WO2011010323A1 - Process containing a step of microwave treatment of shredded tyres - Google Patents

Process containing a step of microwave treatment of shredded tyres Download PDF

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Publication number
WO2011010323A1
WO2011010323A1 PCT/IN2010/000234 IN2010000234W WO2011010323A1 WO 2011010323 A1 WO2011010323 A1 WO 2011010323A1 IN 2010000234 W IN2010000234 W IN 2010000234W WO 2011010323 A1 WO2011010323 A1 WO 2011010323A1
Authority
WO
WIPO (PCT)
Prior art keywords
reactor
pyrolysis
gases
tyre
heating
Prior art date
Application number
PCT/IN2010/000234
Other languages
French (fr)
Inventor
Shriram Iyer
Vishwanathan Ramakrishnan
Original Assignee
B. S. Hydrocarbons Pvt. Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by B. S. Hydrocarbons Pvt. Ltd filed Critical B. S. Hydrocarbons Pvt. Ltd
Publication of WO2011010323A1 publication Critical patent/WO2011010323A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G1/00Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/10Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal from rubber or rubber waste
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B19/00Heating of coke ovens by electrical means
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B49/00Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated
    • C10B49/02Destructive distillation of solid carbonaceous materials by direct heating with heat-carrying agents including the partial combustion of the solid material to be treated with hot gases or vapours, e.g. hot gases obtained by partial combustion of the charge
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B53/00Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
    • C10B53/07Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form of solid raw materials consisting of synthetic polymeric materials, e.g. tyres
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10BDESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
    • C10B57/00Other carbonising or coking processes; Features of destructive distillation processes in general
    • C10B57/02Multi-step carbonising or coking processes
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10Feedstock materials
    • C10G2300/1003Waste materials
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/40Characteristics of the process deviating from typical ways of processing
    • C10G2300/4056Retrofitting operations
    • CCHEMISTRY; METALLURGY
    • C10PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10GCRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2400/00Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/02Gasoline
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00Technologies relating to chemical industry
    • Y02P20/141Feedstock
    • Y02P20/143Feedstock the feedstock being recycled material, e.g. plastics

Definitions

  • Disposed vehicle tyres and other rubber materials have in recent times become a major environmental problem partly because such material is in itself not simply biodegradable and thus currently requires extremely large stores and dumping areas, and partly because combustion of the material to ash in special combustion plants forms environmentally dangerous substances such as sulphur-containing acids and other gases which smell of fuel.
  • the present invention now proposes a new and novel apparatus and process for the pyrolysis of used vehicular tyres.
  • the pyrolysis reactor possesses several unique characteristics which solve the problems of continuous pyrolysis of shredded tyre fragments on a continuing, commercially viable basis.
  • the wasted tyre is shredded into smaller cubes, after the removal of bead wire, steel wire, and nylon cord.
  • the shredded pieces undergo further size reduction through set of pulverizers and the size is brought out to 30 mesh size.
  • the size reduction technique is cost effective and unique where power required for converting tlkg of waste tyre into 30 mesh is only 0.03 kw only which is not accomplished by any prior art.
  • Through a unique pneumatic conveying system automatically it reaches very quickly the jacketed feeding hopper where the raw material powder is Pre-Heated to 150 Degree Celcius.
  • the evolving mixture of hydrocarbon gases are sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter, where all the solid particles are separated and then passes through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form oil and non condensable gases are scrubbed through a packed column scrubber and the purified gas is utilized as fuel for the burner located in the Hot Air Generator.
  • the partially converted material passes through the second stage pyrolysis reactor through an Air Lock System where the temperature of reaction is maintained throughout between 400 to 500 degree Celcius.
  • the evolving hydrocarbon gases are sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter, where all the solid particles are separated and then passes through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form oil and non condensable gases are scrubbed through a packed column scrubber, and the purified gas is utilized as fuel for the burner located in our Hot Air Generator.
  • the first aim of the present invention is therefore to achieve a method which improves the best opportunities for controlling the process of pyrolysis and which makes it possible to recycle significant components such as carbon black and condensed oils from discarded tyres in a more efficient way and with a higher quality.

