Scrap Tires into Diesel Fuel

The proposed novel technology for thermal processing of wasted rubber (worn tires, out-of-use rubber pieces, etc.) into a fuel mix (subsequently cut into a few fuel types, similar to masut 40, masut 100, furnace oil, and fuel suspension) and technical carbon is underlied by the studies of thermolysis of organic wastes and new technical solutions.
 
The process technology is of close nature, i.e. there is no release of decomposition products to the environment. The essence of the process consists in thermolysis (heat decomposition) of a waste matter in a special (ubiquitous and inexpensive) heat-carrying medium. With this, the process is environmentally safe, fire- and blast-safe, as it is run at low temperature and virtually at the atmosphere pressure.

Scrap rubber and waste processing can be designed as an alternative technology, either with activated carbon or, as another option, technical carbon being the ultimate product.
This proposal comprises designing of a recycling plant for waste rubber (worn tires, other kinds of scrapped rubber and wasted general mechanical rubber).

The designing is performed in strict compliance with the current international standards and regulations. The design work is accomplished in 12 weeks.

The design work comprises a set of project documents, as follows: a custom-made specification, a main unit/component list, a heating diagram, a waste/scrap feed diagram, a list of control instrumentation, a general arrangement drawing (layout), a general assembly/working drawing, a general electric circuit drawing, a technical specification, and an explanatory note.

A log book comprises: general documentation, a general arrangement drawing (layout), a pipeline layout, a heating diagram, a waste/scrap feed diagram, a main unit/component list, a cutting list, a list of control instrumentation, a general description of the plant installation.

Electrical layouts and drawings are: general schemes, circuitry layouts and drawings, electrical equipment assembly layouts, assembly drawings, and installation specifications.

Executive paperwork on the equipment: assembly layouts and sectional drawings, a waste/scrap feed diagram, a heating diagram, a cutting list, a general description of the unit operation.

Technical and economic advantages

Processing of wasted rubber materials goes by the following order. The waste materials (worn tires) are chopped to 300 - 400 mm pieces; then the chopped materials are fed in 300-kg batches to the charge casks; the casks are automatically conveyed to the charging chamber; the materials are then supplied from the charging chamber to the thermolysis reactor, to be exposed to heating by a heat-carrying medium (prolate and inexpensive) during 180 minutes (at this processing stage the rubber waste materials are thermally decomposed into gaseous and solid products); the gas products are then supplied from the thermolysis (reactor) chamber to the separators, to be cooled; the condensed fluid flows into the separation unit, in which the oil products of thermolysis (masut 40, masut 100 and furnace oil) are separated and supplied to the collector unit, whereupon the remainder of the condensate is filtered and fed back to the processing cycle, while the noncondensable (combustible) gas is burnt in the furnace to provide the heat supply for the processing.

The solid products are conveyed to the discharge chamber to be cooled to 100 - 170°C, whereupon they are unloaded into the sorting machine that separates metal from carbon residue.

Carbon residue (technical carbon) is either loaded to the bunker, or conveyed to a special furnace (a standard equipment piece) for production of activate carbon; the metal materials are pressed to slabs and transported to the metal store.

Monitoring and control of the process parameters (throughput rate, outcome, temperature, heat-carrier flow rate, thermolysis time, electric power and heat consumption) are performed by the system equipped with a set of control, measuring and automation devices.

The process is fully automated.

See movie here - 19 MB

For details contact: plastictires@gmail.com