The specialty of SGI Technology is a “turn-key-principle” construction of customized, high- quality, modern, efficient, environment-friendly and profit-generating pyrolytic tire recycling facilities, whos components are CE certified and manufactured in EU countries. Our “NexGen” tire recycling line is designed to produce 20 - 210 tons per cycle of high-quality synthetic fuels, carbon black, steel and bitumen (heavy oil).

The following outlines the major milestones for building a customized NexGen pyrolytic tire recycling facility by SGI Technology:

• Understanding local regulations is crucial; if needed, we can aid in acquiring pyrolysis licenses and obtaining the necessary permits from local authorities.
• Identifying the requirements of the final output (recycled product) and proposing an optimal production solution accordingly.
• Identifying the type, accessibility, and feasibility of (acquiring) raw materials (car tires, plastic waste, waste oils)
• Proposing an optimal production capacity.
• Visiting micro-location, assisting in planning / proposing a plant layout based on production and operational requirements.
• Proposing a solution for all other technical requirements, such as truck access, water and electricity requirements, etc.
• Consultation regarding required skilled labor, expert qualifications, and staff training programs.
• Planning the storage, transportation, and if required sales of final products
• Assistance in preparing a proposal for public / investor co-funding
• Assistance in acquiring permits and certification, if required
• Complete installation, commissioning of NexGen facility, and training the local staff.
• After the successful installation and testing of the NexGen facility, our expert staff remains in the plant premises until local staff is fully trained and ready to take over all operations

Types of products and output ratio of the standard “NexGen” pyrolytic recycling of waste tires

Carbon Black Is a product of the future. SGI Technology, in close cooperation with a German company RCB Nanotech Gmbh and research facility Fraunhofer institute, is enriching Carbon Black and reaching up to 98% purity. 

The following is a mass balance, or output ratio based on 1000 kg of pyrolytically processed waste tires (Note that the mass balance of final products can fluctuate from 1% to 10%, depending on the shredding quality, the quality of raw materials, process operating quality, etc.)

• Pyrolytic oil – 45%*
• Carbon black (35%),
• Steel (10%);
• Methane gas CH4 (10%);
  *During the pyrolysis process, the first fuel-output is pyrolytic oil – 45%. Further processing of pyrolytic oil separates the components as follows (as total of 45%):
• Petrol (5%);
• Diesel (35%);
• Bitumen (heavy oils) (5%);

However, note that producing pyrolytic oil is very cost effective and marketable as a final product. It is an ideal fuel for thermal energy, marine fuel, and fuel for power generators - for electric energy generation. (Example: 1 liter of pyrolytic oil = 9.81 kW of electricity).

Pyrolytic oil can also be used for mixing the asphalt base.

SGI Technology - NexGen pyrolytic tire recycling (process summary)

1. Cycle of operation: The entire facility can operate 24 hours per day; one-time maintenance every three months.

2. Raw materials: The raw materials do not need to be cleaned or classified, but have to be appropriately shredded. The production efficiency is significantly higher if shredded 5-7 cm / pcs

A front loader moves the tires to fill the kiln-feed hopper, movable conveyor or gryfer (Photo 3).

This hopper, conveyor or gryfer automatically discharges tire shreds to the kiln-feed system.

3. Cracking and pyrolysis: Due to the specially designed structure of the fractionation tower, in different temperature stages, raw materials fractionate into products of different densities by the reversal process in the fractionation tower (Photo 4).




High density products return to the reactor and react again automatically by the inside and outside backflow function of the fractionation tower. Finally, once the qualified density of the product is obtained, it will directly access the next technological process. The unqualified products will reverse back to the cracking and pyrolysis reactor by the fractionation tower, until qualified. The plastic waste and rubber waste are fed into the cracking and pyrolysis reactor by the automatic feeding machine, heated up to 120—400 degrees until it reacts with the high-density oil catalyst flowing in the bottom of the fractionation tower; molecules crack into CH4 to C20H42, the gas flows up.

n(C+H2+C2H4+C2H6+C3H8+C3H6+C4H8+C4H10+C4H10+C5H12+C6H6+C7H8……
+C12H24+C12H26+……C20H40+C20H42+……+C25H52,)
C6H14—C12H24 are components of petrol, C12H26—C20H42 are components of diesel, CH4—C4H10 are components of combustible gas, flowing into the fractionation tower with a backflow device

4. Heating system: Using a recycle transfer reverse system, the equipment needs external energy in the first 45-60 minutes. The produced quantity of heat cycles heats the reactor, it will not discharge directly, and the temperature of the discharge flue is the same as the normal temperature. The produced oil can heat the system by fuel burner directly; the produced combustible gas can heat the system directly by normal pressure environmental burning device (Photo 5).