Abstract

The present invention relates to a method and process for the recovery of Low viscous /low sulphur fuel oil, carbon black and fuel gas conversion of wasted tyres or similar polymeric material by pyrolysis. Discarded tyre is shredded into smaller cubes, after the removal of bead wire, steel wire, and nylon chord. The shredded pieces undergo further size reduction through set of pulverizers cost effectively where the power consumption per ton of waste tyre is only 30 kilo watts per hour. Once the size is brought out to 30 mesh size through a unique pneumatic conveying system and passed on to a specially manufactured Finned Jacketed, Screw Conveyors. The heat energy required for the pyrolysis reaction is supplied by a hot air generator fuelled by the non-condensable gases evolving from the pyrolysis reaction.

Description

PROCESS CONTAINING A STEP OF MICROWAVE TREATMENT OF SHREDDED
TYRES
DETAILED DESCRIPTION OF INVENTION:
Disposed vehicle tyres and other rubber materials have in recent times become a major environmental problem partly because such material is in itself not simply biodegradable and thus currently requires extremely large stores and dumping areas, and partly because combustion of the material to ash in special combustion plants forms environmentally dangerous substances such as sulphur-containing acids and other gases which smell of fuel.
Since the material of which the tyre is composed itself contains a large fraction of substances which are valuable for the petrochemical industry, it has proved interesting to find efficient methods for recovering these valuable substances. Tyres consist of, among other things, approximately 35% carbon black as reinforcement in the walls and wearable surface of the tyre, approximately 60% styrene-butadiene-rubber (SBR) and considerable amounts of oil, together with cord in the form of steel wire and/or glass fiber polyester. All of these substances are valuable and expensive to produce by conventional methods from current raw materials. On the other hand, unfortunately, the substances which are elements of the tyre material and which give the tyre its desirable properties are also primarily those substances that make the possibilities of efficiently recycling the tyre more difficult.
The present invention now proposes a new and novel apparatus and process for the pyrolysis of used vehicular tyres. The pyrolysis reactor possesses several unique characteristics which solve the problems of continuous pyrolysis of shredded tyre fragments on a continuing, commercially viable basis.
Process:
Generally the wasted tyre is shredded into smaller cubes, after the removal of bead wire, steel wire, and nylon cord. The shredded pieces undergo further size reduction through set of pulverizers and the size is brought out to 30 mesh size. The size reduction technique is cost effective and unique where power required for converting tlkg of waste tyre into 30 mesh is only 0.03 kw only which is not accomplished by any prior art. Through a unique pneumatic conveying system automatically it reaches very quickly the jacketed feeding hopper where the raw material powder is Pre-Heated to 150 Degree Celcius.
Due to gravity it passes through an Air Lock System and gets inside the First stage of Pyrolysis. Reactor having Jacketed, Finned, Screw Conveyor system. The Jacket is externally insulated using Ceramic fiber wool. (The temperature range is in between 300 to 400 degree celcius.).The catalyst and hydrocarbon cracking solutions are dosed through a metering device. The evolving mixture of hydrocarbon gases are sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter, where all the solid particles are separated and then passes through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form oil and non condensable gases are scrubbed through a packed column scrubber and the purified gas is utilized as fuel for the burner located in the Hot Air Generator.
Once the first pyrolysis step is completed the partially converted material passes through the second stage pyrolysis reactor through an Air Lock System where the temperature of reaction is maintained throughout between 400 to 500 degree Celcius. The evolving hydrocarbon gases are sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter, where all the solid particles are separated and then passes through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form oil and non condensable gases are scrubbed through a packed column scrubber, and the purified gas is utilized as fuel for the burner located in our Hot Air Generator.
Other reactors where the main body of the reactor rotates like cement kiln, wherein the agitation inside will be too little due to improper material size and rate of heat transfer will be less. Thereby consuming 30% more heat energy. Moreover feeding cannot be continuous. Also the carbon black removal will be consuming lot of time and will be a huge production loss. Few other conventional designs have vertical reactors having an agitator. Here the feeding of non uniform raw material sizes is a big challenge and every time the lid has to be manually opened and closed. It is not safe to open the lid for every batch since entrapped air inside the reactor may cause explosion. Inside the present reactor agitation given to the waste tyre powder is the maximum due to the revolving paddles fixed on the rotating Screw, Thus the heat transfer coefficient rate is the maximum and minimum energy consumption is ensured.
Due to that agitation not only the Catalyst is uniformly mixed but also the rate of pyrolysis is increased. This design is unique where in preheating chambers can also be used as a main Pyrolysis reactor and the two sets of Jacketed Screw Conveyors used as the main reactors in the earlier occasion can be operational as a carbon black powder coolers and conveyors.
The first aim of the present invention is therefore to achieve a method which improves the best opportunities for controlling the process of pyrolysis and which makes it possible to recycle significant components such as carbon black and condensed oils from discarded tyres in a more efficient way and with a higher quality. To be more precise, what is aimed at is a method which makes it possible to control the pyrolysis process based on a schedule which is predetermined, using parameters set depending on economically reducing the size of raw material as a result the cost of size reduction does not exceed 0.07 US$ /kg which is used, and the method according to the invention is based in principle on the introduction of tyre material for continuous treatment in the reactor, that heating of the reactors are carried out using a hot air heated by the scrubbed non-condensable gas evolving from the pyrolysis reaction. The composition and relative amount of the pyrolysis gas which is produced by the reactor is measured, whereby the information obtained is used to control and regulate the process. A second aim of the invention is to make the handling of the processed tyre waste continuously, and in this way make it possible to rapidly and simply exchange the material through the pneumatic conveying system.

