Tire Pyrolysis Direct Heating Flue Gas
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Solution Overview
Problem
Existing tire pyrolysis methods suffer from high energy losses and reduced quality of carbon black due to indirect heating, leading to decreased yield and quality of hydrocarbons.
Innovation Solution
Direct heating of tires with flue gases enriched with steam in a crossed counterflow configuration within a thermally insulated pyroliser, allowing for efficient pyrolysis at 600-950°C, followed by separation and reuse of steam to minimize cracking and enhance product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect heating through pyroliser wall is used, then tires are heated to pyrolysis temperature, but energy losses increase and carbon black quality decreases
Solution Approach 1:
The patent introduces flue gases as an intermediary heating medium that directly contacts the tires through gas channels, replacing the indirect wall-based heating. The flue gases transfer thermal energy directly to the tire surface, eliminating the thermal resistance of the pyroliser wall and significantly reducing energy losses while achieving uniform pyrolysis temperature distribution.
Solution Approach 2:
The patent replaces the thermal conduction mechanism (heating through solid wall) with convective heat transfer (direct gas-to-tire heating). By substituting the solid-wall heat transfer path with direct flue gas contact, the system achieves more efficient energy transfer and better temperature control, resolving the contradiction between energy efficiency and heating effectiveness.
2Temperature
If pyroliser wall is heated to high temperature, then tires reach pyrolysis temperature, but hydrocarbon cracking increases and product quality lowers
Solution Approach 1:
The flue gases serve as a controllable intermediary that transfers heat directly to tires at lower temperatures than required for wall heating. This allows precise temperature control in the range of 400-950°C, preventing excessive wall temperatures that would cause hydrocarbon cracking, while still achieving effective pyrolysis through direct gas-to-tire heat transfer.
Solution Approach 2:
The patent changes the heating parameter from wall temperature (indirect heating) to gas temperature (direct heating). By controlling the flue gas temperature and residence time, the system achieves effective pyrolysis at lower overall temperatures, preventing thermal degradation and hydrocarbon cracking, thus improving carbon black quality while maintaining pyrolysis efficiency.
3Loss of energy
If direct heating with flue gases is used, then energy efficiency increases, but temperature control precision must be maintained to prevent cracking
Solution Approach 1:
The patent implements temperature monitoring and control of flue gases to ensure they remain within the optimal range for direct heating. By monitoring gas temperature and adjusting combustion conditions, the system maintains efficient energy transfer while preventing excessive temperatures that would cause hydrocarbon cracking, thus resolving the contradiction between energy efficiency and temperature control precision.
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 reduces energy expenses, minimizes product cracking, and produces high-quality carbon black suitable for the rubber industry while recovering steam for further use, enhancing overall energy efficiency and product yield.
Implementation Method 1
tires are heated directly by flue gases in crossed counterflow to temperature of 600-950°C
Implementation Method 2
The heat, necessary for the pyrolysis is supplied by flue gases obtained at pyrolysis gas burning
Implementation Method 3
flue gases being enriched with steam with concentration 15-40%, preferably 18-30%
Implementation Method 4
The heat, necessary for the pyrolysis is supplied by flue gases obtained at pyrolysis gas burning
Implementation Method 5
The mineral oils are separated at the cooling of the pyrolysis gas
Implementation Method 6
one of the streams is cooled additionally to temperature of 80-100°C, part of the mineral oils contained in that stream condensing as a result
Implementation Method 7
the pyroliser is thermally insulated
Data Source
AI summary
The present invention relates to a method and apparatus for waste tyres pyrolysis wherein whole tyres are directly heated with flue gases from the combustion of pyrolysis gases, in a tunnel type furnace. The process produces thermal energy, carbon black and mineral oil; the cooled flue gases are cleaned from sulfur oxides before released into the atmosphere.