WO2016112371A1

WO2016112371A1 - Process and system for pyrolysis of tires to fuels and other products

Info

Publication number: WO2016112371A1
Application number: PCT/US2016/012772
Authority: WO
Inventors: Michael K. CLEMONS; James D. MIDDLETON
Original assignee: Sr20 Holdings Llc
Priority date: 2015-01-09
Filing date: 2016-01-09
Publication date: 2016-07-14

Abstract

The presently disclosed inventive concept(s) relates generally to a process and system for pyrolyzing rubber from tires to form fuels like, for example, naphtha, kerosene, low No. 2 diesel, and fuel oil, as well other products like carbon black, powder activated carbon, sulfur, and non-condensable gases.

Description

PROCESS AND SYSTEM FOR PYROLYSIS OF TIRES TO FUELS

AND OTHER PRODUCTS

FIELD

[0001] The presently disclosed inventive concepts generally relate to processes and systems for producing fuels and other products from tires by pyrolysis. More specifically, the presently disclosed inventive concepts relate to the production of, for example but without limitation, powder activated carbon, carbon black, sulfur, naphtha, kerosene, fuel oil, low sulfur no.2 diesel, and/or non-condensable gases.

BACKGROUND

[0002] By the end of 2003, the United States was generating 290 million scrap tires annually. Historically, these scrap tires would have taken up space in landfills or been illegally discarded as waste. Recently, however, there has been an increased interest in using scrap tires as a fuel source. In 2003, approximately 130 million of the 290 million annual scrap tires were being used in some capacity as a fuel source. Despite the increased efforts to use scrap tires as a fuel source, it is has been found that many of the individuals and companies using scrap tires as a fuel source were, and still are, relying on government subsidies and/or other incentives in order to make such endeavors financially feasible. This is primarily due to the processes and systems in the prior art failing to: (a) capture many of the commercially valuable products produced from tire pyrolysis, (b) produce sufficient yields of (high value) products, and/or (c) produce high quality products having a higher commercial value. The presently disclosed inventive concepts disclose systems and processes capable of obtaining many of the commercially valuable products produced by pyrolyzing scrap waste (e.g., scrap tires).

BRIEF SUMMARY OF THE DRAWING

[0003] Various examples, aspects, and embodiments of the presently disclosed inventive concept(s) are described below in the appended drawings to assist those of ordinary skill in the relevant art in making and using the subject matter herein. It should be recognized that these figures are merely illustrative of the principles of the presently disclosed inventive concept(s), and the appended drawings are not intended to be drawn to scale. Additionally, like reference numerals are intended to refer to similar elements for consistency. For purposes of clarity, not every component may be labeled in every drawing. Further, numerous additional examples, embodiments, modifications, and adaptations thereof will be described below and are readily apparent to those skilled in the art without departing from the spirit and scope of the presently disclosed inventive concept(s).

[0004] FIG. 1 depicts a schematic representation of one embodiment of a tire pyrolysis system capable of producing, for example but without limitation, naphtha, kerosene, diesel, fuel oil, carbon black, powder activated carbon, and/or sulfur from tires.

[0005] FIG. 2 depicts a schematic representation of a tire feed system.

[0006] FIG. 3 depicts a schematic representation of a tire feed system.

[0007] FIG. 4 depicts a schematic representation of a solids processing system.

[0008] FIG. 5 depicts a schematic representation of a solids processing system.

[0009] FIG. 6 depicts a schematic representation of a tire pyrolysis system comprising a de-ashing system.

[0010] FIG. 7 depicts a schematic representation of a tire pyrolysis system comprising a magnetic separator and a de-ashing system.

[0011] FIG. 8 depicts a schematic representation of a de-ashing system.

[0012] FIG. 9 depicts a schematic representation of a tire pyrolysis system having a recirculation loop for the controlled production of powder activated carbon or carbon black.

[0013] It should be understood that the tire pyrolysis systems in FIGS. 1 - 9 are just several examples of systems within which the presently disclosed inventive concepts can be embodied. Additionally, it should be understood that the tire pyrolysis systems, or portions of such, in FIGS. 1 - 9 may be modified to pyrolyze plastics, municipal waste, biomass, and/or other carbon-based materials to produce at least one of, for example but without limitation, naphtha, kerosene, diesel, fuel oil, powder activated carbon, and/or carbon black.

DETAILED DESCRIPTION

[0014] Before explaining at least one embodiment of the presently disclosed inventive concepts in detail, it is to be understood that the presently disclosed inventive concepts are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. The presently disclosed inventive concepts are capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

[0015] Unless otherwise defined herein, technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[0016] All patents, published patent applications, and non-patent publications mentioned in the specification are indicative of the level of skill of those skilled in the art to which the presently disclosed inventive concept(s) pertains. All patents, published patent applications, and non-patent publications referenced in any portion of this application are herein expressly incorporated by reference in their entirety to the same extent as if each individual patent or publication was specifically and individually indicated to be incorporated by reference.

[0017] All of the articles, products, compositions, and/or methods disclosed herein can be made and executed without undue experimentation in light of the present disclosure. While the articles, products, compositions, and methods of the presently disclosed inventive concept(s) have been described in terms of preferred embodiments, it will be apparent to those of ordinary skill in the art that variations may be applied to the articles, products, and compositions, and/or in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the presently disclosed inventive concept(s). All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the presently disclosed inventive concept(s).

[0018] As utilized in accordance with the present disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings.

[0019] The use of the word "a" or "an", when used in conjunction with the term

"comprising", may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one." The use of the term "or" is used to mean "and/or" unless explicitly indicated to refer to alternatives only if the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and "and/or." Throughout this application, the term "about" is used to indicate that a value includes the inherent variation of error for the quantifying device, the method being employed to determine the value, or the variation that exists among the study subjects. For example, but not by way of limitation, when the term "about" is utilized, the designated value may vary by plus or minus twelve percent, or eleven percent, or ten percent, or nine percent, or eight percent, or seven percent, or six percent, or five percent, or four percent, or three percent, or two percent, or one percent. The use of the term "at least one" will be understood to include one as well as any quantity more than one, including but not limited to, 1, 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 100, etc. The term "at least one" may extend up to 100 or 1000 or more depending on the term to which it is attached. In addition, the quantities of 100/1000 are not to be considered limiting as lower or higher limits may also produce satisfactory results. In addition, the use of the term "at least one of X, Y, and Z" will be understood to include X alone, Y alone, and Z alone, as well as any combination of X, Y, and Z. The use of ordinal number terminology (i.e., "first", "second", "third", "fourth", etc.) is solely for the purpose of differentiating between two or more items and, unless otherwise stated, is not meant to imply any sequence or order or importance to one item over another or any order of addition.

[0020] As used herein, the words "comprising" (and any form of comprising, such as

"comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "includes" and "include") or "containing" (and any form of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. The term "or combinations thereof" as used herein refers to all permutations and combinations of the listed items preceding the term. For example, "A, B, C, or combinations thereof" is intended to include at least one of: A, B, C, AB, AC, BC, or ABC and, if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more items or terms, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0021] The term "carbon black" as used herein is defined as the carbon black originating from the tires and recovered therefrom. [0022] Turning now to the presently disclosed inventive concept(s), certain embodiments thereof are directed to a system and process for converting tires by pyrolysis to at least one of, for example but without limitation, naphtha, kerosene, diesel, fuel oil, activated carbon, carbon black, and/or sulfur. Certain other embodiments of the presently disclosed inventive concept(s) are directed to a system and process for converting at least one of municipal waste, plastics, and/or biomass to at least one of naphtha, kerosene, diesel, fuel oil, activated carbon, carbon black, and/or sulfur by pyrolysis.

[0023] Turning now to the drawings, FIG. 1 illustrates one embodiment of a tire pyrolysis system 10. The tire pyrolysis system 10 includes a tire source 12 for storing and supplying a tire feedstock to be converted to products by a pyrolysis reaction. The tire source 12 can be any storage unit capable of holding whole tires, partial tires, and/or pieces of tires. The tire source 12 can be, for example but without limitation, a railcar, storage container, semi-trailer, silo, warehouse, and/or any other container, building, or facility capable of holding tires as would be known by a person of ordinary skill in the art.

