Continuous Pyrolysis Carbon Black Pelletizing
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Solution Overview
Problem
The existing methods for producing starting materials for tire production from pyrolysis of old plastic products face challenges such as inadequate processability of carbon black, high costs, space requirements, and the need for additional additives, which hinder efficient and sustainable tire production.
Innovation Solution
A continuous method using a working device with interconnected grinding and mixing areas, where a solid pyrolysis product is ground and then mixed with pyrolysis binding oil to create an oily dispersion, optimizing particle size and bulk density, and allowing direct use in rubber mixtures without additional preheating or additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If carbon black is produced from recycled plastics via pyrolysis, then recycling rate is improved, but processability is insufficient due to low bulk density and fluffy structure
Solution Approach 1:
The invention changes the physical parameters of carbon black by applying mechanical energy (impact, friction, compression) during pelletization to transform the fluffy, low-density structure into a compact, high-density form with improved processability while maintaining the recycled origin
Solution Approach 2:
The invention introduces binding oil as an intermediary substance during the pelletization process to facilitate the aggregation of carbon black particles into pellets with improved bulk density and handling properties, enabling better incorporation into rubber compounds
2Manufacturing precision
If wet and dry processes are used to improve carbon black quality, then manufacturing precision is improved, but device complexity and space requirements increase
Solution Approach 1:
The invention combines multiple processing functions (drying, grinding, pelletization, binding) into a single integrated extruder device, eliminating the need for separate wet and dry processing equipment while achieving the desired carbon black quality improvement
3Manufacturing precision
If batch processes with separate devices are used, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
The invention implements a continuous processing method where carbon black feedstock is continuously fed into the extruder, processed through grinding and mixing zones, and discharged as finished pellets without interruption, eliminating the downtime associated with batch processing cycles
4Ease of manufacture
If additional additives are used to improve processability, then ease of manufacture is improved, but loss of substance increases and cost increases
Solution Approach 1:
The invention enables the carbon black to self-bind into pellets through mechanical energy input and controlled moisture content, eliminating the need for additional binding agents or additives that would increase material loss and production costs
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
This method produces high-quality starting materials with improved processability, increased recycled content, and reduced energy consumption, enabling efficient and cost-effective tire production with enhanced sustainability and performance.
Implementation Method 1
grinding the solid pyrolysis product in the grinding area to a ground composition
Implementation Method 2
mixing the ground composition with the binding oil composition to an oily dispersion
Implementation Method 3
the pyrolytic decomposition of used tires in a thermochemical conversion process. Here, used tires or other plastic products are treated at high temperatures in the absence of oxygen to break down the organic compounds contained
Data Source
Figure 1
AI summary
The invention relates to a preferably continuous process for producing raw materials for tire manufacturing, comprising a working device comprising: a1) a grinding section with at least one first feed opening, at least one grinding tool for grinding a solid, and at least one first conveying tool for conveying a solid through the grinding section, and a2) a mixing section connected to the grinding section with at least one second feed opening, at least one mixing tool for mixing a dispersion, at least one outlet opening, and at least one second conveying tool for conveying the dispersion to the outlet opening, wherein the process comprises the following steps: v1) feeding a solid pyrolysis product comprising carbon black and/or silicon dioxide into the grinding section via the first feed opening, grinding the solid pyrolysis product in the grinding section to obtain a ground composition,and conveying the ground composition from the grinding area to the mixing area, v2) introducing a binding oil composition into the mixing area via the second addition opening and mixing the ground composition with the binding oil composition to obtain an oil-containing dispersion, and v3) discharge of the oil-containing dispersion from the mixing area through the outlet opening.