using one or more of a motor, an actuator, a piston, a pneumatic system, a hydraulic system, or the like.

[0054] As shown in FIG. 20, the reactor housing 300 may include a first locking mechanism 340 to reversibly lock the first reactor housing frame 320 to the first end of reactor housing body 360. In some embodiments, the first locking mechanism comprises a first locking latch 341 rotationally associated with the reactor housing body to selectively engage or disengage with a first locking tab 342 associated with the first reactor housing frame 320. In some embodiments, the first locking latch 341 is selectively rotated about its pivot by a first locking actuator 343 (e.g., a hydraulic piston). In some embodiments, the first reactor housing frame 320 may be locked to the first end of reactor housing body 360 during the pyrolysis reaction, for example to ensure a tight seal between the reactor(s) 400 and the off-gas ducts 390.

[0055] The reactor housing 300 may include a second locking mechanism 350 to reversibly lock the second reactor housing frame 330 to the second end of reactor housing body 360, for example to ensure a tight seal between the reactor(s) 400 and the pyrolysis gas duct 220. In some embodiments, the first locking mechanism comprises a first locking latch 341 rotationally associated with the reactor housing body to selectively engage or disengage with a first locking tab 342 associated with the first reactor housing frame 320. In some embodiments, the first locking latch 341 is selectively rotated about its pivot by a first locking actuator 343 (e.g., a hydraulic piston). In some embodiments, the second reactor housing frame 330 may be locked to the second end of reactor housing body 360 during the pyrolysis reaction.

[0056] Each reactor 400 may be sized to accommodate tires 110 of any desired size. Typically, the reactor 400 has a diameter only slightly larger than the outer diameter of the tires 1 10 to be pyrolyzed. A reactor 400 having a diameter significantly larger than the outer diameter of the tires 110 to be pyrolyzed is generally disfavored because pyrolysis will be less efficient. Without wishing toAttorney Docket No. 81901 -8001 .WO00 be bound by theory, the inventors currently believe that undesirable cool zones where pyrolysis is stunted or even impossible may perpetuate in a reactor 400 having a diameter significantly larger than the outer diameter of the tires 110 to be pyrolyzed. In some embodiments, the inner diameter of the reactor 400 is at least 0.25 inches larger than the outer diameter of the tires 110 to be pyrolyzed. In some embodiments, the reactor 400 for pyrolyzing nonindustrial vehicle (e.g., car, truck, tractor trailers, and motorcycle) tires has an inner diameter of about 30 inches to about 42 inches, such as 30 inches, 31 inches, 32 inches, 33 inches, 34 inches, 35 inches, 36 inches, 37 inches, 38 inches, 39 inches, 40 inches, 41 inches, or 42 inches. A reactor 400 for pyrolyzing whole tires 1 10 from industrial vehicles (e.g., heavy equipment, buses, and the like) may have a larger inner diameter.Movement of Reactor Housing

[0057] In some embodiments, the reactor housing 300 is configured to move, for example to enable convenient loading of whole tire rubber substrate into the reactor(s) 400 and / or to enable convenient unloading of pyrolysis product (e.g., carbon) from the reactor(s) 400. In some embodiments, the reactor housing 300 is operatively coupled to one or more devices configured to move one or more of the reactor housing body 360, the first reactor housing frame 320, and the second reactor housing frame 330. For example, the reactor housing body 360 may be operatively coupled to one or more jacks configured to lift the reactor housing 300 up or down relative to the plane on which the reactor housing body 360 is disposed on. In some embodiments, the one or more jacks may be powered using one or more of a motor, a pneumatic system, a hydraulic system, and so forth.

[0058] In some embodiments, such as those generally consistent with the embodiment shown representatively in FIG. 2B, a first end of the reactor housing body 360 may be operatively coupled to one or more jacks 365 and a second opposite end of the reactor housing body 360 may be operatively coupled to one or more hinges. In these embodiments, the first end of the reactor housing body 360 may lifted to an angle 301 using the one or more jacks 365 relative to the plane on which the reactor housing 300 is disposed on, while the second end of the reactor housing body 360 remains on the plane on which the reactor housing 300 is disposed during pyrolysis (e.g., with angle 301 equal to or substantially 0°). Such embodiments enable convenient loading of whole tire rubber substrate 110 into the reactor(s) 400 and / or convenient unloading of pyrolysis product (e.g., carbon) after pyrolysis is complete. In some embodiments, the one or more jacks 365 are configured to raise the first end of the reactor housing body 360 to an angle 301 of about 5° to about 75°, for example about 5°, about 6°, about 7°, about 8°, about 9°, about 10°, about 11 °, about 12°, about 13°, about 14°, about 15°, about 16°, about 17°, about 18°, about 19°, about 20°, about 21 °, about 22°, about 23°, about 24°, about 25°, about 26°, about 27°, about 28°, about 29°, about 30°, about 31 °, aboutAttorney Docket No. 81901 -8001 .WO0032°, about 33°, about 34°, about 35°, about 36°, about 37°, about 38°, about 39°, about 40°, about41°, about 42°, about 43°, about 44°, about 45°, about 46°, about 47°, about 48°, about 49°, about50°, about 51°, about 52°, about 53°, about 54°, about 55°, about 56°, about 57°, about 58°, about59°, about 60°, about 61 °, about 62°, about 63°, about 64°, about 65°, about 66°, about 67°, about68°, about 69°, about 70°, about 71 °, about 72°, about 73°, about 74°, or about 75°.

[0059] In one embodiment, the reactor housing 300 is configured to move to a first, second, and third position, for example using one or more jacks 365 and one or more hinges. As shown in FIGS. 3-4, in the first position the reactor housing 300 is disposed flat on a plane, the first reactor housing frame 320 is coupled to the first end of the reactor housing body 360, and the second reactor housing frame 330 is coupled to the second end of the reactor housing body 360. In some embodiments, in the first position, the first reactor housing frame 320 may be locked to the reactor housing body 360 using a first locking mechanism 340 and the second reactor housing frame 330 may be locked to the reactor housing body 360 using a second locking mechanism 350.

[0060] In the second position, the second end of reactor housing body 360 remains on the same plane on which the reactor housing 300 is disposed, and the first end of reactor housing body 360 is disposed at an angle 301 . In this second position, the first reactor housing frame 320 is de-coupled from the first end of reactor housing body 360, and the second reactor housing frame 330 is also decoupled to the second end of reactor housing body 360. In this second position, neither the pyrolysis gas duct 220 nor the off-gas duct 390 are secured to the respective ends of the reactor(s) 400.

[0061] In the third position, the first end of the reactor housing body 360 is raised from the plane in which the reactor housing 300 is disposed in the first and second positions, for example by an angle 301 . The first reactor housing frame 320 is de-coupled from the reactor housing body 360, and the second reactor housing frame 330 is also de-coupled from the reactor housing body 360. In this third position, the reactor(s) 400 are disposed at the angle 301 such that raw substrate 100 (e.g., whole tires 110) may be conveniently loaded into the reactor 400 via the raised first end of the reactor housing body 360, and / or pyrolysis product (e.g., carbon) may be conveniently removed from the reactor(s) 400 via the second end of the reactor housing body 360.

[0062] In one embodiment, the reactor housing 300 may be moved from the first position to the second position and then to the third position for loading of raw substrate 100 (e.g., whole tires 1 10). Applicants have surprisingly discovered that when the reactor housing 300 is in the third position where the first end of reactor housing body 360 is raised to angle 301 , whole rubber tires 110 selfstack when rolled into the reactors 400 one at a time such that a continuous lumen 1 18 is formed by the plurality of tire lumens 116, the continuous lumen 118 extending the length of the reactor. Without being bound by theory, the self-stacked configuration of whole rubber tires provides an optimizedAttorney Docket No. 81901 -8001 .WO00 pyrolysis reaction compared to other loading configurations, at least in part because pyrolysis gas 305 discussed in more detail herein. After the raw substrate 100 has been loaded into reactors 400, the reactor housing 300 may then be returned to the second position, and then to the first position to seal reactors 400 to the pyrolysis gas duct 220 and to the off-gas duct 390 before pyrolysis begins.

[0063] In this embodiment, a plurality of whole rubber tires 110 is arranged in a stacked configuration in the reactors 400 such that the sidewall 114 of a first whole tire 1 10 is adjacent to the sidewall 114 of the next whole tire 110. As shown representatively in FIG. 2B, in this self-stacked configuration, a first sidewall 1 14 of the first tire 110 is disposed at the far end of the reactor 400, a second sidewall 1 14 of the first tire 110 is disposed next to a first sidewall 114 of a second tire 1 10, a second sidewall of the second tire 114 is disposed next to a first sidewall 114 of a third tirel 10, the second sidewall 1 14 of the third tire 1 10 is disposed next to a first sidewall 1 14 of a fourth tire 110, and so forth until the second sidewall 1 14 of the last whole tire 110 is adjacent to the near end of the reactor 400.