[0024] In one embodiment, the tire source 12 holds whole and/or partial tires. In another embodiment, the tire source 12 holds pieces of tires that have been pre-shredded into pieces that are less than about 6 inches, or less than about 5 inches, or less than about 4 inches, or less than about 3 inches, or less than about 2 inches, or less than about 1 inch. The tires may be used tires and/or new tires. The tires may also be combined with one or more additional rubber-containing and/or plastic-containing compositions. The tires may be stored on-site and/or may be delivered as needed.

[0025] As depicted in FIG. 1, the tires and/or tire pieces from the tire source 12 may be supplied to a tire feed system 14. The tire feed system 14 may comprise any system as would be known to a person of ordinary skill in the field that is capable of feeding the tires and/or tire particles to a first pyrolysis reactor 16 via a feed line 18.

[0026] The tire feed system 14 may comprise a shredding apparatus (not pictured) capable of shredding whole and/or partial tires received from the tire source 12 into pieces that are less than about 6 inches, or less than about 5 inches, or less than about 4 inches, or less than about 3 inches, or less than about 2 inches, or less than about 1 inch. The shredding apparatus is also capable of ensuring that any pre-shredded tire pieces from the tire source 12 are within the range of sizes recited above. [0027] The feed line 18 may be, for example but without limitation, a conveyer belt, auger, feed hopper, fluidized bed, bucket elevator, drag chain, and/or any other mechanism for moving tire pieces as would be known to a person of ordinary skill in the art. The feed line 18 can be comprised of one or more lines. For example, the feed line 18 can comprise two lines, or three lines, or four lines, or five lines, or six lines, or seven lines, or eight lines, or nine lines, or ten lines.

[0028] In one embodiment, the feed line 18 comprises at least two lines such that if one feed line 18 is inoperative (either by choice or otherwise), the tire pieces can still be supplied to the first pyrolysis reactor 16 without stopping operation of the tire pyrolysis system 10.

[0029] In one embodiment, it may be desirable to combine the tires and/or tire pieces with a catalyst in the tire feed system 14 prior to feeding the tires pieces to the first pyrolysis reactor 16. The catalyst may alternatively be introduced into the first pyrolysis reactor 16.

[0030] As used from hereon, unless otherwise indicated, the term "tires" is defined to encompass "tire pieces" as defined above, whether pre-shredded or formed by a shredding apparatus in the tire feed system 14.

[0031] The first pyrolysis reactor 16 may be a kiln capable of extracting volatile hydrocarbons and non-condensable gases from the tires using a pyrolysis reaction. In one embodiment, the first pyrolysis reactor 16 is an indirect fired, counter current heated, rotating, continuous feed kiln.

[0032] In one non-limiting embodiment, the first pyrolysis reactor is operated at a temperature in the range of from about 600 to about 1000°F, or from about 650 to about 950°F, or from about 700 to 925°F, or from about 750 to about 900°F, under at least 1" H₂0 vacuum.

[0033] The first pyrolysis reactor can be operated at any of the above-recited temperatures for a residence time ranging from about 30 minutes to 5 hours, or from about 30 minutes to about 4 hours, or from about 45 minutes to about 3 hours, or from about 45 minutes to about 2 hours, or from about 45 minutes to about 1.25 hours. The residence time can be adjusted by at least one of (i) changing the installed pitch of the kiln from 0 degrees (i.e., horizontal) to about 3 degrees down from the tire feed, and/or (ii) varying the nominal rotation of the process drum from 0 rpm to about 4 rpm, or from about 0.5 rpm to about 3.5 rpm, or from about 1 rpm to about 3 rpm, or from 1.5 rpm to about 2.5 rpm, or from about 1.75 rpm to about 2.25 rpm, and/or (iii) varying the orientation of the internal "lifters" in the kiln, as would be understood by a person of ordinary skill in the field.

[0034] The mass flow rate of the tires through the first pyrolysis reactor 16 can be in a range of from about 0.5 to 10 tons per hour, or from about 1 to about 9 tons per hour, or from about 2 to about 8 tons per hour, or from about 3 to about 7 tons per hour, or from about 4 to about 6 tons per hour, or from about 4.5 to about 5.5 tons per hour.

[0035] At least a portion of the volatile hydrocarbons and non-condensable gases are removed from the first pyrolysis reactor via a conduit 20. The composition remaining in the first pyrolysis reactor 16 after pyrolyzing the tires is referred to herein as the "solids".

[0036] In one embodiment, the solids comprise, for example but without limitation, at least one of carbon black, ash, and/or one or more residual metals from the tires. The ash comprises at least one of CaC0₃, Ca(HC0₃)₂, Si0₂, kaolin, and/or dust or dirt from the tire pieces.

[0037] In one embodiment, at least a portion of the solids are removed from the first pyrolysis reactor 16 and introduced into a second pyrolysis reactor 24 via conduit 22. In one embodiment, conduit 22 comprises one or more pipes, conveyor belts, augers, bucket elevators, drag chains, or any other means as would be readily recognized by a person of ordinary skill in the art for removing at least a portion of the solids from the first pyrolysis reactor 16 and introducing at least a portion of the solids into the second pyrolysis reactor 24. The solids may be separated by one or more apparatuses, filters, or other means (not pictured) prior to being introduced into the second pyrolysis reactor 24 such that at least a portion of the one or more metals and/or ash are separated and removed from the carbon black.

[0038] In an alternative embodiment, the solids are removed from the first pyrolysis reactor 16 via conduit 26, and collected and/or packaged. In another embodiment, the solids are removed from the first pyrolysis reactor 16 via conduit 26 and are separated by one or more apparatuses, filters, or other means (not pictured) such that at least a portion of the one or more metals and/or ash are separated and removed from the carbon black, and then the carbon black is either collected for packaging or sent to a solids processing system 28 via conduit 30, and the residuals are either discarded, collected for packaging, or further processed. In yet another embodiment, the solids are removed from the first pyrolysis reactor 16 via conduit 26 and are sent to a solids processing system 28 via conduit 30. The solids processing system 28 is described in more detail further herein.

[0039] The second pyrolysis reactor 24 may also be a kiln capable of extracting volatile hydrocarbons and/or non-condensable gases from at least a portion of the solids produced by the first pyrolysis reactor 16 using a pyrolysis reaction. In one embodiment, the second pyrolysis reactor 24 is an indirect fired, counter current heated, rotating, continuous feed kiln.

[0040] In one non-limiting embodiment, the second pyrolysis reactor 24 is operated at a temperature in a range sufficient to produce activated carbon. More specifically, the second pyrolysis reactor 24 is operated at a temperature in a range of from about 1100 to about 2000°F, or from about 1200 to about 1900°F, or from about 1300 to about 1800°F, or from about 1400 to about 1800°F, under at least 1" H₂0 vacuum to produce activated carbon.

[0041] In another embodiment, the second pyrolysis reactor 24 is operated at a temperature in a range of from about 600 to about 1000°F, or from about 650 to about 950°F, or from about 700 to 925°F, or from about 750 to about 900°F, under at least 1" H₂0 vacuum so that the carbon black produced by the first pyrolysis reactor is substantially remains as carbon black and at least a portion of any unreacted hydrocarbons result in carbon black.

[0042] The second pyrolysis reactor 24 may be operated at any of the above-recited temperatures for a residence time in a range of from about 30 minutes to 5 hours, or from about 30 minutes to about 4 hours, or from about 45 minutes to about 3 hours, or from about 45 minutes to about 2 hours, or from about 45 minutes to about 1.25 hours. The residence time for the second pyrolysis reactor 24 can be adjusted by at least one of (i) changing the installed pitch of the kiln from 0 degrees (i.e., horizontal) to approximately 3 degrees down from the tire feed, and/or (ii) varying the nominal rotation of the process drum from 0 rpm to approximately 4 rpm, or from about 0.5 rpm to about 3.5 rpm, or from about 1 rpm to about 3 rpm, or from 1.5 rpm to about 2.5 rpm, or from about 1.75 rpm to about 2.25 rpm, and/or (iii) internal "lifters" in the kiln, as would be understood by a person of ordinary skill in the field. [0043] The mass flow rate of the solids in the second pyrolysis reactor 24 may be in the range of from about 0.5 to 5 tons per hour, or from about 1 to about 4 tons per hour, or from about 1.5 to about 2 tons per hour.