Redundant gas can be compressed and the storage in the gas tanks to generate electricity in the second stage of the project.

5. Redundant gas can be compressed and the storage in the gas tanks to generate electricity in the second stage of the project.
 

Fractionation: produces green thermal oil according to different density by reverse process reactor and fractionation tower.
 

Cooling: micro-molecule carbon chain gas liquefaction.

Oil water separation: separates different products according to physical property of the liquid.

Oil water separation: separates oil and gas according to solubility.

Online oil refining: refining and purifying the oil according to the chemical property of the green thermal oil.

Online oil reconciling: neutralizing treatment according to the chemical property of inorganic substance.

Waste gas recycling: non-liquefied combustible gas burns fully with oxygen as per scientific ratio by normal pressure environmental burner and anti-backfire device after purifying, finally there is no smoke discharging (Photo 6).



Waste residues treatment: Due to a specific reverse process, some water may appear in green thermal oil. That water has been treated in accordance with the EU Standard regulation for waste water disposal (collector system for waste water treatment) 

Waste water recycling: after the neutralizing treatment, it can produce standard water by special filtration and multi-stage adsorption filtration treatment; it can also recycle cooling water for the equipment. It is self-sufficient, there is no need for external water and it saves water.

Crude carbon black treatment (for waste tires): grinding, magnetic selection, winding selection and water selection by carbon black refining machine to produce N330 and N660 standard carbon black, it also can be the filler for producing rubber tires etc.

In order to simplify usage of the carbon black, we have designed a pressing machine to produce briquettes (Photo 8)



6. Gas products produced during the reaction:
H2S、SO2、Cl2、CO、NO

1. H2S and Cl2 react to generate S and HCl
2. H2S and SO2 react to generate S and H2O
3. HCl and water react to generate HCl
4. HCl and NaOH react to generate NaCl and H2O
5. CO and NO react to generate CO2 and N2 discharge into the air chamber filtrating system directly.
6. Nitrogen (N2）is discharged directly into the air chamber filtrating system. +
7. Ammonia（NH3）and hydrogen chloride (HCl）react and generate salt ammonium chloride（NH4Cl）

8. Gas processing reaction equation:

9. Dealing with residues: Residues mainly include carbon products and steel wires. Residues will be discharged to carbon black dispose warehouse through special discharging system equipped itself. By fabrication processing of carbon black process equipment, go through magnetic selecting, grind, there is no waste water, waste residues and waste gas produced.

10. Flow direction of gas: The oil and waste gas produced through cracking and pyrolysis of tires via layer upon layer processing of the fractionation tower, by means of molecular motion principle and molecular diffusion principle, and then move into oil condensation system. Oil condensation system is a multistage condensation point reducing system. The oil products coming from the multistage condensation point reducing system hang together and enter into the procedure of oil-water sedimentation. Through the condensation system, non-liquefied gas gets through a gas buffer to the gas physicochemical index treating system. After through the processing of gas physicochemical index treating system, there are only non-liquefied and non-polluting combustible gases methane, ethane, propane, butane.

These gases pass through gas environmental burners back to the cracking and pyrolysis heating area to provide heat resource for raw materials. (Photo 9)

Operating requirement

(for up to 60 tons production capacity per cycle)

1. Facility requires 220V 50~60Hz、380V 50--60Hz.
2. Total installed power 290 KW (including shredding machine with conveyors).
3. Floor space is about 1500㎡.
4. Water consumption is about 18 cubic meters for one-time cooling system use only.
5. Overhaul once every 6 months, mainly examine and repair the looseness of the screws, air leakage of sealing gaskets, negotiability inside the system, degree of cleanliness, etc. The span life of other parts, can be used up to 16 years period.