[0064] In some embodiments, the system 10 is configured to rotate each reactor 400 about the longitudinal axis of each reactor 400. Without wishing to be bound by theory, it is currently believed that rotating the reactor 400 improves efficiency of pyrolysis. For example and without limitation, it is currently believed that the presence of long strands of steel within the reactor 400 (e.g., from steel- belted whole tire 110 substrate 100) improves mechanical breakdown of the whole tire 110 substrate 100 during pyrolysis by forming an internal mill as the steel strands entangle each other in response to rotation of the reactor 400. In some embodiments, reactor housing 300 may include one or more components configured to enable rotation of the reactors 400 about their respective longitudinal axes. Some non-limiting examples of such one or more components of reactor housing 300 may be motors, pistons, actuators, joints, chains, belts, pulleys, wheels, and so forth. The speed at which the reactors 400 are rotated is not particularly limited, and may be from about 1 revolution per hour to about 20 revolutions per minute, for example about 1 revolution per hour, about 2 revolutions per hour, about 3 revolutions per hour, about 4 revolutions per hour, about 5 revolutions per hour, about 6 revolutions per hour, about 7 revolutions per hour, about 8 revolutions per hour, about 9 revolutions per hour, about 10 revolutions per hour, about 11 revolutions per hour, about 12 revolutions per hour, about 13 revolutions per hour, about 14 revolutions per hour, about 15 revolutions per hour, about 16 revolutions per hour, about 17 revolutions per hour, about 18 revolutions per hour, about 19 revolutions per hour, about 20 revolutions per hour, about 21 revolutions per hour, about 22 revolutions per hour, about 23 revolutions per hour, about 24 revolutions per hour, about 25 revolutions per hour, about 26 revolutions per hour, about 27 revolutions per hour, about 28 revolutions per hour, about 29 revolutions per hour, about 30 revolutions per hour, about 31 revolutions per hour, about 32 revolutions per hour, about 33 revolutions per hour, about 34Attorney Docket No. 81901 -8001 .WO00 revolutions per hour, about 35 revolutions per hour, about 36 revolutions per hour, about 37 revolutions per hour, about 38 revolutions per hour, about 39 revolutions per hour, about 40 revolutions per hour, about 41 revolutions per hour, about 42 revolutions per hour, about 43 revolutions per hour, about 44 revolutions per hour, about 45 revolutions per hour, about 46 revolutions per hour, about 47 revolutions per hour, about 48 revolutions per hour, about 49 revolutions per hour, about 50 revolutions per hour, about 51 revolutions per hour, about 52 revolutions per hour, about 53 revolutions per hour, about 54 revolutions per hour, about 55 revolutions per hour, about 56 revolutions per hour, about 57 revolutions per hour, about 58 revolutions per hour, about 59 revolutions per hour, about 1 revolution per minute, about 2 revolutions per minute, about 3 revolutions per minute, about 4 revolutions per minute, about 5 revolutions per minute, about 6 revolutions per minute, about 7 revolutions per minute, about 8 revolutions per minute, about 9 revolutions per minute, about 10 revolutions per minute, about 11 revolutions per minute, about 12 revolutions per minute, about 13 revolutions per minute, about 14 revolutions per minute, about 15 revolutions per minute, about 16 revolutions per minute, about 17 revolutions per minute, about 18 revolutions per minute, about 19 revolutions per minute, about or about 20 revolutions per minute.

[0065] FIG. 16 and FIG. 17 show a non-limiting example of system 10 configured to rotate the plurality of reactors 400 about a longitudinal axis of the reactors 400. As shown in FIG. 16, in this embodiment, at least one motor 710 is associated with the reactor housing 300. The motor 710 is also in operative communication with a gear 720 such that the motor 710 causes the gear 720 to move (e.g., rotate). The gear 720, in turn, is in operative communication with at least one drive chain 730. As shown in FIG. 17, the drive chain 730 is engages the outer circumference of the cylindrical body 610 of each reactor 400, for example via a plurality of teeth 740 extending from the outer surface of the cylindrical body 610 of each reactor 400. In the embodiment specifically shown in FIG. 16 and FIG. 17, the reactor housing 300 includes an opening 315 allowing for the gear 720 to engage with the plurality of teeth 740. In operation, the motor 710 rotates the gear 720, which in turn moves chain 730 causing the reactors 400 to rotate about their longitudinal axes. In some embodiments, the motor 710 turns the gear 720 clockwise. In other embodiments, the motor 710 turns the gear 720 counter-clockwise.Reactors

[0066] The reactor housing 300 may include a plurality of reactors 400. FIG. 2A illustrates a nonlimiting example, wherein reactor housing 300 comprises four reactors 400. However, the number of reactors 400 in reactor housing 300 is not limited, any different number of reactors 400 may be used.Attorney Docket No. 81901 -8001 .WO00

[0067] Each reactor 400 defines an interior space configured to hold raw substrate 100 for pyrolysis. Reactors 400 may be of any sufficient size and shape to hold a desired type and amount of raw substrate 100. In some embodiments, the reactors 400 are cylindrical in shape and have an inner diameter sufficient to receive a whole tire 1 10. Reactors 400 may be made of steel. The type of steel used is not particularly limited, and may be any steel compatible with temperatures of the pyrolysis reaction. In some embodiments, the reactors 400 may be made of steel that can withstand temperatures up to about 1 ,000°F (up to about 540°C) without cracking or collapsing.

[0068] FIG. 3 shows a non-limiting example of a system 10 consistent with the present disclosure. As shown in FIG. 3, the system 10 includes three reactor housings 300. Each reactor housing 300 includes four reactors 400. As shown in FIG. 3 and FIG. 4, each reactor 400 has a cylindrical body including a longitudinal axis parallel with the length of the reactors 400. The reactors 400 are each disposed in a reactor housing 300 such that the longitudinal axis of each reactors 400 is parallel to the longitudinal axis of the reactor housing 300. As shown in more detail in FIG. 3, the reactors 400 are stacked in the associated reactor housing 300 in a two-by-two arrangement, although other arrangements are possible.

[0069] As shown in FIG. 3 and FIG. 4, in one embodiment, the reactors 400 may be cylindrical in shape. In this embodiment, reactors 400 may include a cylindrical body 610. The inner diameter of the cylindrical body 610 is sufficient to receive a whole rubber tire. In some embodiments, the length of the cylindrical body 610 is sufficient such that reactors 400 may receive a self-stacked configuration of a plurality of tires, as described herein. The cylindrical body 610 may be sized and shaped to receive at least 4, such as at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11 , at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, at least 20, at least 21 , at least 22, at least 23, or at least 24 whole tires.

[0070] In some embodiments, the cylindrical body 610 has a diameter of about 16 inches to about 36 inches, for example about 16 inches, about 17 inches, about 18 inches, about 19 inches, about 20 inches, about 21 inches, about 22 inches, about 23 inches, about 24 inches, about 25 inches, about 26 inches, about 27 inches, about 28 inches, about 29 inches, about 30 inches, about 31 inches, about 32 inches, about 33 inches, about 34 inches, about 35 inches, or about 36 inches. In other embodiments, the cylindrical body 610 has an inner diameter greater than 36 inches.

[0071] The reactors 400 each include a first opening 620 disposed at a first end of the cylindrical body 610. The cylindrical body 610 of each reactor 400 may have a first tapered portion 640 on an inner surface of cylindrical body 610 proximal to the first opening 620. Without wishing to be bound by theory, it is currently believed that the first tapered portion 640 improves pyrolysis efficiency by reducing or eliminating contact between pyrolysis products (e.g., solid carbon and liquidAttorney Docket No. 81901 -8001 .WO00 hydrocarbons) and the pyrolysis gas injection cap 430 associated with the first opening 620 of the cylindrical body 610.

[0072] The reactors 400 each include a second opening 630 disposed at a second end of the cylindrical body 610 opposite of the first opening. The cylindrical body 610 of each reactor 400 may have a second tapered portion 650 on the inner surface of the cylindrical body 610 proximal to the second opening 630. Without wishing to be bound by theory, it is currently believed that the second tapered portion 650 improves pyrolysis efficiency by reducing or eliminating contact between pyrolysis products (e.g., solid carbon and liquid hydrocarbons) and the exhaust cap 460 associated with the second opening 630 of the cylindrical body 610.

