Rubber Chip Pyrolysis Resin Production With Monomer Purification
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Solution Overview
Problem
Current methods for recycling rubber articles, such as used tires, face challenges in producing raw materials for new tires without degrading performance, leading to a negative environmental impact due to the presence of harmful by-products from depolymerization.
Innovation Solution
A method involving pyrolysis of rubber chips at controlled temperatures with an increasing temperature ramp, followed by separation and purification of pyrolysis oil to produce a resin-rich effluent, which is then polymerized using an acid catalyst and solvent, resulting in hydrocarbon-containing resins suitable for new tire production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rubber articles are recycled through conventional pyrolysis and depolymerization, then raw materials are produced, but harmful by-products are generated that degrade tire performance
Solution Approach 1:
The patent extracts and separates harmful by-products (tar, soot, unreacted monomers) from the pyrolysis oil through a multi-step purification process involving filtration, washing, and distillation, removing the disturbing elements that would otherwise degrade tire performance
Solution Approach 2:
The patent converts the harmful by-products of pyrolysis into useful products by directing them to separate processing streams where they can be utilized as fuels or further processed into valuable chemicals, transforming waste into resources
2Quantity of substance
If pyrolysis temperature is increased to improve monomer recovery, then more valuable monomers are obtained, but harmful by-products increase
Solution Approach 1:
The patent employs a multi-stage pyrolysis process with progressively increasing temperatures (first stage: 300-500°C, second stage: 500-700°C, third stage: 700-900°C), allowing optimal monomer recovery at each stage while managing by-product formation through controlled temperature ramps and residence times
Solution Approach 2:
The patent divides the pyrolysis process into multiple sequential stages, each operating at different temperature ranges and producing different product distributions, allowing selective recovery of valuable components while isolating harmful by-products for separate handling
3Manufacturing precision
If separation and purification steps are added to remove harmful compounds, then resin quality improves, but process complexity increases
Solution Approach 1:
The patent introduces intermediate purification steps (filtration through activated carbon, washing with acid and base solutions, drying stages) that act as mediators between the crude pyrolysis oil and the final resin product, systematically removing harmful impurities while maintaining process integrity
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 effectively recycles rubber articles into high-quality resins that maintain tire performance while reducing environmental impact by concentrating valuable monomers and minimizing harmful compounds.
Implementation Method 1
A step of pyrolysis of the rubber chips carried out at a temperature between 300 and 900° C. with an increasing temperature ramp, giving a gaseous effluent, a pyrolysis oil and a solid effluent
Implementation Method 2
A step of separation of the pyrolysis oil into at least one raffinate, an intermediate fraction and an extract, the intermediate fraction comprising at least 20 wt % of C4-C12 olefinic monomers
Implementation Method 3
A resin synthesis step comprising a polymerization section supplied at least with the intermediate fraction resulting from step b) and with a solvent, followed by a finishing section producing a polymerized effluent
Data Source
AI summary
A method of production of hydrocarbon-containing resins starting from a charge comprising rubber chips comprises at least one pyrolysis step and a resin synthesis step.