*Note: The analysis of carbon produced by pyrolysis system including carbon black and other additives used in manufacturing tires, is as follows:

Pyrolysis exhaust gas

Below is an estimate of the gas products of combustion, if all of the unliquefied combustible gas is burned in a combustion chamber with a burner temperature of 982 °C (temperature of the reactors and chamber remains the same and does not exceed 400°C), with no treatment of the sulphur compounds. This is only meant as an approximation to assist the owners in determining what emissions treatment may be necessary for their specific location. We would work with the Site engineering company that is responsible for environmental permitting to provide specific information pertaining to the actual process utilizing the pyrolysis exhaust gas.

System description

The owner of the technology is responsible for the installation and commissioning of the entire equipment. The equipment includes a single set processing production line, processing maximally from 20 - 210 tons of tires per cycle, and it is designed to operate at a maximum of 25 cycles per month.
 

The equipment is maintained every six months.
 

1. Feeding system A: the receiving of the cracking tires; it will transfer to the automatic feeding system 2 through the inclined conveyor 1, and send to the cracking and pyrolysis reactor 3 via automatic feeding system.
   
    
2. Heating system B: Burning system with natural gas, which includes the burners, pre-piped natural gas rack, combustion air fan with air control valves for each zone, and a burner management system. The system will include multiple burners in 3 zones. The burner’s ratio is from 0.24 to 0.59 Gigajoules per hour between zones. Each burner is equipped with its own flame igniter and flame detector to keep the remaining burners in burning mode.
   
    
3. Discharge system C: One enshrouding 304 l stainless steel discharge hood, complete with openings, is provided for trammel discharge of char, oversized discharge of metal wire, and kiln exhaust gas. The hood will be mounted on a structural support, include explosion relief vents, one pneumatically operated double flap valve to mate with char product discharge flange and a discharge chute for recovered steel to the discharge hoe, unit no. 301. The external surfaces of the discharge hood are field insulated. (Photo 10)
   
   
   
   (Carbon black discharging device)
   
    
4. Oil condenser D: Material quality is Stainless Steel. We will supply an oil condenser system, which is a multi-stage condenser system. The condenser is designed to reduce the fractionation tower exit gas temperature from 190 to 600° C.
   
    
5. Oil refining process system E: Material quality is stainless steel of the highest quality. The oil refining process system will automatically treat discoloration, deodorant and cast colloid of oil product produced from the cooling system.
   
    
6. Desulphurization and dealcoholization system F: Material quality is chrome-nickel steel; dislodges the sulphur composition in the oil product.
   
    
7.  The physical and chemical index of gas treating system G: Material quality is produced exclusively for NEXGEN purposes.
   
    
8. Chimney H: The chimney discharges water vapor into the atmosphere which is produced in the procedure of cracking and pyrolysis heating and gas burning in the environmentally friendly burner. (Photo 11)
   
   
   
    
9. Pressure buffer system I: Material quality is carbon steel produced exclusively for NEXGEN purposes. Relieves the pressure, lets the complete process take place under security and ordinary pressure.
   
    
10. Oil physical treatment system J: Material quality is synthetic steel produced exclusively for NEXGEN purposes.
    
     
11. Computer-controlled automatic system K: Together with the PLC hardware (Siemens) and the personal computer MM I, the software will perform the control logic and provide the interface for operator control, data handling, generation reporting, monitoring and alarming. (Photo 12)
    
    
    
    
    (NexGen mobile controlling system)
     
12. Gas anti-backfire apparatus L: This apparatus uses steel produced exclusively for NEXGEN purposes; the main function is to prevent gas reversal.

Gas emissions

It is important to note that all exhaust systems have their own filters and emission-measuring devices; all emissions created by the pyrolysis cycle of the NexGen facility are significantly lower than the limits set by EU standards.

Quality Assurance (QA) and Quality Control (QC):

 

Quality Assurance means the quality in the processes by which products are developed. Quality Control ensures the quality of the final product.

To determine compliance with all national standards (of a specific market), we are prepared to take part in any shape and form in an in-house or independent laboratory testing for quality assurance and quality control.