[0073] As shown in FIGS. 6-9, the reactor 400 may include one or more guide rails 615 disposed circumferentially about the outer surface of the cylindrical body 610. Such guide rails 615 may contact one or more guide rollers 370 of the reactor housing body 360 to support the reactor 400 and reduce warping of the reactor 400 at operating pyrolysis temperatures.Pyrolysis Gas Injection

[0074] As shown in FIG. 15, each reactor 400 may include a pyrolysis gas injection manifold 420. The pyrolysis gas injection manifold 420 is configured to introduce pyrolysis gas 305 from the heat generation module 200, via the pyrolysis gas duct 220, to reactors 400. In some embodiments, such as those where the raw rubber substrate 100 consists of, consists essentially of, or comprises whole tires 110, the pyrolysis gas injection manifold 420 may be configured to introduce pyrolysis gas 305 from the heat generation module 200, via the pyrolysis gas duct 220, to the continuous lumen 1 18 formed by the lumens 116 of each stacked whole tire 110 in the cylindrical body 610 of the reactor 400.

[0075] The pyrolysis gas injection manifold 420 is supported by the first reactor housing frame 320, for example as shown in FIG. 15. The pyrolysis gas injection manifold 420 is configured to be in operative communication with the first end of the reactors 400 when the first reactor housing frame 320 is engaged with (e.g., is reversibly coupled with) the reactor housing body 360. In some embodiments, the pyrolysis gas injection manifold 420 is configured to be disengaged from (e.g., is not in operative communication with) the first end of the reactors 400 when the first reactor housing frame 320 is not engaged with (e.g., is reversibly uncoupled from) the reactor housing body 360. The pyrolysis gas injection manifold 420 is oriented and located on first reactor housing frame 320 such that when first reactor housing frame 320 is coupled to reactor housing body 360, pyrolysis gas injection manifold 420 closes the first end of cylindrical body 610 of reactor 400, as discussed in more detail herein. In some embodiments, the first locking mechanism 340 (e.g., FIG. 20) securesAttorney Docket No. 81901 -8001 .WO00 the pyrolysis gas injection manifold 420 to the first end of cylindrical body 610 of the reactor(s) 400 when the first locking mechanism 340 locks the first reactor housing frame 320 to the reactor housing body 360, for example during pyrolysis.

[0076] As shown in FIG. 15, the pyrolysis gas injection manifold 420, in some embodiments, includes a pyrolysis gas injection cap 430 configured to seal the first end of the reactor 400. For example, the pyrolysis gas injection cap 430 may engage the first end of the cylindrical body 610 to close the reactor 400 when the first reactor housing frame 320 mates with the reactor housing body 360,. In such embodiments, the pyrolysis gas injection cap 430 seals the first end of the cylindrical body 610 of the reactor 400 closed, for example to prevent ambient air (e.g., oxygen) from entering the reactor 400 during pyrolysis and / or to prevent pyrolysis products from exiting the cylindrical body 610 during pyrolysis and / or to ensure pyrolysis gas 305 passes from the pyrolysis gas injection manifold 420 into the reactor 400. The pyrolysis gas injection cap 430 may include at least one gas injection port 440 (FIG. 12) configured to enable pyrolysis gas 305 to enter each reactor from the heat generation module 200 via the pyrolysis gas duct 220 and the pyrolysis gas injection manifold 420. In some embodiments, the pyrolysis gas injection cap 430 includes a plurality of gas injection ports 440, such as at least on gas injection port 440 per reactor 400. As shown best in FIG. 12, the gas injection port 440 is located at the center of pyrolysis gas injection cap 430 in some embodiments. The pyrolysis gas injection cap 430 may optionally include a screen 445 disposed over the gas injection port 440. In general, the screen 445 is configured to prevent solid materials from obscuring (e.g., blocking) the gas injection port 440. Without wishing to be bound by theory, it is currently believed that blockage of the gas injection port 440 may result in undesirable restriction of the pyrolysis gas 305 into the reactors 400, or an undesirable uneven flow of pyrolysis gas 305 among a plurality of reactors 400, which may negatively impact pyrolysis efficiency. In some embodiments, the screen 445 includes a conical or pyramidal shape, for example having an apex disposed colinear with the central longitudinal axis of the reactor 400. In such embodiments, the screen 445 interacts with the lumen 116 of at least the first whole tire 110 disposed adjacent to the pyrolysis gas injection cap 430 to, for example, prevent the first whole tire 1 10 from obstructing flow of pyrolysis gas 305 passing from the gas injection port 440 into the reactor 400.

[0077] Referring now specifically to FIG. 13, the pyrolysis gas injection cap 430 may include a seal 435 configured to contact the first end of the cylindrical body 610. The seal 435 reduces or prevents pyrolysis gas 305 and pyrolysis products (e.g., off-gases 410) from escaping the reactor 400 during pyrolysis. The seal 435 may also reduce or prevent oxidizing agents from entering the associated reactor 400 during pyrolysis. In some embodiments, the seal 435 comprises, consists essentially of, or consists of a self-healing and / or self-lubricating material resistant to degradation at operatingAttorney Docket No. 81901 -8001 .WO00 temperatures of about 1 ,000°F (540°C) or greater. In some embodiments, the seal 435 comprises, consists essentially of, or consists of graphite (e.g., Pure Expanded Flexible Graphite Yarn, part no. 5000, Palmetto, LLC; Denton, Maryland).

[0078] Applicant has discovered that the use of a self-healing and / or a self-lubricating seal can be advantageous when used with reactors 400 consistent with the present disclosure. Without wishing to be bound by theory, it is currently believed that the cylindrical body 610 of reactors 400 as disclosed herein are subject to substantial expansion and may even warp under pyrolysis operating conditions. Rotation of the reactors 400 after expansion / warping at high temperature can cause other types of vapor seals to fail, resulting in loss of off-gases and / or introduction of undesired ambient air (e.g., oxygen) into the reactor 400.

[0079] Referring now to FIGS. 14A-14B, the pyrolysis gas injection cap 430 may be secured, rotationally about the longitudinal axis of the reactor 400, with the cylindrical body 610 by one or more rotational locking joints 436. The rotational locking joint(s) 436, when present, are configured to prevent the pyrolysis gas injection cap 430 from rotating about the longitudinal axis of the reactor 400 at a different rate than the rate at which the cylindrical body 610 rotates about the longitudinal axis of the reactor 400. In some embodiments, the locking joints 436 each include a locking pin 437 associated with the cylindrical body 610, and a locking pin receiver 438 associated with the pyrolysis injection cap 430. In some embodiments, one or more engaging blades 439a is associated with the cylindrical body 610 and is configured to engage with an engaging blade receiver 439b associated with the pyrolysis injection cap 430 while the cylindrical body 610 is rotated relative to the pyrolysis injection cap 430. When the engagement blade 439a mates with the engagement blade receiver 439b, the rotation of the cylindrical body 610 causes the pyrolysis injection cap 430 to rotate at the same rate. The engagement blade(s) 439a are disposed on the cylindrical body 610 relative to the locking pin(s) 437 in the same manner that the engagement blade receiver 439b is disposed on the pyrolysis injection cap 430 relative to the locking pin receiver(s) 438 such that mating of the engagement blade 439a and the engagement blade receiver 439b ensures that all locking pins 437 are aligned with the locking pin receivers 438.

[0080] As shown in FIG. 15, the pyrolysis gas injection manifold 420 may include a first safety system 480 for preventing pyrolysis gas injection cap 430 from uncoupling from the first end of cylindrical body 610 of reactor 400. For example, the first safety system 480 may be configured to exert pressure against the outside surface of the pyrolysis gas injection cap 430 towards the reactor 400 to reduce or prevent the pyrolysis gas injection cap 430 from decoupling from the first end of the cylindrical body 610 when the first reactor housing frame 320 is coupled to reactor housing body 360 via one or more joints. The first safety system 480 may include one or more casters 483 or similarAttorney Docket No. 81901 -8001 .WO00 low-friction engagement points that contact and transfer pressure to the outside surface of the pyrolysis gas injection cap 430 while enabling the pyrolysis gas injection cap 430 to rotate with the cylindrical body 610, for example when one or more rotational locking joints 436 are present to prevent the pyrolysis gas injection cap 430 from rotating about the longitudinal axis of the reactor 400 at a different rate than the rate at which the cylindrical body 610 rotates about the longitudinal axis of the reactor 400. In some embodiments, the first safety system 480 is configured to remain in a locked position by default (e.g., exerting pressure on the outer surface of the pyrolysis gas injection cap 430 towards the associated reactor 400) to prevent accidental or inadvertent opening of the reactor 400 during operation, for example, in the event that the system 10 loses power during pyrolysis or when an emergency state is realized in an associated reactor 400 before pyrolysis has completed.

