Zinc Oxide Recovery From Scrap Rubber Pyrolysis Gas
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Solution Overview
Problem
Existing processes for producing zinc oxide and carbon black from conventional liquid or gaseous feedstocks are inefficient and environmentally problematic, particularly due to low solid yield and undesirable coke and ash content, while alternative feedstocks like scrap rubber materials face challenges in pyrolysis and transformation.
Innovation Solution
A process involving heat treatment of zinc-containing carbonaceous materials, such as scrap rubber, in a gas atmosphere to transfer zinc into the gas phase for deposition as zinc oxide, while forming carbon black, followed by separation and recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional liquid or gaseous feedstocks are used for producing zinc oxide and carbon black, then the production process is established and reliable, but the solid yield is low and the coke and ash content is undesirable
Solution Approach 1:
The invention changes the physical state parameter of the feedstock from liquid/gaseous to solid particulate form. This fundamental parameter change enables direct use of carbonaceous materials like scrap rubber and tire waste, transforming them into viable feedstocks for zinc oxide and carbon black production, thereby significantly improving solid yield while maintaining process reliability
Solution Approach 2:
The process utilizes phase transitions during pyrolysis and vaporization. The carbonaceous material undergoes thermal decomposition (phase transition from solid to gas/vapor), zinc compounds volatilize and then condense to form zinc oxide. These controlled phase transitions enable efficient conversion of solid waste into valuable products with high solid yield
2Reliability
If conventional liquid or gaseous feedstocks are used for producing zinc oxide and carbon black, then the production process is established and reliable, but the coke and ash content is undesirable
Solution Approach 1:
The invention converts harmful waste materials (scrap rubber, tire waste with high coke and ash content) into beneficial products. By using these carbonaceous materials as feedstocks and implementing appropriate heat treatment and separation processes, the harmful waste is transformed into valuable zinc oxide and carbon black products, eliminating the harm while creating economic value
Solution Approach 2:
The invention changes the chemical composition parameters of the feedstock by selecting carbonaceous materials with specific characteristics. By choosing appropriate scrap materials and controlling pyrolysis conditions, the process optimizes the ratio of desired products (zinc oxide, carbon black) versus unwanted byproducts (coke, ash), effectively reducing harmful content while maintaining process reliability
3Adaptability or versatility
If particulate carbon-containing feedstocks are used in entrained flow reactors, then alternative waste materials can be utilized, but the transformation to gaseous components is considerably slower
Solution Approach 1:
The invention applies preliminary size reduction and preparation of particulate feedstocks before entrainment. By pre-processing the carbonaceous materials into fine particles and properly distributing them into the reactor, the transformation speed is significantly enhanced while maintaining the advantage of using diverse waste materials. This preliminary action addresses the slow transformation issue without sacrificing feedstock versatility
Solution Approach 2:
The invention utilizes pneumatic entrainment technology to rapidly accelerate and distribute particulate feedstocks throughout the reactor. The high-velocity gas stream instantly accelerates the particles, achieving rapid heating and transformation rates comparable to liquid feedstocks. This pneumatic approach enables fast transformation while maintaining the flexibility to use various particulate waste materials
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
Efficient production of zinc oxide and carbon black with properties comparable to conventional materials, offering a cost-effective and environmentally beneficial alternative using scrap materials, suitable for applications in vulcanizable rubber compositions and other uses.
Implementation Method 1
heat treating the zinc containing carbonaceous material in a gas atmosphere to thereby transfer at least a part of the zinc contained by the carbonaceous material into the gas atmosphere
Implementation Method 2
the volatilized zinc vapour is then oxidized to form zinc oxide
Implementation Method 3
depositing a zinc oxide material from said gas atmosphere
Implementation Method 4
pyrolyzing the zinc containing carbonaceous feedstock in a gas atmosphere in the reactor to form and/or recover carbon black
Data Source
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AI summary
The present disclosure relates to a process for recovering zinc oxide material from a zinc containing carbonaceous material, and a related process for producing carbon black with recovery of zinc oxide material. The associated products obtainable by these processes, including carbon black and particularly recovered zinc oxide material, and uses and applications thereof, including in particular vulcanizable rubber compositions and articles made therefrom are also described.