Multiple-Hearth Pyrolysis Reactor for Purified Recycled Carbon Black
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Solution Overview
Problem
Recycled carbon black (rCB) produced from end-of-life products like scrap tires has poor performance compared to carbon black derived from standard hydrocarbon feedstocks due to the presence of impurities and inorganic additives, necessitating improved production methods.
Innovation Solution
A multi-layered pyrolysis reactor with a pyrolysis zone and gasification zone is used to treat rubber granulate, employing multiple hearths, a rotating central shaft, rabble arms, and controlled heating to produce treated carbon black with enhanced properties through pyrolysis and gasification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pyrolysis of scrap tires is performed to produce recycled carbon black, then carbon black is obtained from waste material, but the carbon black contains impurities and inorganic additives resulting in poor performance
Solution Approach 1:
The process is divided into two distinct stages: pyrolysis (decomposition of rubber) followed by gasification (purification of carbon black). This segmentation allows separate optimization of each stage - pyrolysis maximizes carbon black recovery while gasification removes impurities, resolving the contradiction between obtaining carbon black from waste and achieving high performance
Solution Approach 2:
The gasification stage specifically targets and extracts harmful inorganic additives and impurities from the pyrolyzed carbon black. By selectively removing these unwanted components through controlled chemical reactions, the process produces high-performance carbon black while maintaining the beneficial properties of recycled material
2Reliability
If multiple processing steps (pyrolysis, demineralization, milling) are used to produce recycled carbon black, then carbon black is obtained from scrap tires, but the process complexity increases and performance improvement is limited
Solution Approach 1:
The patent combines pyrolysis and gasification into an integrated two-stage process that achieves both impurity removal and performance enhancement. This merged approach is more effective than conventional separate pyrolysis followed by mechanical milling, as gasification chemically transforms and removes impurities rather than merely physically separating them
Solution Approach 2:
The process utilizes controlled changes in temperature and atmospheric conditions between stages - pyrolysis occurs at elevated temperatures in inert atmosphere, then gasification follows at different temperature and composition conditions. These parameter changes enable selective chemical reactions that purify carbon black without requiring complex mechanical processing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in carbon black with improved cumulative pore volume, reduced impurities, and better performance as a filler in rubber articles, such as tires, by effectively removing inorganic additives and enhancing structural properties.
Implementation Method 1
pyrolysis of rubber granulate at a temperature of 360 °C to 740 °C and in the absence of oxygen
Implementation Method 2
gasification of the pyrolyzed carbon black-containing particulate at a temperature of 750 °C to 950 °C
Data Source
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AI summary
The present invention relates to multi-layered pyrolysis reactor for the heat treatment of a rubber granulate. The multi-layered pyrolysis reactor has a pyrolysis zone and a gasification.