[0081] In some embodiments, the first safety system 480 is configured such that power (e.g., electrical power) is required to retract the pyrolysis gas injection cap 430 away from the reactor 400, while no power (e.g., electricity) is required to advance the pyrolysis gas injection cap 430 to engage with the reactor 400 or to keep the pyrolysis gas injection cap 430 securely engaged with the reactor 400. In one embodiment, shown in FIG. 26, the first safety system 480 includes a multi-jointed locking arm 481 in operable communication with a hydraulic piston 482. The first safety system 480 is configured shorten to operable length of the multi-jointed locking arm 481 when power (e.g., electricity) is applied to extend the hydraulic piston 482, and to lengthen the operable length of the multi-jointed locking arm 481 when power (e.g., electricity) is absent and causes the hydraulic piston 482 to retract. Lengthening the multi-jointed locking arm 481 (by removing power from the hydraulic piston 482) causes the pyrolysis gas injection cap 430 to extend toward and engage with the cylindrical body 610, while shortening the multi-jointed locking arm 481 (by applying power to the hydraulic piston 482) causes the pyrolysis gas injection cap 430 to retract away from the cylindrical body 610.Off-Gas Capture

[0082] As shown in FIG. 27, each reactor 400 is in fluid communication with an exhaust manifold 450. The exhaust manifold 450 is configured to collect off-gases 410 emitted from the reactors 400 and pass them to an associated off-gas duct 390.

[0083] The exhaust manifold 450 is in fluid communication with the exhaust ports 470 of the exhaust caps 460. In general, the exhaust manifold 450 is supported by the first reactor housing frame 320, for example as shown in FIG. 3. In some embodiments, the exhaust manifold 450 is coupled to the first reactor housing frame 320 such that it is in operative communication with the off-gas duct 390 when the first reactor housing frame 320 is in its closed position relative to the reactor housing bodyAttorney Docket No. 81901 -8001 .WO00360. In some embodiments, the exhaust manifold 450 is coupled to the first reactor housing frame 320 such that it disengages with the at least a portion of the off-gas duct 390 when the first reactor housing frame 320 is in its open position relative to the reactor housing body 360.

[0084] The exhaust cap 460 couples to the second end of cylindrical body 610 of reactor 400 to close the reactor 400 when the first reactor housing 320 is in its closed position relative to the reactor housing body 360. In this position, the exhaust cap 460 seals the second end of the cylindrical body 610, for example to prevent off-gases from exiting the reactor 400 other than via the exhaust port 470. The exhaust cap 460 may include at least one exhaust gas port 470 configured to enable offgases 410 from the reactor to exit the reactor and enter the exhaust manifold 450. In some embodiments, the exhaust cap 460 may include a plurality of exhaust ports 470. In some embodiments, the exhaust gas port 470 is disposed at the center of the exhaust cap 460. The exhaust cap 460 may include a screen 445 disposed over the exhaust gas port 470. In some embodiments, the screen 445 is configured to prevent solid materials from obscuring (e.g., blocking) the exhaust gas port 470. Without wishing to be bound by theory, it is currently believed that blockage of exhaust gas port 470 may result in undesirable restriction of the off-gas 410 into the reactors 400, or an undesirable uneven flow of pyrolysis gas 305 into a plurality of reactors 400 due to pressure differentials between the reactors 400, which may negatively impact pyrolysis efficiency.. In some embodiments, the screen 445 includes a conical or pyramidal shape, for example having an apex disposed colinear with the central longitudinal axis of the reactor 400. In such embodiments, the screen 445 interacts with the lumen 116 of at least the first whole tire 110 disposed adjacent to the exhaust cap 460 to, for example, prevent the first whole tire 1 10 from obstructing flow of off-gas 410 passing from the reactor 400 into the exhaust manifold 450.

[0085] The exhaust cap 460 may include a seal 465 configured to contact the second end of the cylindrical body 610. The seal 465 reduces or prevents off-gas 410 and pyrolysis gas 305 from escaping the reactor 400 during pyrolysis. The seal 465 may also reduce or prevent oxidizing agents from entering the associated reactor 400 during pyrolysis. In some embodiments, the seal 465 comprises, consists essentially of, or consists of a self-healing and / or self-lubricating material resistant to degradation at operating temperatures of about 1 ,000°F (540°C) or greater. In some embodiments, the seal 465 comprises, consists essentially of, or consists of graphite (e.g., Pure Expanded Flexible Graphite Yarn, part no. 5000, Palmetto, LLC; Denton, Maryland).

[0086] Applicant has discovered that the use of a self-healing and / or a self-lubricating seal 465 can be advantageous when used with reactors 400 consistent with the present disclosure. Without wishing to be bound by theory, it is currently believed that the cylindrical bodies 610 of reactors 400 as disclosed herein are subject to substantial expansion and may even warp under pyrolysisAttorney Docket No. 81901 -8001 .WO00 operating conditions. Rotation of the reactors 400 after expansion / warping at high temperature can cause other types of vapor seals to fail, resulting in loss of off-gases and / or introduction of undesired ambient air (e.g., oxygen) into the reactor 400.

[0087] Referring now to FIG. 14, the exhaust cap 460 may be secured, rotationally about the longitudinal axis of the reactor 400, with the cylindrical body 610 by one or more rotational locking joints 436. The rotational locking joint(s) 436, when present, are configured to prevent the exhaust cap 460 from rotating about the longitudinal axis of the reactor 400 at a different rate than the rate at which the cylindrical body 610 rotates about the longitudinal axis of the reactor 400.Heat Module

[0088] Referring again to FIG. 2A, the system 10 includes a heat module 200 configured to supply pyrolysis gas 305 to the reactors 400. An initial burner 210 may be present to generate an initial small amount of heat to begin producing pyrolysis gas 305. In some embodiments, the pyrolysis gas 305 includes one or more light hydrocarbon (e.g., propane, ethane, methane), carbon dioxide, carbon monoxide, nitrogen, argon, and combinations thereof. In some embodiments, the pyrolysis gas includes about 70-80% nitrogen, about 0.5-2% hydrogen, not more than about 5% oxygen, about 1 - 10% carbon monoxide, about 0.5-5% methane, and about 2-10% carbon dioxide. In some embodiments, the pyrolysis gas includes not more than 5 %, not more than 4 %, not more than 3 %, not more than 2%, or not more than 1 % oxygen.

[0089] In some embodiments, the heat module 200 produces pyrolysis gas 305 from fuel that includes combustible products produced by pyrolysis in the associated reactors 400. For example and without limitation, the off-gas duct 390 may feed off-gases 410 into an off-gas recycler 230 configured to pass a portion of the off-gases 410 back to the heat module 200.

[0090] As shown in FIG. 2A, pyrolysis gas produced by heat module 200 is supplied to the reactors 400 via one or more pyrolysis gas ducts 220. The pyrolysis gas ducts 220 are in fluid communication with the pyrolysis gas injection port(s) 440 of each associated pyrolysis gas injection cap 430.Pyrolysis Reaction

[0091] As discussed herein, the system 10 is configured to convert a raw substrate 100 (e.g., whole tires 110) into sold carbon and other gaseous and liquid products through pyrolysis. Unlike pyrolysis systems commonly available in the art, systems 10 consistent with the present disclosure are configured to efficiently pyrolyze whole tire substrate without mechanical pre-processing (e.g., chopping or shredding). In some embodiments, the raw substrate 100 is pyrolyzed by injecting pyrolysis gas 305 into a central lumen 118 of the raw substrate 100, such as in the central lumens 1 16 of whole tires 1 10 oriented side-by-side inside each reactor 400. Without wishing to be bound byAttorney Docket No. 81901 -8001 .WO00 theory, it is currently believed that the observed high efficiencies realized by the systems 10 and processes of the present disclosure are due at least in part to the direct contact between pyrolysis gas 305 and the raw substrate 100, even in the absence of heat applied to the outer surfaces of the reactors 400.

[0092] In some embodiments, pyrolysis occurs at a temperature (inside the reactor 400) of about 700°F to about 1 ,200°F (about 370°C to about 650°C). In some embodiments, the process begins at or near ambient temperature and rises over the course of several hours (e.g., about 2 hours, about 3 hours, about 4 hours, about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, or more than 12 hours) to an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C).