Claims

CLAIMS: We Claim;
(1) A unique process for recovery of Low Viscous-Low Suphur-High Pour Point -Fuel Oil by converting wasted tyres are comprises of the following steps - a. Wasted tyre is shredded into smaller cubes, after the removal of bead wire, steel wire, and nylon chord. The shredded pieces undergo further size reduction through set of pulverize and once the size is brought out to 30 mesh size. The size reduction technique is cost effective and unique where power required for converting lkg of waste tyre into 30 mesh is only 0.03 kw only which is not accomplished by any prior art.
b. Transferring the product pieces from a supply into an Air lock system which then gets inside the First stage of Pyrolysis; it reaches the jacketed feeding hopper where the raw material powder is Pre-Heated to 150 Degree Celsius.
Also a provision for heating by a Micro Wave heating system.
c. Transferring the product powder from the first heating zone to a second heating zone in the pyrolysis chamber; heating the product powder between 3OO.degree to 400.degree in the second heating zone,• also a provision given for Micro Wave Heating system .The waves transmitted through a glass/plastic tube reactor, through which the raw material powder is passed through. d. Transferring the product powder from the second heating zone to a third heating zone meanwhile catalyst and Hydrocarbon cracking solutions are dosed through a metering device, heating the product powder at a third temperature in the third heating zone, the third temperature being more than the second heating zone(between 400 to 500 degree eel) the evolving mixture of hydrocarbon gases are sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter where fine particles of carbon black powder is separated from the evolving gases.
(2) The process recited in Claim 1 wherein said all the solid particles are separated and then pass through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form Low Viscous/Low Sulphur oil and non condensable gases are scrubbed through a packed column scrubber and the purified gas is utilized as fuel for the burner located in our hot air generator.
(3) The process recited in Claim 1 wherein said once the first pyrolysis step is completed the partially converted material passes through the second stage pyrolysis reactor through an Air Lock System where the temperature of reaction is maintained throughout between 300 to 400 degree Celsius.
(4) The process recited in Claim 1 wherein said the tyre powders are transferred into pneumatic conveying system by a rotatable feeding vane, radially formed along an inside wall of the feed valve, the flight being constructed to direct the tyre powder from a first end of the feed hopper to a second end of the feed valve as the feed vane rotates.
(5) The process recited in Claim 4 wherein said the evolving hydrocarbon gases have been sucked out of the reactor using a blower and the hot mixture of hydrocarbon gases pass through a cyclone filter, where all the solid particles are separated and then passes through a shell and tube condenser, where the condensable hydrocarbon gases are condensed to form oil and non condensable gases are scrubbed through a packed column scrubber, and the purified gas is utilized as fuel for the burner located ihoour hot air generator.
(6) The process recited in Claim 4 wherein said due to gravity it passes through an air lock system and gets inside the First stage of pyrolysis. Reactor having jacketed, finned, screw conveyor system. The Jacket is externally insulated using Ceramic fiber wool. (The temperature range is in between 300 to 400 degree Celsius.)
(7)The process recited in Claim 3 wherein said the other reactors where the main body of the reactor rotates like a cement kiln, where in the agitation inside will too little due to improper material size and rate of heat transfer will be less. Consuming lot of heat energy 30% more heat energy.
(8). The process recited in Claim 11 wherein said preheating chambers can use as a main pyrolysis reactor and the sets of jacketed screw conveyors used as the main reactors in the earlier occasion can be operational as a carbon black powder coolers and conveyors.
(9) The process recited in Claim 11 wherein said inside these reactor agitations given to the waste tyre powder is the maximum due to the revolving paddles fixed on the Rotating Screw. The heat transfer coefficient rate is the maximum. Due to that agitation not only the catalyst is uniformly mixed but also the rate of pyrolysis is increased.
(10) The process recited in Claim 1 wherein said the evolving non condensable gases after Heating and Generating Hot Air required for the process, is called Flu Gases, passes through a specially designed system for removal of Co2 called Algae Bio Reactor where the Micro organism consumes the entire Co 2 in the flu gas stream, ensuring an emission free atmosphere.
(11) The process recited in Claim 1 wherein said Any waste shredded material like Rubber, Tyre, Plastics, Rice husk, Algae, fed continuously through an extruder fixed at an angle in a Reactor filled with Lead material Kept at a temperature between 250 degree to 1000 degree Celsius, will be PYROLISED and the evolving hydrocarbon gases will pass through a condenser where condensable gases will be converted into fuel oil and non- condensable gases is passed through a gas generator to drive an alternator to generate power. The generating capacity will be in the range of 5kw to 5megawatt.The heating system of the reactor can be Infra Red or Induction Heating. Otherwise we can use the Non condensable gas can be used to heat up the water circulated through a Boiler and generate steam inturn will drive the Turbine and generate Power from (5 K. Watt) to (5 Mega Watt).
PCT/IN2010/000234 2009-07-23 2010-04-12 Process containing a step of microwave treatment of shredded tyres WO2011010323A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN1697/MUM/2009 2009-07-23
IN1697MU2009 2009-07-23