[0044] At least a portion of the volatile hydrocarbons and/or non-condensable gases are removed from the second pyrolysis reactor 24 via conduit 34. The composition remaining in the second pyrolysis reactor 24 is referred to herein as "secondary solids". Depending on the pyrolysis reaction conditions of the second pyrolysis reactor (as described above), the secondary solids can either comprise (a) at least one of carbon black, ash, and/or one or more residual metals from the tires, or (b) at least one of activated carbon, carbon black, ash, and/or one or more residual metals from the tires.

[0045] Similar to the solids of the first pyrolysis reactor, the ash in the secondary solids may comprise at least one of CaC0₃, Ca(HC0₃)₂, Si0₂, kaolin, and/or dust or dirt from the tire pieces.

[0046] In one embodiment, at least a portion of the secondary solids are removed from the second pyrolysis reactor 24 via conduit 36 and introduced into the solids processing system 28. In one embodiment, conduit 36 comprises one or more pipes, conveyor belts, augers, bucket elevators, drag chains, or any other means as would be readily recognized by a person of ordinary skill in the art for moving the secondary solids from the second pyrolysis reactor 24 to the solids processing system 28. Prior to being introduced into the solids processing system 28, the secondary solids removed via conduit 36 can be separated by one or more apparatuses, filters, or other means (not pictured) prior to being collected such that at least a portion of the one or more metals and/or ash are separated and removed from the carbon black and/or activated carbon.

[0047] In an alternative embodiment, at least a portion of the secondary solids are removed from the second pyrolysis reactor 24 via conduit 38 and collected. Prior to being collected, the secondary solids removed via conduit 38 can be separated by one or more apparatuses, filters, or other means (not pictured) such that at least a portion of the one or more metals and/or ash are separated and removed from the carbon black and/or activated carbon.

[0048] In one embodiment, at least a portion of the volatile hydrocarbons and non- condensable gases produced by pyrolyzing the tires in the first pyrolysis reactor 16 are removed via conduit 20 and introduced into a two stage hydrogenation apparatus 40. During the two stage hydrogenation, hydrogen sulfide may be separated from the volatile hydrocarbons and non-condensable gases using, for example but without limitation, a sulfur removal system 42. In one embodiment, the sulfur removal system 42 is a methyldiethanolamine (MDEA) system. The separated hydrogen sulfide may be transferred via conduit 44 to a sulfur recovery system 46, wherein the hydrogen sulfide is oxidized into elemental sulfur and removed from the system via conduit 48. In one embodiment, the sulfur recovery system 46 is a Stretford unit. In one embodiment, the sulfur removed via conduit 48 is in liquid form and has a mass flow rate of at least 0.5 ton per day, or at least 1 ton per day, or at least 1.5 tons per day, or at least 2 tons per day, or at least 2.5 tons per day, or at least 3 tons per day.

[0049] Additionally, at least a portion of the non-condensable gases may be separated from the volatile hydrocarbons and returned to the first pyrolysis reactor 16 via conduits 50 and 52 to be used as a hot gas and/or a fuel source for any heater in the system including, for example but without limitation, the combustion chamber of the first pyrolysis reactor 16. In one embodiment, the non-condensable gas may comprise, for example but without limitation, methane, ethane, propane, butane, and/or other hydrocarbon compounds that are gases at standard temperature and pressure.

[0050] In one embodiment, at least a portion of the hydrogenated volatile hydrocarbons are condensed and transferred from the two stage hydrogenation apparatus via conduit 54 to a separator 56 along with at least a portion of the non-condensable gas. In one embodiment, the condensed hydrogenated hydrocarbons have a volumetric flow rate of about 250 to 2000 barrels per day, or about 500 to about 1500 barrels per day, or about 750 to about 1250 barrels per day, or about 900 to about 1100 barrels per day, or about 950 to about 1050 barrels per day. The condensed hydrogenated hydrocarbons may, for example but without limitation, comprise hydrocarbons having a number of carbon atoms of 5 or higher, or from about 5 to about 30, or from about 5 to about 28, or from about 5 to about 27. The separator 56 may, in one embodiment, comprise a distillation column. The distillation column, in one non-limiting embodiment, may have about 24 plates with a bubble plate design.

[0051] The separator 56 may, in one non-limiting example, produce one or more streams substantially comprising at least one of a naphtha stream 58, a kerosene stream 60, a diesel stream 62, a fuel oil stream 64, and/or at least a portion of the above-mentioned non-condensable gas. The non-condensable gas may be removed from the separator via conduit 66 and either (i) be removed from the system entirely by, for example but without limitation, burning the non-condensable gas and/or releasing the gases to the environment, and/or (ii) returning the non-condensable gas to the first pyrolysis reactor 16 via conduits 66 and 52 to be used as a fuel source for any heater in the system including, for example but without limitation, the combustion chamber of the first pyrolysis reactor 16.

[0052] The diesel stream 62 substantially comprises a low sulfur diesel having a cetane number of at least 42, or at least 50, or at least 60, or at least 70, and/or a sulfur content of less than about 15 parts per million.

[0053] Together, the processing units for the volatile hydrocarbons and/or non- condensable gases produced by at least one of the first pyrolysis reactor 16 and/or the second pyrolysis reactor 24 are collectively referred to herein as the liquids and gases processing system 68, which may include, but is not limited to, the two stage hydrogenation apparatus 40, separator 56, sulfur removal system 42, and/or sulfur recovery system 46 described above, or any additional refining, treating or separation apparatuses as would be known by a person of ordinary skill in the art for processing the volatile hydrocarbons and/or non-condensable gases produced by the first pyrolysis reactor 16 and/or the second pyrolysis reactor 24 and the liquids collected therefrom.

[0054] Additionally, it is envisioned that the tire pyrolysis system 10 could further comprise one or more additional reactors in addition to the first pyrolysis reactor 16 and second pyrolysis reactor 24 as described above.

[0055] In one embodiment, the tire pyrolysis system 10 comprises a fire extinguisher system (not pictured) comprising a pipe leading into the heating chamber of at least one of the first pyrolysis reactor 16 and the second pyrolysis reactor 24 and/or a metal shroud surrounding at least one of the first pyrolysis reactor 16 and/or the second pyrolysis reactor 24, wherein the pipe and/or metal shroud may be filled will nitrogen that may be heated by the heating chamber of at least one of the first pyrolysis reactor 16 and/or the second pyrolysis reactor 24 such that the nitrogen can create a reduced oxygen environment to contribute to putting out any fire resulting from the first pyrolysis reactor 16 and/or the second pyrolysis reactor 24. The location of the pipe and/or the metal shroud are such that the nitrogen is sufficiently heated so as to not create a substantial temperature gradient when contacted with the fire which may decrease the chance of generating stress fractures and/or mechanical failures in the system.

[0056] In one embodiment, the tire pyrolysis system 10 further comprises a magnetic separator (not pictured) between the first pyrolysis reactor 16 and the second pyrolysis reactor 24 and/or between the second pyrolysis reactor 24 and the solids processing system 28. Additionally, a magnetic separator may be used prior to collecting the solids from conduit 26 or sending the solids to the solids processing system 28 via conduit 30. In one embodiment, the magnetic separator is a rotary drum having a magnetic roller at the end of a shaker table. In one non-limiting embodiment, the shaker table is designed for solid flow of the solids exiting the first pyrolysis reactor 16, wherein the solids are dispersed in a wide, thin layer, which passes over the magnetic rotary drum. The shaker table and magnetic rotary drum are elevated so that (i) at least a portion of the non-magnetic solids can gravity feed to the next step of the tire pyrolysis system 10 and (ii) the magnetic solids (e.g., steel) can gravity feed into a storage container and/or to a packaging system. In one embodiment, the non-magnetic solids (e.g., carbon black and ash, or activated carbon and ash) are discharged from the magnetic rotary drum first and then the magnetic solids are discharged on the back of the roller when the magnetic solids reach a non-magnetized discharge area of the magnetic rotary drum.

