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Continuous close-loop fast pyrolysis technology for processing plastic, organic and end-of-life tires (ELT) waste

Country of Origin: Cyprus
Reference Number: TOCY20190618001
Publication Date: 18 June 2019

Summary

A Cypriot engineering SME, specialized in waste management offers an innovative recycling solution for the plastic, organic and end-of-life tires (ELT) waste, based on the solid-to-solid heat transfer.The solution can be customized according to client needs. 
Manufacturers of recycling equipment, recycling and engineering companies, municipalities and large industrial waste producers are sought for joint venture or commercial agreement with technical assistance.

Description

Cypriot engineering SME specializing in waste management solutions is offering a continuous close-loop fast pyrolysis technology for processing plastic, organic, and end-of-life tires (ELT) waste. The company represents R&D entities and manufacturing corporations in Russia, specialized in waste management.
Currently, on the market, there are 2 technology types for processing plastic, organic, and end-of-life tires (ELT) waste:
- Batch technology: the waste is loaded into the vessels, which are heated then opened, emptied and loaded again. When opened, these vessels emit pollutants and toxins into the atmosphere. The process takes several hours, sometimes days.
- Continuous technology: the rubber waste is fed into the rotary kiln, where it is heated in presence of inert gases. This process is long (several hours to one day) and the waste is not always 100% treated. These kilns’ environmental performance is quite often below standards.

The SME’s technology is based on fast Pyrolysis process, where the rubber and/or plastic waste matter thermal destruction takes place in a fraction of a second in oxygen-deprived environment, followed by rapid exposure and fast cooling to prevent pollutants re-formation. This allows minimizing the secondary reactions effect, when Pyrolysis products react with each other at high temperatures.

The rubber and plastic waste thermal treatment (Pyrolysis) technology aims to obtain synthetic gas and liquid (“Green Oil” later refracted into diesel/petrol) products from the subject waste plus any Hydrocarbons (HC) containing organic matter such as ELT, chip wood and sawdust, petrochemical/oil sludge and other waste, lignite, poultry farm refuse, thinners and paint refuse etc.
As a prerequisite, the ELT and other waste needs to be shredded to pieces no bigger than 100 mm. Bead wire separation is not essential.

In this process, heat transfer is performed from one solid body to another. At high temperatures and lack of oxygen, an organic particle passes from one form to another, while experiencing an entropic explosion (breaking of molecular bonds), accompanied by release of a large amount of thermal energy. Then, atoms form new molecules, with new substances having properties different from the source materials’ ones.
For the process temperature modes, two main options are offered:
1. Mid range temperatures, resulting in mostly (up to 80%) liquid products a.k.a. synthetic oil (subject to waste mix feedstock properties and other conditions): diesel, petrol, and others e.g. limonene
2. High temperatures, resulting in mostly (up to 70%) gaseous products a.k.a. SynGas (subject to waste mix feedstock properties and other conditions):
a. Simple HC gases: Hydrogen (H2), Methane (CH4), Ethane (C2H6), Ethene (C2H4), Propane (C3H8), Propene (C3H6), Butane (C4H10), Butene (C4H8), Butadiene (C4H6)
b. Unsaturated Hydrocarbons - Ethylene, Propylene, and Butylene
Gaseous and liquid products may be used for power generation through the turbine, as well as for district heating or water de-salination. Alternatively, adding the refiner will allow to market those as ready-to-use goods such as diesel fuel/petrol, bottle gas etc.
Solid residues outcome is minimal, between 15% and 20%.

The SME is prepared to design and calculate the parameters for a recycling plant as part of the larger facility or as a stand-alone unit. Also, it can offer full customization based on the end user’s data and local market specifics (i.e. end user’s goals, types of waste, local standards and regulations, etc).

Manufacturers of recycling equipment, recycling companies, engineering companies, municipalities and large industrial companies (waste producers) are sought for joint venture or commercial agreement with technical assistance.
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Advantages and Innovations

The SME’s technology is based on fast Pyrolysis process, where the rubber and/or plastic waste matter thermal destruction takes place in a fraction of a second in oxygen-deprived environment, followed by rapid exposure and fast cooling to prevent pollutants re-formation. This allows minimizing the secondary reactions effect, when Pyrolysis products react with each other at high temperatures.
The technology offers benefits such as:
- efficient performance
- small footprint
- reduced costs
- improved process control allowing flexibility

Innovative aspects of the technology are as follows:
- continuous and fast process
- no need for external infrastructure
- flexible parameters allowing to obtain various useful products (diesel/petrol vs. Syngas)
- less frequent service stand-by’s (i.e. more operational days)
- readily available and affordable materials used in the process
- simplified rubber waste preparation
- resulting products more suitable for further utilization, improving return on investment
- 100% process automation
- no need for batches cooling and lifting
- flue gas cleaning system prevents air pollution
- bead wire separation is not essential for ELT
- steel bead wires will be readily accepted by the metal recycling companies
- limonene as a high added value end product

Stage Of Development

Already on the market

Stage Of Development Comment

During the trials, all the main elements of the technology were tested. Process control techniques tested and improved. A couple of units have already been sold and are in operation.

Requested partner

The following partners are sought:
- Manufacturers of recycling equipment and engineering companies who are interested in providing the proposed technology to their clients, either as it is, or complementary to other technologies. The technology can be made available to the interested parties under a joint venture agreement or a commercial agreement with technical assistance.
- End users, such as recycling companies, or municipalities and city councils or other industrial companies (waste producers), planning to build a recycling facility to process plastic, organic, and end-of-life tires (ELT) waste. The Cypriot SME can provide the design, construction and operation of such a facility according to the client’s needs. The technology can be made available under a commercial agreement with technical assistance.

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