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
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
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
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
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
(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