[0057] In one non-limiting embodiment, the tire pyrolysis system 10 comprising a magnetic separator further comprises a surge bin (not pictured) for the non-magnetic solids (e.g., carbon black and ash, or activated carbon and ash) exiting the magnetic separator. The non-magnetic solids can be controllably removed from the surge bin and directed to the next step of the tire pyrolysis system 10, including, for example but without limitation, the second pyrolysis reactor 24, the solids processing system 28, and/or a processing system like, for example, a de-ashing system (not pictured).

[0058] In one embodiment, the tire pyrolysis system 10 can have airlocks (not pictured) before and/or after the first pyrolysis reactor 16. Additionally, it is envisioned that additional airlocks may be present in the tire pyrolysis system 10 at, for example, before and after the second pyrolysis reactor 24. In one non-limiting embodiment, the airlocks before and after the first pyrolysis reactor 16 are rotary airlocks capable of handling the volumetric flow of tire pieces going into the first pyrolysis reactor 16 and the volumetric flow of the pyrolysis products exiting the first pyrolysis reactor 16, respectively, and, when present, the airlocks before and after the second pyrolysis reactor 24 are rotary airlocks capable of handling the volumetric flow of at least a portion of the solids produced by the pyrolysis reaction in the first pyrolysis reactor 16 and the secondary solids produced by the second pyrolysis reactor 24, respectively.

[0059] A non-limiting example of the above-mentioned tire feed system 14 is illustrated in FIG.2. Although not pictured in FIG. 2, it is envisioned that a tire shredding apparatus can be present in the tire feed system 14 between the tire source and a storage unit 70. The tire shredding apparatus is designed to produce pieces of rubber tire having sizes less than or equal to 1 inch while removing at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 91%, or at least 92%, or about 93%, or at least 94%, or at least 95%, or at least 96%, or at least 97%, or at least 98%, or at least 99% of the metals in the whole or partial tires fed into the shredding apparatus. In one embodiment, the shredding apparatus removes at least 92% of the metals in the whole or partial tires fed into the shredding apparatus.

[0060] Returning to FIG. 2, depicted therein is a shredded tire line 72 extending from at least one of a tire shredding apparatus (not pictured) and/or a tire source (not pictured) to the storage unit 70. In an alternative embodiment (not pictured), the shredded tire line 72 may feed directly into the first pyrolysis reactor. In one embodiment, the shredded tire line 72 comprises two or more lines from the tire source and/or the tire shredding apparatus. The shredded tire line 72 may comprise a conveyer belt, auger, feed hopper, fluidized bed, bucket elevators, drag chain, and/or any other mechanism for moving tire pieces as would be known to a person of ordinary skill in the art.

[0061] Additionally, as illustrated in FIG. 2, the tire feed system 14 may also comprise one or more dust collectors 74. In one embodiment, the one or more dust collectors 74 are sized to be capable of handling the volumetric flowrate and size of tires into the storage unit 70 such that the mean particle size of the tires remains suspended in air until reaching the main cyclonic separators and subsequent filters of the one or more dust collectors 74. The one or more dust collectors 74 are sized such that they do not discharge more than 1 lb. per hour of particulates of 10 microns or smaller.

[0062] A feeder line 76 removes at least a portion of the tires from the storage unit

70 and transports the tires to either a reactor feed hopper (not pictured) and/or to a first pyrolysis reactor (not pictured). The feeder line 76 may comprise a conveyer belt, auger, feed hopper, fluidized bed, bucket elevator, drag chain, and/or any other mechanism for moving tire pieces as would be known to a person of ordinary skill in the art. In one embodiment, the feeder line 76 comprises two or more lines from the storage unit 70 to a reactor feed hopper (not pictured) and/or to a first pyrolysis reactor (not pictured).

[0063] The feeder line 76 may further comprise one or more feeder recirculation lines 80 which lead back to the storage unit 70. The one or more feeder recirculation lines 80 assist in controlling the flow of tires into a reactor feed hopper (not pictured) and/or the flow of tires into a first pyrolysis reactor (not pictured).

[0064] FIG. 3 illustrates a tire feed system 14a that is similar to the tire feed system illustrated in FIG. 2, except the tire feed system 14a comprises multiple shredded tire lines 72-1 and 72-2, multiple feeder lines 76-1 and 76-2, and multiple feeder recirculation lines 80-1 and 80-2.

[0065] Turning now to FIG. 4, FIG. 4 illustrates a schematic of the solids processing system 28. As illustrated in FIG. 4, the solids processing system 28 comprises a sizing apparatus 84. Although not depicted in FIG. 4, the sizing apparatus can receive one or more of (a) at least a portion of the secondary solids produced by the above-described second pyrolysis reactor, (b) at least a portion of the solids produced by the above-described first pyrolysis reactor, (c) at least a portion of the non-magnetic solids discharged from the above-described magnetic separator, and/or (d) at least a portion of the solids from the above-mentioned de-ashing system.

[0066] The sizing apparatus 84 generally provides a substantially uniform particle size for the carbon black and/or activated carbon produced by the first pyrolysis reactor and second pyrolysis reactor, respectively.

[0067] The sizing apparatus 84 comprises, for example but without limitation, at least one of a hammer mill and/or a jet mill. In one embodiment (not pictured), there can be one sizing apparatus 84 for the carbon black produced by the first pyrolysis reactor (or by the second pyrolysis reactor if the second pyrolysis reactor is operated to produce carbon black rather than activated carbon) and one sizing apparatus 84 for the activated carbon produced by the second pyrolysis reactor if the second pyrolysis reactor is operated to produce activated carbon.

[0068] In one embodiment, the sizing apparatus 84 mills the activated carbon to produce a powder activated carbon having particles sizes less than about 50 microns, or less than about 45 microns, or less than about 40 microns, or less than about 35 microns, or less than about 30 microns, or less than about 20 microns, or less than about 15 microns, or less than about 10 microns, or less than about 5 microns. In one embodiment, the sizing apparatus 84 produces powder activated carbon having particles sizes less than 20 microns. In another embodiment, the sizing apparatus 84 produces powder activated carbon having particle sizes less than about 10 microns.

[0069] As represented by line 86 in FIG.4, at least a portion of the powder activated carbon leaving the sizing apparatus 84 may be collected for storage, packaging, and/or distribution. In one embodiment, the powder activated carbon leaving the sizing apparatus 84 have a 325 mesh (i.e., about 44 microns) and surface areas in the range of from about 300 to 800 m²/g as measured by iodine adsorption using ASTM D1510. In another embodiment, the powder activated carbon leaving the sizing apparatus 84 has a 200 mesh.

[0070] In one embodiment, the activated carbon has particles in the range of about

200 microns prior to contacting the sizing apparatus 84.

[0071] Alternatively, or additionally, at least a portion of the powder active carbon leaving the sizing apparatus 84 can be directed to a activated carbon pelletizing apparatus 88 that pelletizes the powder activated carbon in the presence of a liquid binder to form pellets of activated carbon ranging from about 1 mm to about 4 mm. The activated carbon pelletizing apparatus 88 can comprise, for example but without limitation, a pin mixer, a disc pelletizer, and/or combinations thereof. The mechanical strength of the pellets can be modified by the selection of a particular binder, as would be recognized by a person of ordinary skill in the art.

[0072] After the activated carbon pellets are formed by the activated carbon pelletizing apparatus 88, the pellets are then directed to a drying apparatus 90. The drying apparatus 90 can be, for example but without limitation, a direct dryer and/or an indirect dryer. In one embodiment, the drying apparatus 90 can be chosen from one or more of a fluid bed dryer, a tray dryer, a belt dryer, a vacuum tray dryer, a rotary dryer, a freeze dryer, and/or combinations thereof.

[0073] The drying apparatus 90 is operated at effective conditions such that the pellets of activated carbon have a moisture content of less than 5 % by weight. In one embodiment, the drying apparatus 90 is operated at a temperature in a range of from about 400 to about 800 °F, or from about 425 to about 700 °F, or from about 450 to about 600 °F, or from about 460 to about 575 °F, or from about 470 to about 550 °F, or from about 480 to about 540 °F, or from about 485 to about 525 °F, or from about 490 to about 510 °F. In one embodiment, the drying apparatus 90 is operated at about 500 °F so as to adequately cure the binder used to form the pellets, minimize the residence time in the dryer, and avoid heating the carbon too high prior to packaging.