[0093] In some embodiments, the residence time of the substrate 100 inside the reactor 400 (e.g., at an operating temperature of about 700°F to about 1 ,200°F) is about 0.25 hours to about 24 hours, for example about 0.25 hours, about 0.5 hours, about 0.75 hours, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, about 16 hours, about 17 hours, about 18 hours, about 19 hours, about 20 hours, about 21 hours, about 22 hours, about 23 hours, or about 24 hours. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 3 hours. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 2 hours. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 1 hour. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 0.75 hours. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 0.5 hours. In some embodiments, the residence time of the substrate 100 at an operating temperature of about 700°F to about 1 ,200°F (about 370°C to about 650°C) is not more than about 0.25 hours.

[0094] In some embodiments, a process consistent with the present disclosure pyrolyzes about 600 lbs. to about 900 lbs. (about 270 kg to about 410 kg) of whole tires 110 to pyrolysis products consisting essentially of, or consisting of solid carbon and off-gases over a residence time at a reactor temperature of about 700°F to about 900°F (about 370°C to about 480°C) of not more than 2 hours.Attorney Docket No. 81901 -8001 .WO00

[0095] In some embodiments, a process consistent with the present disclosure pyrolyzes about 600 lbs. to about 900 lbs. (about 270 kg to about 410 kg) of whole tires 110 to pyrolysis products consisting essentially of, or consisting of solid carbon and off-gases over a residence time at a reactor temperature of about 700°F to about 900°F (about 370°C to about 480°C) of not more than 1 hour.

[0096] In some embodiments, a process consistent with the present disclosure pyrolyzes about 600 lbs. to about 900 lbs. (about 270 kg to about 410 kg) of whole tires 110 to pyrolysis products consisting essentially of, or consisting of solid carbon and off-gases over a residence time at a reactor temperature of about 700°F to about 900°F (about 370°C to about 480°C) of not more than 0.75 hours.

[0097] In some embodiments, a process consistent with the present disclosure pyrolyzes about 600 lbs. to about 900 lbs. (about 270 kg to about 410 kg) of whole tires 110 to pyrolysis products consisting essentially of, or consisting of solid carbon and off-gases over a residence time at a reactor temperature of about 700°F to about 900°F (about 370°C to about 480°C) of not more than 0.5 hours.

[0098] In some embodiments, a process consistent with the present disclosure pyrolyzes about 600 lbs. to about 900 lbs. (about 270 kg to about 410 kg) of whole tires 110 to pyrolysis products consisting essentially of, or consisting of solid carbon and off-gases over a residence time at a reactor temperature of about 700°F to about 900°F (about 370°C to about 480°C) of not more than 0.25 hours.

[0099] In embodiments where the raw substrate 100 consists or consists essentially of whole rubber tires 110, applicants have surprisingly discovered that the systems 10 and processes consistent with the present disclosure provide substantial improvements over systems and methods known in the art. Without wishing to be bound by theory, it is currently believed that the steel belt portions of whole tires 110 enhance pyrolysis by acting as an internal mill, enabling rapid breakdown of solid rubber substrate in part due to rotation of the reactors 400 during pyrolysis. Additionally, separation of the metal components of whole tire substrate 110 is accomplished conveniently and efficiently in that the steel belt material typically forms one or a small number of self-assembled tangled arrays that can be removed by a user (e.g., by hand or assisted by a small winch).Off-Gases

[0100] As shown in FIG. 1 , off-gases 410 produced during pyrolysis are routed from the reactors 400 by the exhaust manifold 450 to an off-gas duct 390. Off-gases 410 may include one or more of light hydrocarbon, carbon dioxide, carbon monoxide, nitrogen, argon, and combinations thereof.Attorney Docket No. 81901 -8001 .WO00Optionally, off-gases 410 are pre-processed by an off-gas recycler 230 where a portion of the offgases 410 are returned to the heat module 200 to produce additional pyrolysis gas 305. As shown representatively in FIG. 2C, the off-gas recycler 230 is configured to trap condensable gases and / or solid particles within the off-gases 410 in the off-gas duct 390. In some embodiments, the off-gas recycler 230 includes one or more oil spray nozzles 235 configured to spray oil in a cone shape 236 within the off-gas duct 390. The off-gases 410 pass through the sprayed oil 236. Condensable gases within the off-gases 410 are cooled by contact with the sprayed oil 236, and the sprayed oil may trap solid particles in the off-gases 410. The sprayed oil 236 falls into a collection tank 238 where solid particles settle to the bottom. Liquid oil may be collected and moved to a storage tank 239 via a duct 239. Stored oil may be pumped from the storage tank 232 to the one or more oil spray nozzles 235 via ducts 234 and a recycling pump 233. In some embodiments, the system 10 includes a single offgas recycler 230 in operative communication with the off-gas duct 390 and configured to cause sprayed oil 236 to contact the off-gases 410. In other embodiments, the system 10 includes more than one off-gas recycler 230 in operative communication with the off-gas duct 390 and configured to cause sprayed oil 236 to contact the off-gases 410. In some embodiments, the off-gas duct includes a safety baffle (not shown) configured to allow a system user to close (e.g., remotely close) a portion of an off-gas duct, for example if the off-gas duct 390 is breached thus allowing ambient air to enter the off-gas duct and react with the hot off-gases present in the off-gas duct 390. When present, the safety baffle may be a butterfly valve or similar valve capable of being quickly activated. The valve (e.g., butterfly valve) may include a self-healing and / or self-lubricating material resistant to degradation at operating temperatures of about 1 ,000°F (540°C) or greater. In some embodiments, the seal comprises, consists essentially of, or consists of graphite (e.g., Pure Expanded Flexible Graphite Yarn, part no. 5000, Palmetto, LLC; Denton, Maryland).

[0101] In some embodiments, off-gases 410 are processed in a chiller 500 (alternatively referred to as a heat exchanger) to convert condensable gases into potentially valuable liquid byproducts 510, such as West Texas Intermediate grade oil. The liquid byproducts 510 may be collected in a collector 600 and further processed or sold as-is.

[0102] As shown in FIG. 1 , off-gases that are not condensed by the chiller 500 are routed via a duct 710 to a an exhaust stack 700 as a flue gas 520. The flue gas 520 may include one or more of argon, nitrogen, carbon dioxide, water, and small amounts of oxygen. The exhaust stack 700 may optionally include a bag house filter or similar environmental capture system to comply with relevant laws and regulations for venting flue gas to the atmosphere.Attorney Docket No. 81901 -8001 .WO00Solid Pyrolysis Products

[0103] As shown in FIG. 1 , the pyrolysis reaction in reactors 400 may produce finished products 800. The finished products 800 (e.g., carbon, activated carbon) may be collected into a finished products storage vessel 900. In some embodiments, the finished products storage vessel 900 may hold the finished products 800 for sale or for further processing. In other embodiments, the finished products storage vessel 900 may hold the finished products 800 for optional further processing. Optional further processing processes may include one or more of purification, separation, filtration, compacting, shaping, sieving, packaging, and so forth.

[0104] In some embodiments, at least some of finished product 800 is activated carbon. Activated carbon is used in a wide variety of applications, including separation media (in separation and filtration processes), as a fuel, as a component in pharmaceutical and cosmetic formulations, and so forth.

[0105] In some embodiments, activated carbon in finished products storage vessel 900 may be recycled back into system 10. For example, activated carbon may be conveyed from finished products storage vessel 900 to heat module 200 to use the activated carbon as fuel in the initial burner 210. In another example, activated carbon may be conveyed from finished products storage vessel 900 to exhaust stack 700 so it may be used as separation media, e.g., a sorbent, to treat flue gas 520.

[0106] In other embodiments, activated carbon in finished products storage vessel 900 may be optionally further processed. For example, activated carbon may be conveyed from finished products storage vessel 900 to one or more processes, including briquetting, shaping, compacting, pressing, purifying, refining, sieving, grinding, and so forth.

[0107] In some embodiments, the activated carbon may be formed into a powder. The activated carbon from finished products storage vessel 900 may be sieved to a mesh size of about 200, about 100, about 50, about 10, about 6, about 4, or about 2. In some embodiments, the activated carbon may be formed into a suitable shape through mechanical processes, such as briquetting, compacting, pressing, and so forth. Optionally, a binder may be used to aid in the mechanical process. In some embodiments, the activated carbon may be shaped into a briquette. The activated carbon from finished products storage vessel 900 may be mechanically processed into a shape having a maximum dimension from about 1 to 10 inches.Control Unit

[0108] Referring again to FIG. 1 , the system 10 may include by a control unit 1000 to control, monitor, and operate the various components of the system 10. In some embodiments, the controlAttorney Docket No. 81901 -8001 .WO00 unit 1000 includes a controller 1010, an input / output (I / O) interface 1012, one or more communication devices 1014, a communication network 1016, and memory 1018.

