A fully continuous 2,000 t/d tire pyrolysis plant is a technologically advanced, large-scale solution addressing the global challenge of end-of-life tire (ELT) management.
These plants align with circular economy principles by converting waste tires into valuable products tire pyrolysis oil (TPO), syngas, recovered carbon black (rCB), and steel while integrating power and co-generation systems to maximize resource efficiency and minimize environmental impact.
This model is increasingly favored due to tightening environmental regulations, the need for sustainable energy, and the economic opportunity presented by resource recovery.
The industry is driven by increasing tire waste, stricter environmental regulations, and the demand for alternative energy and materials. Plants are designed to comply with international standards such as those of the World Bank Group and International Finance Corporation (IFC), ensuring robust environmental, social, and financial performance.”
Converts all pyrolysis oil (297,000 t/y) into 1,398,276 MWh of electricity annually, with >35% electrical efficiency and >50% total energy utilization far surpassing industry norms.
Advanced emission controls (SCR, wet scrubbers, activated carbon filtration, real time CEMS) ensure stack emissions and effluent quality not only meet but exceed IFC EHS Guidelines.
- Annual GHG Reduction: 660,000 tCO₂e (via landfill diversion, fossil fuel displacement, and material recovery).
- Carbon Credits: 660,000 VCUs/year (Verra VCS certified).
- 20-year Cumulative Reduction: 13.2 million tCO₂e.
- Methane Avoidance: 132,000 tCO₂e/year from landfill diversion.
- Fossil Fuel Offset: 839,000 tCO₂e/year via renewable electricity.
- Virgin Material Displacement: 581,000 tCO₂e/year (carbon black, steel recovery).
Converting Waste into Valuable Resources The global environmental challenge of waste tire disposal has found an innovative solution through advanced Full Continuous Tire Pyrolysis Technology. Our cutting-edge thermal decomposition process represents a revolutionary approach to transforming millions of discarded tires into valuable resources while addressing critical environmental concerns.
Advanced Full Continuous Tire Pyrolysis Technology operates through a sophisticated thermal decomposition process in a precisely controlled oxygen-free environment at temperatures ranging from 300-600°C. This innovative approach breaks down the complex polymeric structure of waste tires at the molecular level, converting them into valuable products through carefully orchestrated chemical reactions.
The process begins when tire materials reach approximately 300°C, initiating the decomposition of volatile substances such as oils, plasticizers, and additives. As temperatures increase, natural rubber components decompose between 300-450°C, followed by synthetic rubber degradation at 400-500°C. This staged thermal breakdown ensures optimal resource recovery while maintaining process efficiency.
Our advanced pyrolysis technology achieves remarkable energy recovery efficiency of 70-80%, positioning it as a leader in sustainable waste-to-energy conversion. This exceptional efficiency stems from innovative heat recovery systems that capture, and reuse energy generated during the pyrolysis process. The technology incorporates hot air circulation heating systems that utilize non-condensed gases produced during pyrolysis, creating a self-sustaining energy loop that minimizes external energy requirements.
The integrated system design enables the capture of syngas (synthesis gas) produced during decomposition, which is recycled back to fuel the pyrolysis reactor itself. This closed-loop energy system significantly reduces operational costs while maximizing the conversion of waste tire materials into useful energy resources.
The advancement to full continuous Full Continuous Tire Pyrolysis Technology represents a paradigm shift from traditional batch processing systems. Our continuous operation systems eliminate the downtime associated with batch processing, enabling 24/7 operation with uninterrupted feedstock processing. This technological breakthrough increases throughput by up to 200% compared to conventional batch systems while maintaining consistent product quality.
The continuous feeding and discharge system utilizes automated screw conveyors and weighing systems that ensure precise material flow control. Advanced PLC (Programmable Logic Controller) systems monitor and control every aspect of the process, from temperature regulation to material handling, requiring minimal human intervention.
Advanced Full Continuous Tire Pyrolysis Technology transforms waste tires into four primary valuable products. Pyrolysis oil comprises 35-45% of total output and serves as an excellent alternative fuel with a high calorific value of 35-45 MJ/kg. This oil can be refined further into diesel-grade fuel or used directly in industrial heating applications.
Recovered carbon black represents 30-40% of output and provides a sustainable alternative to virgin carbon black in rubber and plastic manufacturing. The steel wire recovery system captures 8-12% of tire mass, yielding high-quality steel suitable for metallurgical applications. Additionally, the process generates combustible gas (10-15% of output) with calorific values up to 33 MJ/Nm³, which powers the pyrolysis system itself.
The environmental benefits of advanced Full Continuous Tire Pyrolysis Technology extend far beyond waste reduction. The process prevents the accumulation of waste tires in landfills, where a single tire can take over 1,000 years to decompose naturally. By operating in an oxygen-free environment, the technology eliminates the release of toxic emissions associated with tire incineration.
Advanced emission control systems ensure all exhaust gases meet stringent environmental standards including EU EEA and US EPA requirements. Multi-stage gas purification systems incorporate desulfurization towers, electrostatic precipitators, and activated carbon filters to capture and neutralize any potential pollutants.
Modern tire pyrolysis plants incorporate sophisticated automation technologies including PLC control systems, SCADA interfaces, AI and IoT connectivity. These intelligent control systems enable real-time monitoring of critical parameters such as temperature, pressure, and gas composition. Advanced sensors and thermocouples provide continuous feedback to PID control algorithms that automatically adjust process conditions for optimal performance.
The integration of artificial intelligence and machine learning capabilities enhances process optimization by predicting maintenance needs, optimizing energy consumption, and improving product quality consistency. Remote monitoring capabilities allow operators to oversee multiple facilities from centralized control centers, reducing operational costs and improving safety.
Advanced Full Continuous Tire Pyrolysis Technology represents more than just waste management; it embodies the principles of circular economy by transforming waste streams into valuable resources. Technology’s continuous improvement through research and development ensures it remains at the forefront of sustainable waste-to-energy solutions.
Integration with emerging technologies such as RFID tracking for tire lifecycle management and AI-driven process optimization positions this technology as a cornerstone of future sustainable manufacturing. As global environmental regulations become increasingly stringent, advanced Full Continuous Tire Pyrolysis Technology provides industries with a proven, profitable pathway to environmental compliance while generating valuable products from waste streams.
The convergence of environmental necessity, technological innovation, and economic opportunity makes advanced Full Continuous Tire Pyrolysis Technology an essential component of sustainable industrial development. Through precise thermal control, intelligent automation, and comprehensive resource recovery, this technology transforms the environmental challenge of waste tire disposal into a valuable opportunity for sustainable resource generation.