[0074] In another embodiment, the sizing apparatus 84 mills the carbon black to produce carbon black having particles sizes less than about 50 microns, or less than about 45 microns, or less than about 40 microns, or less than about 35 microns, or less than about 30 microns, or less than about 20 microns, or less than about 15 microns, or less than about 10 microns, or less than about 5 microns. In one embodiment, the sizing apparatus 84 produces carbon black having particles sizes less than 20 microns. In another embodiment, the sizing apparatus 84 produces carbon black having particle sizes less than about 10 microns. In one non-limiting embodiment, the sizing apparatus 84 produces carbon black having particles sizes less than 20 microns. In another embodiment, the sizing apparatus 84 produces carbon black having particles sizes less than 10 microns.

[0075] As represented by line 92 in FIG. 4, at least a portion of the carbon black leaving the sizing apparatus 84 may be collected for storage, packaging, and/or distribution. In one embodiment, the carbon black has an iodine absorption number in a range of from about 60 to 75 mg/g, or from about 65 to about 70 mg/g.

[0076] Alternatively, or additionally, at least a portion of the carbon black leaving the sizing apparatus 84 can be directed to a carbon black pelletizing apparatus 94 that pelletizes the carbon black in the presence of a liquid binder to form pellets of carbon black having sizes in a range of from about 1 to about 25 mm, or from about 1 to about 10 mm, or from about 1 to about 6 mm, or from about 1 to about 4 mm. The carbon black pelletizing apparatus 94 can comprise, for example but without limitation, a pin mixer, a disc pelletizer, and/or combinations thereof. Similar for the pellets of activated carbon, the mechanical strength of the pellets of carbon black can be modified by the selection of a particular binder, as would be recognized by a person of ordinary skill in the art. In one embodiment (not pictured), a single pelletizing apparatus can be used to pelletize both the carbon black and the activated carbon at different times.

[0077] After the carbon black pellets are formed by the pelletizing apparatus 90, the pellets are then directed to a drying apparatus 90 as previously described. Although it is not pictured in FIG. 4, the drying apparatus 90 may be two separate units, one specifically for activated carbon pellets and one specifically for carbon black pellets.

[0078] FIG. 5 illustrates a schematic of a solids processing system 500 that is similar to the solids processing system 28 in FIG. 4 except that (1) there are two separate process lines - one for the carbon black from the first pyrolysis reactor (or by the second pyrolysis reactor if the second pyrolysis reactor is operated to produce carbon black rather than activated carbon) and one for activated the activated carbon produced by the second pyrolysis reactor (if the second pyrolysis reactor is operated to produce activated carbon), and (2) the two lines have re-conditioning loops for pellets that are either undersized or oversized.

[0079] The solids processing system 500 comprises an arrangement specifically for carbon black comprising a carbon black sizing apparatus 96, a carbon black pelletizing apparatus 98, and a carbon black dryer 100, all of which are the same as those described above for the solids processing system 28 depicted in FIG. 4. The solids processing system 500 further comprises a carbon black screening apparatus 102 capable of separating out both (i) carbon black pellets that are oversized and (ii) carbon black pellets that are undersized, leaving carbon black pellets having a preferred size. In one embodiment, the preferred size of carbon black pellets is about 1 mm. Therefore, the oversized carbon black pellets are those greater than 1 mm and the undersized carbon black pellets are those less than about 1 mm. In another embodiment, the preferred size of carbon black pellets can be in a range of from about 0.25 mm to about 7 mm, or from about 0.5 to about 6 mm, or from about 0.75 to about 5 mm, or from about 2 to about 3 mm. The sizes of oversized carbon black pellets and undersized carbon black pellets can be readily determined by a person of ordinary skill based on the preferred pellet sizes.

[0080] The solids processing system 500 further comprises an oversized carbon black pellet reworking loop 104 that directs the oversized carbon black pellets separated by the carbon black screening apparatus 102 to a carbon black milling apparatus 106 that mills the oversized carbon black pellets. The carbon black milling apparatus 106 can be, for example but without limitation, at least one of a hammer mill and/or a ball mil l. After leaving the carbon black milling apparatus 106 the milled carbon black particles are then re-introduced into the carbon black sizing apparatus 96. [0081] The solids processing system 500 further comprises an undersized carbon black reworking loop 108 that directs the undersized carbon black pellets separated by the carbon black screening apparatus 102 back to the carbon black sizing apparatus 96.

[0082] In one embodiment, the carbon black screening apparatus 102 comprises one or more stacks of sieve screens, wherein each stack comprises a top sieve screen capable of preventing the "oversized" pellets from passing through and a bottom sieve screen allowing the "undersized" pellets to pass through but not the pellets of the preferred size. In one embodiment, the carbon black screening apparatus 102 comprises three stacks of the above-described sieve screens.

[0083] The solids processing system 500 additionally comprises an arrangement for activated carbon comprising an activated carbon sizing apparatus 110, an activated carbon pelletizing apparatus 112, and an activated carbon dryer 114, all of which are the same as those described above for the solids processing system 28 depicted in FIG. 4. The solids processing system further comprises an activated carbon screening apparatus 116 capable of separating out both (i) activated carbon pellets that are oversized, and (ii) activated carbon pellets that are undersized, leaving activated carbon pellets having a preferred size. In one embodiment, the preferred size of activated carbon pellets is in a range of from about 1 mm to about 4 mm. Therefore, the oversized activated carbon pellets are those greater than 4 mm and the undersized activated carbon pellets are those less than about 1 mm. In another embodiment, the preferred size of activated carbon pellets can be in a range of from about 0.25 mm to about 7 mm, or from about 0.5 to about 6 mm, or from about 0.75 to about 5 mm, or from about 2 to about 3 mm. The sizes of oversized activated carbon pellets and undersized activated carbon pellets can be readily determined by a person of ordinary skill based of the preferred pellet sizes.

[0084] The solids processing system 500 further comprises an oversized activated carbon pellet reworking loop 118 that directs the oversized activated carbon separated by the activated carbon screening apparatus 116 to an activated carbon milling apparatus 120 that mills the oversized activated carbon pellets. The activated carbon milling apparatus 120 can be, for example but without limitation, at least one of a hammer mill and/or ball mill.

[0085] The solids processing system 500 additionally comprises an undersized activated carbon reworking loop 122 that directs the undersized activated carbon pellets separated by the activated carbon screening apparatus 116 back to the activated carbon sizing apparatus 110.

[0086] In one embodiment, the activated carbon screening apparatus 116 is the same as that described above for the carbon black screening apparatus 102.

[0087] Although not illustrated in FIGS. 4 or 5, the solids processing systems 28 and

500 can further comprise a carbon impregnation step whereby the activated carbon pellets are impregnated with a chemical agent chosen from KOH, NaOH, K₂C0₃, Fe₂0₃, Cu₂Cr₂C)5, KMn0₄, Kl, Kl₃, CuO, H₂S0₄, H₃P0₄, S, Ag (metallic), Ni(N0₃), and/or combinations thereof.

[0088] Turning to FIG. 6, FIG. 6 illustrates a tire pyrolysis system 10a that is substantially similar to the tire pyrolysis system 10 in FIG. 1 except the tire pyrolysis system 10 a further comprises a de-ashing system 124. The components in FIG. 6 having an "a" following their number correspond to like components in FIG. 1 having the same number without the "a", and the above descriptions regarding such (and their various embodiments) are hereby incorporated herein below.

[0089] As noted, the tire pyrolysis system 10a in FIG. 6 comprises a de-ashing system

124. The tire pyrolysis system 10a in FIG. 6 further has a conduit 126 capable of removing at least a portion of the solids produced by the first pyrolysis reactor 16a and introducing at least a portion of the solids to the de-ashing system 124. The conduit 126 can comprise one or more pipes, conveyor belts, augers, bucket elevators, drag chains, or any other means as would be readily recognized by a person of ordinary skill in the art for moving at least a portion of the solids leaving the first pyrolysis reactor 16a.