[0109] Referring now to FIG. 27, the controller 1010 may perform various functions for the system 10, including operating, monitoring, and communicating with the various components of the system 10. The controller 1010 may be in electrical communication with the components of the system 10 to transmit or receive any combination of data, information, and signals (e.g., analog signals, digital signals, etc.). The controller 1010 may be in electrical communication through a wired or wireless connection. The controller 1010 may include various hardware, such as one or more central processing units (CPUs), graphics processing units (GPUs), microcontroller(s), Raspberry PI board(s), and so forth, which may be programmed to execute code or machine-readable instructions. In some embodiments, the code or machine-readable instructions may be stored in a non-transitory computer-readable storage medium, such as memory 1018, or may be hard-wired in one or more dedicated processing units.

[0110] The I / O interface 1012 may be used by user (local or remote to) system 10 to input various inputs to system 10, such as parameters, settings, user selections, modes of operation, and so forth. The I / O interface 1012 may be used by user to receive various outputs from system 10, such as reports, images, data, information, and so forth. In some embodiments, I / O interface 1012 may include one or more input and output elements. Example input and output elements are buttons, microphones, dials, knobs, touchscreens, keyboards, monitors, screens, panels, buzzers, speakers, lights, and so forth.

[0111] One or more communication devices 1014, when present, may receive and transmit data from one or more components of the system 10 using an associated communication network 1016, a remote server, a user device (e.g., a computer, smartphone, or tablet), or a combination thereof. In some embodiments, one or more communication devices 1014 may include one or more of include a modem, a Bluetooth™ device, a radio-frequency (RF) device, and so forth.

[0112] The communication network 1016 may include one or more communication buses that connect the components of system 10 and implement one or more communication protocols. Nonlimiting examples of communication protocols include Control Area Network (CAN), Vehicle Area Network (VAN), Media Oriented System Transport (MOST), Local Interconnect Network (LIN), Flex- Ray, Ethernet, and so forth. The communications network 1016 may also include one or more components and devices to facilitate communication, such as ways, bridges, receivers, transmitters, transceivers, modems, routers, cables, wires, fibers, and so forth. In some embodiments, communication network 1016 may provide connectivity to devices and systems external to systemAttorney Docket No. 81901 -8001 .WO0010, such as a remote server, a cloud, a user device (e.g., computer, smartphone, tablet), and so forth.

[0113] The memory 1018 stores and provides access to data, information, and executable instructions. The executable instructions may include instructions for controller 1010 to operate, monitor, and communicate with components of system 10. In some embodiments, memory 1018 may be a non-transitory computer-readable storage medium. In some embodiments, memory 1018 may include executable instructions for generating a report indicative of a status of system 10 or one or more components of system 10. In this embodiment, the report may include data or information covering a specific range of time. Some non-limiting examples of reports include the daily power consumption of system 10, the rate (on a per hour basis) of pyrolysis gas generated by heat module 200, the amount (e.g., weight) of finished products 800 generated by the system (on a per hour basis), and so forth. In some embodiments, the report may be generated in response to a predetermined event, e.g., the failure and / or malfunction of one or more components of system 10. In some embodiments, the report, or a copy of the report, may be stored in memory 1018. In other embodiments, a report, or a copy of the report may be displayed for a user, for example using I / O 1012, or transmitted locally or remotely to a user, for example using the communication network 1016 and one or more communication devices 1014.

[0114] In operation, the controller 1010 may control, monitor, and operate the various components of the system 10 using the I / O interface 1012, one or more communication devices 1014, communication network 1016, and memory 1018. In one non-limiting example, a user may use I / O interface 1012 to select a mode of operation of the initial burner, for example, a start-up mode of operation. The controller 1010 receives the user selection from I / O interface 1012 and executes one or more instructions, stored in memory 1018, in response to the user selection. For example, controller 1010 may execute instructions to heat module 200 to initiate start-up of initial burner 210. The controller 1010 may communicate the instructions to heat module 200 using communication network 1016, one or more communication devices 1014, or a combination thereof. The controller 1010 may also execute instructions, stored in memory 1018, to generate a report of the user selection. The report may include, for example, the time, date, and location of the user selection, the mode of operation (i.e., start-up) selected by the user, the time and date the controller 1010 executed instructions to initiate the start-up mode, and so forth. The controller 1010 may transmit the report to memory 1018 for storage, for example using one or more communication devices, 1014 communication network 1016, or a combination thereof.Attorney Docket No. 81901 -8001 .WO00Sensors

[0115] In some embodiments, the system 10 comprises one or more sensors (not shown). The one or more sensors are not particularly limited, and may be selected based on the functionality of the particular component of the system 10. The one or more sensors may include temperature sensors, humidity sensors, level sensors, analyte (e.g., oxygen, carbon dioxide, sulfur dioxide) sensors, and combinations thereof. The one or more sensors may be located inside components of system 10, e.g., inside reactors 400, may be located outside of components of system 10, or a combination thereof.

[0116] The one or more sensors may be in electrical communication with control unit 1000 (not shown). The one or more sensors may communicate with controller 1010 using the communication network 1016, one or more communication devices 1014, and combinations thereof. In some embodiments, controller 1010 may receive data from sensors (e.g., temperature data from a temperature sensor, level data from a level sensor, and so forth), process the data, execute one or more instructions based on data received, data processed, or a combination thereof, and transmit generated or measured data. In one non-limiting example, controller 1010 may receive temperature data from a sensor inside heat module 200 via one or more communication devices 1014 and communication network 1016. Controller 1010 may execute instructions, stored in memory 1018, to process the temperature data to determine whether the temperature of the pyrolysis gas in heat module 200 is at a predetermined threshold. After processing the temperature data, controller 1010 may execute instructions, stored in memory 1018, to heat module 200 to initiate start-up or a mode of operation of the initial burner 210 based on the processed temperature data. Controller 1010 may generate a report of the measured temperature data, processed temperature data, or a combination thereof. Controller 1010 may transmit the report to memory 1018 for storage, for example using one or more communication devices, 1014 communication network 1016, or a combination thereof.Method steps

[0117] Turning now to FIG. 28, a method 1 100 consistent with the present disclosure is illustrated. Steps of the method 1100 may be carried out using any combination of suitable devices or systems, as well systems described in the present disclosure. In some embodiments, steps of the method 100 may be implemented as instructions stored in non-transitory computer readable media, such as memory 1018, as a program, firmware or software, and executed by a general-purpose, programmed or programmable computer, processer or other computing device, such as controller 1010. Although method 1100 is illustrated and described as a sequence of steps, the steps may be performed in anyAttorney Docket No. 81901 -8001 .WO00 order or combination, and need not include all of the illustrated steps. In some embodiments, steps of method 1100 are performed simultaneously, sequentially, or a combination thereof.

[0118] The method 1 100 may begin with step 1110, loading reactors with raw substrate. To do so, step 1110 may include operating a material feed system including one or more ladders, steps, catwalks, cranes, platforms, chutes, conveyers, belts, pulleys, and so forth. In some embodiments, raw substrate may be whole rubber tires. Step 1 110 may include moving, e.g., lifting, rotating, and so forth, the reactors in order to load the raw substrate using the material feed system. Step 11 10 may also include opening and closing reactors.

[0119] Method 1100 may include a step of generating pyrolysis gas 1 120. Step 1120 may include burning a fuel, such as oil, combustible gas, or a combination thereof to generate the pyrolysis gas. To do so, step 1 120 may include operating one or more burners to burn the fuel. In some embodiments, the fuel may include one or more products produced by method 1 110. In some embodiments, the pyrolysis gas includes one or more light hydrocarbon (e.g., propane, ethane, methane), carbon dioxide, carbon monoxide, nitrogen, argon, and combinations thereof. The pyrolysis gas may be at a temperature of about 700°F to about 1 ,200°F.

[0120] Method 1100 may include a step of pyrolyzing raw substrate using pyrolysis gas 1 130 to produce finished products and off-gases. To do so, step 1 130 may include a step of introducing pyrolysis gas from step 1120 into reactors loaded with raw substrate from step 1110. Pyrolysis gas may be introduced via one or more pipes, pumps, conduits, manifolds, valves, and so forth. In some embodiments, the pyrolysis reaction is conducted in a substantially non-oxidizing environment. Step 1 130 may include a step of sealing the reactors to prevent pyrolysis gas from escaping, to prevent exhaust gas from escaping, to keep the reactors free from air or oxygen, or a combination thereof. Step 1 130 may also include locking the reactors using one or more locking mechanisms. The steps of sealing the reactors, locking the reactors, or a combination thereof may be performed before pyrolysis gas is introduced into the reactors.

