Pyrolysis Reactor with Steam or CO2 for High-Surface rCB
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Solution Overview
Problem
Existing methods for recycling end-of-life tires (ELTs) are inefficient, failing to produce high-quality recovered carbon black (rCB) suitable for full replacement of virgin carbon black in tire carcass and tread, leading to significant environmental hazards and waste accumulation.
Innovation Solution
A reactor system that thermally converts ELT materials in an oxygen-free atmosphere, using water steam and/or CO2 gas to control temperature and reaction conditions, producing high surface area and structure carbon black by creating micro-, meso-, and macropores, enhancing rCB quality for rubber reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing pyrolysis methods are used to recycle ELTs, then some materials can be recovered, but the quality of recovered carbon black is insufficient for full replacement of virgin carbon black in tire tread applications
Solution Approach 1:
The patent applies parameter changes by controlling temperature profiles (heating to 400-800°C then maintaining at 700-950°C), adjusting residence time (0.5-5 hours), and modifying atmospheric composition (introducing water steam or CO2) to transform the pyrolysis process and produce high-quality rCB suitable for tire tread reinforcement
Solution Approach 2:
The patent utilizes porous materials by introducing water steam or CO2 gas during the second processing zone to create micro-, meso-, and macropores in the carbon black structure, enhancing surface area and reinforcement properties for high-demand rubber applications
2Object-affected harmful factors
If ELTs are disposed of in landfills, then waste accumulation occurs, but environmental hazards are minimized compared to uncontrolled burning
Solution Approach 1:
The patent converts the harmful waste ELTs into beneficial products through pyrolysis, transforming environmental hazards into valuable recovered carbon black, oil, and gas that can be reused in rubber and plastic applications, eliminating the need for landfilling
Solution Approach 2:
The patent implements discarding and recovering by systematically processing ELTs to extract and recover valuable materials (carbon black, oil, gas, metal) that can be reused, preventing waste accumulation while eliminating environmental hazards
3Adaptability or versatility
If advanced pyrolysis technologies are used, then rCB can replace vCB in tire carcass, but not in tire tread due to insufficient quality
Solution Approach 1:
The patent uses parameter changes by implementing a two-zone temperature control system with specific residence times and atmospheric conditions (water steam or CO2 introduction) to develop the micro-, meso-, and macropore structure necessary for rCB to meet tire tread reinforcement requirements
Solution Approach 2:
The patent applies porous materials principles by intentionally creating micro-, meso-, and macropores in the rCB structure through controlled introduction of water steam or CO2 during processing, achieving the structural quality needed for high-demand tire tread applications
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 system achieves high-quality rCB production, enabling its use in tire carcass and potentially tread, with improved yield of gaseous and liquid products, addressing environmental waste and meeting regulatory demands for recycled materials.
Implementation Method 1
conversion of tire-derived materials into high surface area and high structure carbon black, liquid and gaseous products
Implementation Method 2
at least one water steam injector configured to introduce water steam into the interior of the second processing zone
Implementation Method 3
at least one CO2 gas injector configured to introduce CO2 gas into the interior of the second processing zone
Data Source
AI summary
A reactor for converting polymer containing materials, such as rubber, including tire rubber, or pyrolyzed rubber, including pyrolyzed tires, or plastic, including pyrolyzed plastic, into output products includes a feed section, a central heating-zone section having a first processing zone configured to heat the material to a first temperature and a second processing zone configured to maintain the material at the first temperature, a discharge section, means for withdrawal of vaporized short-chain hydrocarbon compounds being formed, at least one water steam injector configured to introduce water steam into the interior of the second processing zone and positioned at the bottom of the second processing zone, or at least one CO2 gas injector configured to introduce CO2 gas into the interior of the second processing zone and positioned at the bottom of the second processing zone, or both, and heating means for heating the material. The reactor can include at least one more reactor thereby forming a modular system having a battery of side-by-side positioned reactors.