[0090] Further, at least a portion of the solids leaving the de-ashing system 124 of the tire pyrolysis system 10a in FIG. 6 are either (a) collected via conduit 128, (b) sent to the solids processing system 28a via conduit 130, and/or (c) sent to the second pyrolysis reactor 24a via conduit 132. Conduits 128, 130, and 132 can be one or more pipes, conveyor belts, augers, bucket elevator, drag chains, or any other means as would be readily recognized by a person of ordinary skill in the art for moving at least a portion of the solids leaving the de- ashing system 124.

[0091] It is also to be understood that the de-ashing system 124 can be integrated into any of the above-described embodiments. For example, FIG. 7 illustrates a tire pyrolysis system 10b that is substantially similar to the tire pyrolysis system 10 in FIG. 1 and the tire pyrolysis system 10a in FIG. 6 except that the tire pyrolysis system 10b further comprises a magnetic separator 134 (as described above) and a surge bin 136 (as described above) after the first pyrolysis reactor 16b but before the above-described de-ashing system 124b. The components in FIG. 7 and discussed herein having a "b" following their number correspond to the components in FIG. 1 and/or FIG. 6 having the same number without the "b", and above descriptions regarding such (and their various embodiments) are hereby incorporated herein with respect to the embodiment depicted in FIG. 7.

[0092] Although not illustrated in FIG. 7, the tire pyrolysis system 10b can be modified such that: (i) at least a portion of the non-magnetic solids from the magnetic separator can bypass the de-ashing system 124b and can either be (a) collected, (b) directed to the second pyrolysis reactor 24b, or (c) directed to the solids processing system 28b; (ii) at least a portion of the non-magnetic solids in the surge bin 136 can bypass the de-ashing system 124b and can either be (a) collected, (b) directed to the second pyrolysis reactor 24b, or (c) directed to the solids processing system 28b; and/or (iii) at least a portion of the solids leaving the de-ashing system 124b can bypass the second pyrolysis reactor 24b and be collected or directed to the solids processing system 28b.

[0093] FIG. 8 provides a schematic representation of one embodiment of the above- described de-ashing system 124. In particular, the de-ashing system 124 comprises an acid washing step 138, a bulk dewatering step 140, and a post-dewatering drying step 142. The post-dewatering drying step 142 releases vapors as represented by the outlet 144 and outputs a "clean" carbon black as represented by outlet 146.

[0094] In one embodiment, the acid washing step 138 comprises treating the solids leaving the first pyrolysis reactor (or, alternatively, the solids leaving a magnetic separator following the first pyrolysis reactor) with an acid solution to remove at least a portion of the inorganic materials (i.e., the ash) in the solids by density separation. In one non-limiting embodiment, the acid solution comprises HCI at a 0.1N concentration. However, the acid solution can comprise any effective concentration of an acid that would encourage density separation of the inorganics (i.e., the ash) from the carbon black, as would be readily ascertained by a person of ordinary skill in the art.

[0095] In one embodiment, the inorganic materials are removed from the carbon black by a mechanically inclined auger that picks up the bottom of the wash tank after the inorganic materials have had a chance to settle. Water removed with the inorganic materials is separated from the inorganic materials using, for example but without limitation, a cyclonic separator and then neutralized to a pH of about 6.5 to about 8.5 using one or more bases, including, for example but without limitation, sodium hydroxide.

[0096] In one embodiment, the ratio of the volume of acid solution to the weight of carbon black in the acid washing step 138 is such that at least 3.5 tons of carbon black can be processed per hour. However, the ratio of the volume of acid solution to weight of carbon black in the solids produced by the first pyrolysis reactor can be adjusted such that at least 0.25, or at least 0.5, or at least 0.75, or at least 1, or at least 1.25, or at least 1.5, or at least 1.75, or at least 2, or at least 3, or at least 4, or at least 5, or at least 10, or at least 20 tons of carbon black are processed per hour. In one embodiment, the ratio of the volume of acid solution to weight of carbon black in the solids produced by the first pyrolysis reactor is adjusted such that about 3 to 4 tons of carbon black are processed per hour. In one embodiment, the ratio of the volume of acid solution to weight of carbon black in the solids from the first pyrolysis reactor is adjusted such that about 3.25 to about 3.75 tons of carbon black are processed per hour. In another embodiment, the ratio of the volume of acid solution to the weight of carbon black in the solids from the first pyrolysis reactor is adjusted so that about 3.5 tons of carbon black are processed per hour.

[0097] In one embodiment, the acid washing step 138 is carried out at ambient temperature.

[0098] The process conditions of the acid washing step 138, including the concentration of the acid in the acid solution, can further be adjusted based on the weight percent of the material to be removed and held in solution until the clean carbon black is removed.

[0099] After the clean carbon black is removed from the acid washing step 138, the clean carbon black is subjected to a bulk dewatering step 140 to remove excess water. In one embodiment, the bulk dewatering step 140 comprises subjecting the clean carbon black to a cyclonic separator to remove water.

[0100] The water removed from the bulk dewatering step 140 is monitored and the pH of the water is adjusted to a range of 6.5 to 8.5 using one or more bases, including, for example but without limitation, sodium hydroxide.

[0101] After the bulk dewatering step 140, the dewatered clean carbon black is then subjected to a post-dewatering drying step 142. The post-dewatering drying step 142 comprises drying the dewatered clean carbon black using, for example but without limitation, a direct dryer and/or an indirect dryer. In one embodiment, the dryer is chosen from one or more of a fluid bed dryer, a tray dryer, a belt dryer, a vacuum tray dryer, a rotary dryer, a freeze dryer, and/or combinations thereof.

[0102] The conditions of the post-dewatering drying step 142 are such that the carbon black has a moisture content of less than 5 % by weight. In one embodiment, the post-dewatering drying step 142 comprises a dryer operated at a temperature in a range of from about 400 to about 800 °F, or from about 425 to about 700 °F, or from about 450 to about 600 °F, or from about 460 to about 575 °F, or from about 470 to about 550 °F, or from about 480 to about 540 °F, or from about 485 to about 525 °F, or from about 490 to about 510 °F. In one embodiment, the dryer in the post-dewatering drying step 142 is operated at about 500 °F.

[0103] In one embodiment, the ash content of the solids or secondary solids is reduced from a range of about 10 to 15 wt% to less than 2 weight percent of the carbon black or activated carbon recovered.

[0104] Turing to FIG. 9, FIG. 9 is directed to a tire pyrolysis system 900 designed to allow for continued operation while the tire pyrolysis system 900 is modified to produce either activated carbon or carbon black.

[0105] The tire pyrolysis system 900 comprises a tire source 912, a tire feed system

914, a reactor feed hopper 916, a first pyrolysis reactor 918, a liquids and gases processing system 920, a second pyrolysis reactor 922, a storage section 924, a recirculation loop 926, an auxiliary receiving hopper 928, and a solids processing system 930.

[0106] The tire source 912, tire feed system 914, first pyrolysis reactor 918, liquids and gases processing system 920, second pyrolysis reactor 922, and solids processing system 930 all correspond to components described above, the descriptions of which (and their various embodiments) are all incorporated by reference herein, including the operating conditions for the first and second pyrolysis reactors and products (e.g., "solids" and "secondary solids") produced by such.

[0107] Turning back to FIG. 9, the reactor feed hopper 916 assists in controlling the amount of tires into the first pyrolysis reactor. The storage section 924 of the tire pyrolysis system 900 comprises an area capable of holding at least two hours' worth of carbon black or activated carbon leaving the second pyrolysis reactor 922. In one embodiment, the storage section 924 is an enlarged section of, for example but without limitation, a pipe, conveyor belt, and/or any other transport mechanism for the carbon black or activated carbon that is capable of holding an amount of carbon black or activated carbon equal to the amount produced by the second pyrolysis reactor 922 over at most two hours. In one embodiment, the storage section 924 is capable of holding up to 1, or up to 2, or up to 3, or up to 4, or up to 5, or up to 10, or up to 15, or up to 20 tons of carbon black or activated carbon.

[0108] The ability of the storage section 924 to hold an amount of carbon black or activated carbon produced by the second pyrolysis reactor 922 allows the tire pyrolysis system 900 to continue to operate while the temperature and/or other reaction conditions of the second pyrolysis reactor 922 are adjusted to produce either activated carbon or carbon black.