[0121] Step 1 130 may be performed at for about 0.25 hours to about 12 hours. In some embodiments, step 1 130 is performed for not more than about 3 hours. In other embodiments, step 1 130 is performed for not more than about 2 hours. In still other embodiments, step 1130 is performed for not more than about 1 hour. In other embodiments, step 1 130 is performed for not more than about 0.5 hours.

[0122] In some embodiments, steps 1120 and 1130, combined, are performed for not more than about 12 hours. In other embodiments, steps 1120 and 1130, combined, are performed for not more than about 11 hours. In other embodiments, steps 1120 and 1130, combined, are performed for not more than about 10 hours. In other embodiments, steps 1120 and 1 130, combined, are performedAttorney Docket No. 81901 -8001 .WO00 for not more than about 9 hours. In other embodiments, steps 1 120 and 1130, combined, are performed for not more than about 8 hours. In other embodiments, steps 1120 and 1130, combined, are performed for not more than about 7 hours. In other embodiments, steps 1 120 and 1130, combined, are performed for not more than about 6 hours. In other embodiments, steps 1 120 and 1 130, combined, are performed for not more than about 5 hours. In other embodiments, steps 1120 and 1130, combined, are performed for not more than about 4 hours. In other embodiments, steps 1 120 and 1130, combined, are performed for not more than about 3 hours.

[0123] In step 1140, the finished products produced from step 1 130 may be collected. Step 1 140 may include unlocking the reactors, opening the reactors, or a combination thereof. The finished products may be conveyed, for example, via one or more of pipes, conduits, pumps, valves, manifolds, and so forth, a storage vessel. In some embodiments, the finished products include activated carbon. The products from step 1 140 may be collected manually, semi-automatically, or automatically. The finished products collected in step 1140 may be subjected to optional further processing steps, such as one or more of including briquetting, shaping, compacting, pressing, purifying, refining, sieving, grinding, and so forth. In some embodiments, the finished products may be sent back to step 1120 to be used as fuel to generate the pyrolysis gas. In other embodiments, the finished products may be sent to step 1170 to be used as a separation media for treating flue gases, as described in more detail herein.

[0124] In step 1150, the off-gases produced from step 1130 may be collected. To do so, the reactors may be unlocked, opened, or a combination thereof. The off-gases may be conveyed, for example, via one or more pipes, conduits, pumps, valves, manifolds, and so forth, to be collected. Off-gases may include one or more of light hydrocarbon, carbon dioxide, carbon monoxide, nitrogen, argon, and combinations thereof. In some embodiments, at least a portion of the off-gases contains a combustible gas fraction, such as one or more of light hydrocarbons, hydrogen, and combinations thereof, which may be sent to step 1120 to be used as fuel to generate the pyrolysis gas.

[0125] At step 1160 of method 1100, the off-gases are condensed to produce flue gases and crude oil. In some embodiments, crude oil 510 may be West Texas Intermediate grade oil. To do so, the off-gases are conveyed, via one or more pipes, conduits, and so forth, to a chiller.

[0126] The method 1 100 may optionally include a step of collecting the crude oil 1190. To do so, the crude oil may be conveyed, for example via one or more pipes, conduits, pumps, valves, manifolds, and so forth, to a crude oil collector. In some embodiments, crude oil collector may hold crude oil for sale. In other embodiments, crude oil collector may hold crude oil for optional further processing. Optional further processing processes may include one or more of purification, separation, filtration,Attorney Docket No. 81901 -8001 .WO00 packaging, and so forth. In some embodiments, crude oil may be sent to step 1120 to be used as fuel to generate the pyrolysis gas.

[0127] The method 1 100 may optionally include a step of treating the flue gases 1 170. Without being bound by theory, the flue gases may include greenhouse gases, toxic gases, hazardous gases, or a combination thereof. Thus, to reduce pollution, greenhouse gas emissions, or otherwise comply with environmental regulations, method 1100 may include a step of treating the flue gases 1170. To do so, step 1170 may include subjecting the flue gases to a carbon sequestration or carbon capture process. Step 1 170 may include one or more of filtering, scrubbing, sorbing, adsorbing, or absorbing the flue gases.

[0128] Step 1 100 may also include a step of venting the flue gases 1180 to the atmosphere. To do so, step 1180 may include conveying flue gases, for example via one or more pipes, conduits, pumps, valves, manifolds, and so forth, to an exhaust stack or pipe. Step 1180 may be performed after optional step 1 170 or may be performed immediately after step 1 160.

[0129] Any embodiment disclosed herein may further include an initial step of prewashing the tires 1 10 to remove dirt, rocks, and / or road detritus. In some embodiments, the prewash step comprises prewashing the tires 110 with oil, such as oil recovered from prior pyrolysis methods. In some embodiments, the oil is preheated before being used to prewash the tires 1 10.

[0130] Referring now to FIG. 29, a system 10 consistent with the present disclosure may additionally include a dust reclamation subsystem 1000 configured to capture a substantial portion of dust (e.g., carbon dust) released during loading and unloading of the reactors 300. In some embodiments, the dust reclamation subsystem 1000 includes a dust enclosure 1100 that surrounds the reactors 300, and one or more dust ducts 1200 configured to route any airborne dust from the dust enclosure 1100 to a baghouse or similar dust capturing component (not shown). One advantage of a dust reclamation subsystem 1000 is the reduction in airborne carbon dust particulate matter to which users of the system 10 may be exposed. An additional advantage of a dust reclamation subsystem 1000 is reduced exposure of system users to off-gases and intense heat if an off-gas duct 390 is breached such that ambient air is able to enter the off-gas duct 390.

[0131] Also as shown in FIG. 29, a system 10 consistent with the present disclosure may additionally include a metal waste handling subsystem 2000. In some embodiments, the metal waste handling subsystem 2000 includes a quenching trough 2100 configured to cool down or quench metal waste (e.g., steel) as it is released from the reactors 300. The quenching trough 2100 may be filled with water or a similar liquid capable of quickly reducing the temperature of any metal waste exiting the reactors 300. The quenching trough 2100 may also include an auger 2200 or similar propulsion component configured to convey the metal waste along the length of the quenching trough 2100. TheAttorney Docket No. 81901 -8001 .WO00 metal waste handling subsystem 2000 may also include an overhead conveyor 2300 configured to pull the metal waste out of the quenching trough 2100 without requiring a human user to contact the metal waste. The overhead conveyor 2300 may in some embodiments convey the quenched metal waste to a collection bin or recycling station (not shown).

[0132] While the present disclosure has described a number of embodiments and implementations, the disclosure is not so limited but covers various obvious modifications and equivalent arrangements, which fall within the purview of the appended claims. Although certain features are expressed in certain combinations among the claims, it is contemplated that these features can be arranged in any combination and order. It should be appreciated that many equivalents, alternatives, variations, and modifications, aside from those expressly stated, are possible.

Claims

Attorney Docket No. 81901 -8001 .WOOOClaims1 . A system for pyrolyzing whole tires, the system comprising: a heat generation module configured to generate pyrolysis gas; at least one reactor housing, the at least one reactor housing configured to: house a plurality of reactors, each reactor configured to house and pyrolyze whole tires and having: a cylindrical body having an interior space, the cylindrical body having a diameter sufficient to receive a whole tire, a first opening disposed at a first end of the cylindrical body, a second opening disposed at a second end of the cylindrical body opposite the first opening, a longitudinal axis parallel with a length of the reactor, and a pyrolysis gas injection manifold configured to introduce the pyrolysis gas from the heat generation module to each reactor, and an exhaust manifold configured to capture off-gases emitted from each reactor; a chiller in communication with the first reactor module, the chiller configured to condense at least a portion of the off-gases emitted from each reactor; and an exhaust stack in gaseous communication with the chiller, the exhaust stack configured to process non-condensable gases from the chiller.

2. The system of claim 1 , wherein the reactor housing includes four reactors.

3. The system of claim 1 or claim 2, wherein each reactor is configured to prevent liquids from contacting the exhaust manifold.

4. The system of claim 3, wherein the cylindrical wall includes, on its inner surface: a first tapered portion proximal to the first opening; and a second tapered portion proximal to the second opening.Attorney Docket No. 81901 -8001 .WO005. The system of any one preceding claim, wherein the reactor housing is configured to rotate each reactor about the longitudinal axis of the reactor.

6. The system of any one preceding claim, wherein the pyrolysis gas injection manifold is configured to selectively pivot away from the reactors.

7. The system of any one preceding claim, wherein the exhaust manifold is configured to selectively pivot away from the reactors.