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9441113B2 (en) 2013-07-18 2016-09-13 Ut-Battelle, Llc Pyrolytic carbon black composite and method of making the same
US9884804B2 (en) 2016-05-24 2018-02-06 Ut-Battelle, Llc Surface treated carbon catalysts produced from waste tires for fatty acids to biofuel conversion
US9941058B2 (en) 2015-05-26 2018-04-10 Ut-Battelle, Llc Flexible and conductive waste tire-derived carbon/polymer composite paper as pseudocapacitive electrode
CN108018062A (en) * 2016-11-03 2018-05-11 江苏林达智思环保科技有限公司 Waste rubber cracking method and system
US10320000B2 (en) 2013-07-18 2019-06-11 Ut-Battelle, Llc Pyrolytic carbon black composite and method of making the same
WO2019202387A1 (en) * 2018-04-18 2019-10-24 Александр ТЕПЛИЦКИЙ Method of obtaining carbon-containing material from recyclable tires and/or rubber products

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9441113B2 (en) 2013-07-18 2016-09-13 Ut-Battelle, Llc Pyrolytic carbon black composite and method of making the same
US10320000B2 (en) 2013-07-18 2019-06-11 Ut-Battelle, Llc Pyrolytic carbon black composite and method of making the same
US10985372B2 (en) 2013-07-18 2021-04-20 Ut-Battelle, Llc Pyrolytic carbon black composite and method of making the same
US9941058B2 (en) 2015-05-26 2018-04-10 Ut-Battelle, Llc Flexible and conductive waste tire-derived carbon/polymer composite paper as pseudocapacitive electrode
US10460881B2 (en) 2015-05-26 2019-10-29 Ut-Battelle, Llc Flexible and conductive waste tire-derived carbon/polymer composite paper as pseudocapacitive electrode
US9884804B2 (en) 2016-05-24 2018-02-06 Ut-Battelle, Llc Surface treated carbon catalysts produced from waste tires for fatty acids to biofuel conversion
CN108018062A (en) * 2016-11-03 2018-05-11 江苏林达智思环保科技有限公司 Waste rubber cracking method and system
WO2019202387A1 (en) * 2018-04-18 2019-10-24 Александр ТЕПЛИЦКИЙ Method of obtaining carbon-containing material from recyclable tires and/or rubber products
KR20200141082A (en) * 2018-04-18 2020-12-17 알렉산더 텝리츠키 How to obtain carbon-containing materials from recyclable tires and/or rubber products
US11084937B2 (en) 2018-04-18 2021-08-10 Alexander Teplitsky Method of obtaining carbon containing material from recyclable tires and rubber products
KR102453460B1 (en) 2018-04-18 2022-10-11 알렉산더 텝리츠키 Methods for obtaining carbon-containing materials from recyclable tires and/or rubber products

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