[0109] If operating under normal conditions (i.e., not modifying the second pyrolysis reactor 922 to produce either carbon black or activated carbon), at least a portion of the carbon black or activated carbon in the storage section 924 is directed the solids processing system 930 or is collected for packaging or storage.

[0110] If modifying the tire pyrolysis system 900 to go from producing activated carbon to producing carbon black or vice versa, an indeterminate mixture of carbon black and/or activated carbon will be produced while modifying the pyrolysis system 900, which can be collected in the storage section 924 for up to two hours so that the indeterminate mixture of carbon black and/or activated carbon is not sent for further processing via the solids processing system 930 or collected for packaging.

[0111] The indeterminate mixture of carbon black and/or activated carbon in the storage section 924 is directed to an auxiliary receiving hopper 928 via the recirculation loop 926 that collects at least a portion of the recirculated mixture of carbon black and/or activated carbon. The recirculation loop 926 can be any conveyor belt or other transport mechanism capable of moving the indeterminate mixture of carbon black and/or activated carbon in the storage section 924 to the auxiliary receiving hopper 928. In one embodiment, the recirculation loop 926 is a conveyor assembly.

[0112] The auxiliary receiving hopper 928 allows the recirculated mixture of carbon black and/or activated carbon to be controllable mixed with the tires in the reactor feed hopper 916. The auxiliary receiving hopper 928 can be any room, storage facility, bin, container, or combination of such that is in communication with the reactor feed hopper 916 such that at least a portion of the recirculated mixture of carbon black and/or activated carbon can be mixed with the tires in the reactor feed hopper 916.

[0113] The amount of the recirculated mixture of carbon black and/or activated carbon added to the tires in the reactor feed hopper 916 can be less than about 1, or less than about 2, or less than about 3, or less than about 4, or less than about 5, or less than about 6, or less than about 7, or less than about 8, or less than about 9, or less than about 10₇ or less than about 11, or less than about 12, or less than about 13, or less than about 14, or less than about 15, or less than about 20, or less than about 30, or less than about 40, or less than about 50 wt% of the tires in the reactor feed hopper 916.

[0114] In one embodiment, the amount of the recirculated mixture of carbon black and/or activated carbon added to the tires in the reactor feed hopper 916 is less than about 15 wt% of the tires in the reaction feed hopper. In another embodiment, the amount of the recirculated mixture of carbon black and/or activated carbon added to the tires in the reactor feed hopper 916 is less than about 10 wt%. In one embodiment, the amount of recirculated carbon black and/or activated carbon in the reactor feed hopper 916 is in a range of from about 1 to about 20 wt%, or from about 2 to 19 wt%, or from about 3 to about 18 wt%, or from about 4 to about 17 wt%, or from about 5 to 16 wt%, or from about 6 to about 15 wt%, or from about 7 to about 14 wt%, or from about 8 to about 13 wt%, or from about 9 to about 11 wt%, or about 10 wt% of the amount of tires in the reaction feed hopper.

[0115] Although not illustrated in FIG. 9, the tire pyrolysis system 900 can have multiple feed lines from (i) the tire source 912 to the tire feed system 914, (ii) the tire feed system 914 to the reactor feed hopper 916, (iii) the reactor feed hopper 916 to one or more first pyrolysis reactors 918, (iii) the one or more first pyrolysis reactors 918 to one or more second pyrolysis reactors 922, (iv) and the one or more second pyrolysis reactors 922 to the storage section 924. The multiple feed lines can all be operating or one or more of the lines can act as a back up to a single line.

[0116] Additionally, although not illustrated in FIG. 9, the tire pyrolysis system 900 can have multiple first pyrolysis reactors and second pyrolysis reactors, wherein the first pyrolysis reactors are operated at the same conditions as each other and the second pyrolysis reactors are operated at the same conditions as each other. The multiple feed lines from, for example, reactor feed hopper 916 (as described above) can each individually lead into one of the first pyrolysis reactors and the solids removed from each of the first pyrolysis reactors can individually lead into one of the second pyrolysis reactors. The secondary solids from the second pyrolysis reactors can all lead into the storage section 924. In one embodiment, the tire pyrolysis system comprises a series of first pyrolysis reactors and second pyrolysis reactors operating in parallel, such that both of the first pyrolysis reactors and second pyrolysis reactors are operated at the same conditions, so that the second products for each series of first pyrolysis reactors and second pyrolysis reactors can be homogenously blended and comprise substantially the same secondary solids.

[0117] Although not pictured in FIG. 9, the tire pyrolysis system 900 can further comprise a magnetic separator (as described above) between the first pyrolysis reactor 918 and/or the second pyrolysis reactor 922. Additionally, in one non-limiting embodiment, the tire pyrolysis system 900 comprising a magnetic separator can further comprise a surge bin (as described above) for the non-magnetic solids (e.g., carbon black and/or ash) exiting the magnetic separator.

[0118] Additionally, although not pictured in FIG. 9, the tire pyrolysis system 900 can have airlocks before and after the first pyrolysis reactor 918.

[0119] Thus, in accordance with the presently disclosed inventive concept(s), a process and system has been provided for pyrolyzing rubber from tires to form fuels like, for example, naphtha, kerosene, low No. 2 diesel, and fuel oil, as well other products like carbon black, powder activated carbon, sulfur, and non-condensable gases. Although the presently disclosed inventive concept(s) has been described in conjunction with the specific language set forth herein above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the presently disclosed inventive concept(s). Changes may be made in the construction and the operation of the various components, elements, and assemblies described herein, as well as in the steps or the sequence of steps of the methods described herein, without departing from the spirit and scope of the presently disclosed inventive concept(s).

Claims

What is claimed is:

1. A tire pyrolysis system for producing carbon black, powder activated carbon, elemental sulfur, diesel, naphtha, kerosene, fuel oil, and non-condensable gases from tires, the tire pyrolysis system comprising:

a tire feed system,

a first pyrolysis reactor,

a second pyrolysis reactor,

a two stage hydrogenation apparatus,

a sulfur removal system,

a sulfur recovery system, and

a separator.

2. The system of claim 1, wherein the tire feed system comprises a tire shredding apparatus.

3. The system of claim 2, wherein the tire shredding apparatus shreds at least one of whole tires and partial tires to pieces less than 1 inch in size.

4. The system of claim 2, wherein the tire shredding apparatus removes at least 90% of one or more metals in the whole or partial tires.

5. The system of any one of claims 1 to 4, wherein the system further comprises at least two feed lines from the tire feed system to the first pyrolysis reactor whereby the tire pieces are transferred from the tire feed system to the first pyrolysis reactor.

6. The system of claim 5, wherein the at least two feed lines have one or more recirculation lines.

7. The system of claim 1, wherein the first pyrolysis reactor is operated at a temperature in a range of from about 750 to about 900 °F.

8. The system of claim 1 or 7, wherein the second pyrolysis reactor is operated at a temperature in a range of from about 750 to about 900 °F.

9. The system of claim 1 or 7, wherein the second pyrolysis reactor is operated at a temperature in a range of from about 1400 to 1800 °F.

10. The system of any one of claims 7 to 9, wherein the first pyrolysis reactor has a residence time in a range of from about 45 minutes to about 1.25 hours.

11. The system of claim 10, wherein the first pyrolysis reactor has a residence time of about 1 hour.

12. The system of any one of claims 8 to 11, wherein the second pyrolysis reactor has a residence time in a range of from about 45 minutes to about 1.25 hours.

13. The system of claim 12, wherein the second pyrolysis reactor has a residence time of about 1 hour.

14. The system of claim 1, wherein the two stage hydrogenation apparatus is in fluid communication with the first pyrolysis reactor such that non-condensable gases removed from the two stage hydrogenation apparatus can be directed to the combustion chamber of the first pyrolysis reactor and used as a fuel source.

15. The system of claim 1, wherein the sulfur removal system is a methyldiethanolamine system.

16. The system of claim 1, wherein the sulfur recovery system is a Stretford unit.

17. The system of any one of claims 1 to IS, further comprising a solids processing system comprising at least one of a sizing apparatus and a pelletizing apparatus.

18. The system of claim 17, wherein the solids processing system further comprises a separating apparatus after the pelletizing apparatus that separates out undersized and oversized pellets produced by the pelletizing apparatus.