8. The system of any one preceding claim, wherein the exhaust manifold includes an exhaust cap configured to reversibly couple with each reactor.

9. The system of claim 8, wherein each exhaust cap includes: an exhaust port configured to enable off-gases from the reactor to exit the reactor and enter the exhaust manifold; a screen disposed over the exhaust port and configured to prevent solid materials from blocking the exhaust port, a seal configured to couple with the second opening of the reactor and configured to prevent air from entering the reactor during pyrolysis and to prevent off-gases from exiting the reactor during pyrolysis.

10. The system of claim 8 or claim 9, wherein the seal comprises, consists essentially of, or consists graphite.1 1. The system of any one of claims 8-10, wherein the exhaust manifold further includes an exhaust cap safety system configured to prevent each exhaust cap from uncoupling from each reactor upon loss of electrical power to the system.

12. The system of claim 11 , wherein the exhaust cap actuator system comprises: an electrical piston configured to: extend upon application of an electrical current, and retract in the absence of an electrical current, and a jointed actuator arm in mechanical communication with the motorized piston and with the exhaust manifold, the jointed actuator arm configured to:Attorney Docket No. 81901 -8001 .WOOO lengthen upon retraction of the electrical piston, and shorten upon extension of the electrical piston.

13. The system of any one preceding claim, wherein the pyrolysis gas injection manifold includes a pyrolysis gas injection cap configured to reversibly couple with each reactor.

14. The system of claim 13, wherein each pyrolysis gas injection cap includes: a gas injection port configured to enable pyrolysis gas to enter each reactor from the heat generation module; a screen disposed over the gas injection port and configured to prevent solid materials from blocking the gas injection port, a seal coupled with the first opening of the reactor and configured to prevent air from entering the reactor during pyrolysis and to prevent off-gases from exiting the reactor during pyrolysis.

15. The system of claim 13 or claim 14, wherein the seal comprises, consists essentially of, or consists graphite.

16. The system of any one of claims 13-15, wherein the pyrolysis gas injection manifold further includes pyrolysis gas injection cap safety system configured to prevent each pyrolysis gas injection cap from uncoupling from each reactor upon loss of electrical power to the system.

17. The system of claim 16, wherein the pyrolysis gas injection cap safety system comprises: an electrical piston configured to: extend upon application of an electrical current, and retract in the absence of an electrical current, and a jointed actuator arm in mechanical communication with the electrical piston and with the pyrolysis gas injection manifold, the jointed actuator arm configured to: lengthen upon retraction of the electrical piston, and shorten upon extension of the electrical piston.

18. The system of any one preceding claim, wherein the second reactor housing includes four reactors.Attorney Docket No. 81901 -8001 .WO0019. The system of any one preceding claim further comprising a second reactor housing in operative communication with the heat generation module and the chiller, the second reactor housing configured to: house a plurality of reactors, each reactor configured to house and pyrolyze whole tires and having: a cylindrical body having an interior space, the cylindrical body having a diameter sufficient to receive a whole tire, a first opening disposed at a first end of the cylindrical body, a second opening disposed at a second end of the cylindrical body opposite the first opening, a longitudinal axis parallel with a length of the reactor, and a pyrolysis gas injection manifold configured to introduce the pyrolysis gas from the heat generation module to each reactor; and an exhaust manifold configured to capture off-gases emitted from each reactor.

20. The system of claim 19, wherein the second reactor housing has four reactors.

21. The system of claim 19 or claim 20 further comprising a third reactor housing in operative communication with the heat generation module and the chiller, the third reactor housing configured to: house a plurality of reactors, each reactor configured to house and pyrolyze whole tires and having: a cylindrical body having an interior space, the cylindrical body having a diameter sufficient to receive a whole tire, a first opening disposed at a first end of the cylindrical body, a second opening disposed at a second end of the cylindrical body opposite the first opening, a longitudinal axis parallel with a length of the reactor, andAttorney Docket No. 81901 -8001 .WOOO a pyrolysis gas injection manifold configured to introduce the pyrolysis gas from the heat generation module to each reactor; and an exhaust manifold configured to capture off-gases emitted from each reactor.

22. The system of claim 21 , wherein the third reactor housing includes four reactors.

23. The system of any one preceding claim further comprising an exhaust duct in gaseous communication between the exhaust manifold and the chiller, the exhaust duct configured to carry off-gases from the exhaust manifold to the chiller.

24. The system of claim 23, wherein the exhaust duct is in further gaseous communication with the heat generation module.

25. The system of claim 24, wherein the exhaust duct is configured to return at least a portion of a combustible gas fraction of the off-gases to the heat generation module.

26. The system of any one preceding claim further comprising a dust reclamation subsystem configured to capture a substantial portion of airborne dust (e.g., carbon dust) proximal to the reactors.

27. The system of claim 26, wherein the dust reclamation subsystem comprises a dust enclosure surrounding the reactors and one or more ducts associated with the dust enclosure.

28. The system of any one preceding claim further comprising a metal waste handling subsystem configured to convey metal waste exiting the reactors to a collection bin or recycling center without requiring a human user to contact the metal waste.

29. The system of claim 28, wherein the metal waste handling subsystem comprises: a quenching trough configured to cool down or quench metal waste (e.g., steel) as it is released from the reactors; a liquid quenching agent (e.g., water) housed within the quenching trough; and an overhead conveyor configured to remove the metal waste from the quenching trough.

30. The system of claim 29, wherein the quenching trough includes an auger configured to convey the metal waste along a length of the quenching trough.Attorney Docket No. 81901 -8001 .WOOO31 . A reactor for pyrolyzing a plurality of whole tires, the reactor configured to house and pyrolyze whole tires and comprising: a cylindrical body having an interior space and an inner diameter sufficient to receive a whole tire, a first opening disposed at a first end of the cylindrical body, a second opening disposed at a second end of the cylindrical body opposite the first opening, and a longitudinal axis parallel with a length of the reactor.

32. The reactor of claim 31 , wherein the cylindrical body further comprises: a first tapered portion on its inner surface and proximal to the first opening; and a second tapered portion on its inner surface and proximal to the second opening.

33. The reactor of claim 31 or claim 32, wherein the reactor is configured to rotate the longitudinal axis.

34. The reactor of claim 31 , wherein the reactor further comprises a plurality of teeth disposed circumferentially on its outer surface, the plurality of teeth configured to engage with a motorized drive chain.

35. The reactor of any one of claims 31 -34 further comprising: at least one rotational locking pin disposed at the first opening and configured to mate with one or more rotational locking connectors of a pyrolysis gas injection cap; and at least one rotational locking pin disposed at the second opening and configured to mate with of an exhaust cap, wherein the pyrolysis gas injection cap and the exhaust cap are configured to engage with and seal the first opening and the second opening, respectively.

36. The reactor of claim 35, wherein the pyrolysis gas injection cap includes a pyrolysis gas injection port configured to introduce pyrolysis gas into the cylindrical body.

37. The reactor of claim 35 or claim 36, wherein the exhaust cap includes an exhaust port configured to enable off-gases to exit the cylindrical body.Attorney Docket No. 81901 -8001 .WO0038. The reactor of claim 35 or claim 36, wherein the pyrolysis gas cap further includes a screen disposed over the pyrolysis gas injection port.

39. The reactor of claim 38, wherein the screen is conical or pyramidal in shape.

40. The reactor of any one of claims 37-39, wherein the exhaust cap further includes a screen disposed over the exhaust port.41 . The reactor of claim 40, wherein the screen is conical or pyramidal in shape.

42. A method for converting whole tires into pyrolysis products, the method comprising: stacking, in a cylindrical reactor, a plurality of whole rubber tires; generating, in a heat module, a pyrolysis gas; injecting the pyrolysis gas into a central lumen formed by the stack of whole rubber tires within the reactor to pyrolyze the plurality of whole rubber tires; collecting, during the step of injecting pyrolysis gas, off-gases from the reactor; collecting, after the step of injecting pyrolysis gas, solid pyrolysis products from the reactor; and separating metal metallic pyrolysis products from nonmetallic pyrolysis products.

43. The method of claim 42, wherein the step of injecting pyrolysis gas further includes rotating the reactor about its longitudinal axis.

44. The method of claim 43, wherein the reactor is rotated at a rate of about 1 revolution per hour to about 20 revolutions per minute.

45. The method of any one of claims 42-44, wherein the step of injecting the pyrolysis gas is performed for not more than about 2 hours at a reactor temperature of about 700°F to about 1 ,200°F.

46. The method of any one of claims 42-45, wherein the step of separating comprises removing one or more self-assembled tangled masses of steel belt material from the reactor.

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