Waste Rubber Cracking with Composite Catalyst
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Solution Overview
Problem
Current waste rubber cracking technologies require high temperatures (up to 800°C) leading to excessive energy consumption, poor quality carbon black, and environmental pollution due to high sulfur content in gas products, with inefficient recycling and high energy costs.
Innovation Solution
A cracking technology using a catalyst mixture of aluminosilicate, active alumina, zinc oxide, active clay, and kaolin at temperatures between 350°C to 450°C, with controlled temperature differences in the cracking chamber to produce high-quality oil and gas products, and subsequent purification of carbon black.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature cracking (500-800°C) is used to completely crack waste rubber, then cracking completeness is improved, but energy consumption increases significantly and carbon chain is broken down excessively producing more gas products
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperature (500-800°C) to low temperature (200-450°C) range, and introduces catalysts to compensate for the reduced thermal energy, achieving complete cracking at lower energy input
Solution Approach 2:
The patent introduces catalysts (alumina, silica gel, zeolite, or their composites) as intermediaries to facilitate the cracking reaction at lower temperatures, replacing the need for high thermal energy and reducing energy consumption
2Reliability
If high temperature (700-800°C) is used for cracking, then cracking completeness is improved, but product quality deteriorates with excessive gas production and poor carbon black quality
Solution Approach 1:
The patent changes the temperature parameter to a lower range (200-450°C) and uses catalysts to achieve complete cracking, thereby maintaining product quality with appropriate carbon chain length and good carbon black quality
Solution Approach 2:
The catalyst acts as an intermediary that enables complete cracking at low temperatures without excessive carbon chain scission, preserving the quality of oil products and carbon black
3Reliability
If high temperature cracking is used, then cracking completeness is improved, but environmental pollution increases due to high sulfur content in gas products
Solution Approach 1:
The patent changes the temperature to lower range (200-450°C) which reduces the formation of sulfur-containing compounds, and the catalyst further promotes selective cracking that minimizes sulfur release into gas phase
4Reliability
If high temperature (500-800°C) is used for cracking, then cracking completeness is improved, but the heating time and energy cost increase significantly
Solution Approach 1:
The patent changes the temperature profile to lower temperatures (200-450°C) with catalyst presence, which achieves complete cracking faster due to catalytic acceleration of the reaction kinetics
Solution Approach 2:
The catalyst serves as an intermediary that accelerates the cracking reaction rate at lower temperatures, reducing the time required to achieve complete cracking compared to thermal cracking at high temperatures
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
Reduces energy consumption, improves product quality, lowers environmental pollution, and enhances recycling efficiency by producing high-quality oil and gas products while minimizing sulfur content in the carbon black.
Implementation Method 1
adding the rubber mass with the catalyst to the cracking chamber... The main contents and weight percentage of catalyzer are as following: the aluminosilicate is from 35 to 50 wt %, the active alumina is from 15 to 30 wt %, the zinc oxide is from 10 to 20 wt %, the active argil is from 5 to 15 wt % and the kaoline is from 5 to 15 wt %
Implementation Method 2
The cracking temperature is from 350 to 450° C. The rubber mass crack completely in low temperature by using this combinatorial catalyst... the temperature difference in different part of cracking chamber without adding the raw material, should be controlled at or within 10° C
Data Source
AI summary
This invention is about a cracking technology of waste rubber, and the content of this technology is as following: the rubber mass with the catalyst were added in the cracking chamber and the cracking process of the raw material is finished. The main contents and weight percentage of catalyzer are as following: the aluminosilicate is from 35 to 50, the active alumina is from 15 to 30, the zinc oxide is from 10 to 20, the active argil is from 5 to 15, the kaoline is from 5 to 15, the weight ratio of catalyst and rubber is 2-7:1000; The cracking temperature is from 350 to 450° C. The rubber mass crack comparative downright in low temperature by using this combinatorial catalyst, that's because the temperature is controlled between 350 and 450° C., which commendably control the cracking process of the carbon chain of rubber. Moreover, more low carbon chain products can be gained for the symmetrical cracking. Therefore, the emerging ratio of the oil will become higher, the exhaust gas emission will become lower and the eligible emission will really come ture.