19. The system of claim 18, wherein the separating apparatus is in communication with at least one of (a) a milling apparatus for the oversized pellets and (b) the sizing apparatus for the undersized pellets.

20. The system of claim 18 or 19, wherein the separating apparatus comprises at least one stack of sieves, the at least one stack of sieves comprising a top sieve screen to remove oversized pellets from an elected pellet size and a bottom sieve screen to allow undersized pellets to be removed from the elected pellet size.

21. The system of claim 20, wherein the separating apparatus comprises three stacks of sieves.

22. The system of claim 20 or 21, wherein the elected pellet size is in a range of from about 1 mm to about 4 mm.

23. The system of any one of claims 1 to 22, further comprising a magnetic separator.

24. The system of any one of claims 1 to 23, further comprising a de-ashing system.

25. The system of claim 1, further comprising a storage section after the second pyrolysis reactor capable of holding up to 20 tons of material.

26. The system of claim 25, wherein the storage section is in communication with the first pyrolysis reactor via at least one of one or more feed hoppers and the tire feed system so that at least a portion of the material in the storage section can be blended with the tires to be fed to the first reactor.

27. The system of claim 26, wherein the amount of material in the storage section blended with the tires to be fed to the first reactor is at most about 15 weight percent of the tires to be fed to the first reactor.

28. The system of claim 27, wherein the amount of material in the storage section blended with the tires to be fed to the first reactor is at most about 10 weight percent of the tires to be fed to the first reactor.

29. A method of producing diesel, naphtha, kerosene, fuel oil, carbon black, and powder activated carbon, the method comprising:

pyrolyzing at least one or more pieces of tires in a first pyrolysis reactor to form at least one of (a) volatile hydrocarbons and non-condensable gases and (b) solids comprising carbon black,

separating the volatile hydrocarbons and the non-condensable gases from at least a portion of the solids,

removing and recovering sulfur from the volatile hydrocarbons and the non- condensable gases,

subjecting the volatile hydrocarbons to hydrogenation,

condensing the hydrogenated hydrocarbons,

separating diesel, naphtha, kerosene, and fuel oil from the condensed hydrogenated hydrocarbons, and

pyrolyzing at least a portion of the solids comprising carbon black in a second pyrolysis reactor to produce secondary solids comprising at least one carbon black and activated carbon.

30. The method of claim 29, wherein the first pyrolysis reactor is operated at a temperature in a range of from about 750 to about 900 °F.

31. The method of claim 29 or 30, wherein the second pyrolysis reactor is operated at a temperature in a range of from about 750 to about 900 °F such that the secondary solids comprise carbon black.

32. The method of claim 29 or 30, wherein the second pyrolysis reactor is operated at a temperature in a range of from about 1400 to 1800 °F such that the secondary solids comprise activated carbon.

33. The method of any one of claims 29 to 32, wherein the first pyrolysis reactor has a residence time in a range of from about 45 minutes to about 1.25 hours.

34. The method of claim 33, wherein the first pyrolysis reactor has a residence time of about 1 hour.

35. The method of any one of claims 31 to 34, wherein the second pyrolysis reactor has a residence time in a range of from about 45 minutes to about 1.25 hours.

36. The method of claim 35, wherein the second pyrolysis reactor has a residence time of about 1 hour.

37. The method of claim 29 or 30, wherein the mass flow rate of tires into the first pyrolysis rector is in a range of from about 0.5 to about 10 tons per hour.

38. The method of claim 37, wherein the mass flow rate of tires into the first pyrolysis reactor is in a range of from about 4.5 to about 5.5 tons per hour.

39. The method of any one of claims 29 to 38, wherein the mass flow rate of solids into the second pyrolysis reactor is in a range of from about 0.5 to about 5 tons per hour.

40. The method of claim 39, wherein the mass flow rate of solids into the second pyrolysis reactor is in a range of from about 1.5 to about 2 tons per hour.

41. The method of any one of claims 29 to 31, wherein at least a portion of the carbon black is collected.

42. The method of claim 31, wherein at least a portion of the carbon black is directed to a solids processing system and milled to a size less than about 20 microns.

43. The method of claim 42, wherein the carbon black is milled to a size less than 10 microns.

44. The method of any one of claims 31 and 42 to 43, wherein the carbon black is pelletized into pellets ranging in size from about 1 to about 4 mm.

45. The method of claim 32, wherein at least a portion of the activated carbon is collected.

46. The method of claim 32, wherein at least a portion of the activated carbon is directed to a solids processing system and milled to a size less than about 20 microns.

47. The method of claim 46, wherein the activated carbon is milled to a size less than about 10 microns.

48. The method of claim 29, wherein at least a portion of the non-condensable gases are removed and directed to the combustion chamber of at least one of the the first pyrolysis reactor and the second pyrolysis reactor and used as a fuel source.

49. The method of claim 29, wherein the recovered sulfur is in liquid form and has a mass flow rate of at least 0.5 tons per day.

50. The method of claim 49, wherein the recovered sulfur is in liquid form and has a mass flow rate of at least 3 tons per day.

51. The method of claim 29, wherein the condensed hydrogenated hydrocarbons have a volumetric flow rate in a range of from about 25 to about 2000 barrels per day.

52. The method of claim 51, wherein the condensed hydrogenated hydrocarbons have a volumetric flow rate of from about 950 to 1050 barrels per day.

53. The method of claim 29, wherein the solids from the first pyrolysis reactor are directed to a magnetic separator, whereby one or more metals in the solids are removed from solids and separated from the carbon black.

54. The method of claim 29 or 53, wherein the solids from the first pyrolysis reactor are directed to a de-ashing system whereby at least a portion of inorganic particles are removed from the solids and separated from the carbon black.

55. A tire pyrolysis system for producing carbon black, powder activated carbon, elemental sulfur, diesel, naphtha, kerosene, fuel oil, and non-condensable gases from tires, the tire pyrolysis system comprising:

a tire feed system,

a reactor feed hopper,

a first pyrolysis reactor,

a second pyrolysis reactor,

a storage section,

a recirculation loop from the storage section to an auxiliary receiving hopper, a two stage hydrogenation apparatus,

a sulfur removal system,

a sulfur recovery system, and

a separator.

56. The system of claim 55, wherein the reactor feed hopper comprises one or more of at least one of a container, storage facility, room, and bin capable of holding an amount of tires to be added to the first pyrolysis reactor.

57. The system of claim 55 or 56, wherein the storage section is a portion of the system after the second pyrolysis reactor capable of holding up to about 20 tons of material.

58. The system of any one of claims 55 to 57, wherein the recirculation loop is a conveyor assembly from the storage section to the auxiliary receiving hopper.

59. The system of any one of claims 55 to 58, wherein the auxiliary receiving hopper comprises one or more of at least one of a container, storage facility, room, and bin capable of holding an amount of material from the storage section.

60. The system of claim 59, wherein the auxiliary receiving hopper is in communication with the reactor feed hopper such that a portion of the material in the auxiliary receiving hopper can be blended with the tires in the reactor feed hopper.

61. The system of claim 60, wherein the amount of material in the storage section blended with the tires in the reaction feed hopper is at most about 15 weight percent of the tires in the reaction feed hopper.

62. The system of claim 60, wherein the amount of material in the storage section blended with the tires in the reaction feed hopper is at most about 15 weight percent of the tires in the reaction feed hopper.

63. A method for transitioning a tire pyrolysis system comprising a first pyrolysis reactor and a second pyrolysis reactor to produce activated carbon rather than carbon black, comprising:

Adjusting the temperature of the second pyrolysis reactor to a temperature sufficient to produce activated carbon,

Collecting the product produced from the second pyrolysis reactor while the second pyrolysis reactor is adjusted to a temperature sufficient to produce activated carbon, and

Blending the collected product with unreacted tires and feeding the blend to the first reactor once the second reactor has reached the temperature sufficient to produce activated carbon.

64. The method of claim 63, wherein the temperature for the second pyrolysis reactor to produce activated carbon is in a range of from about 1400 to about 1800 °F.

65. The method of claim 63 or 64, wherein the amount of collected product blended with the unreacted tires is at most 15 % by weight of the unreacted tires.

66. The method of claim 65, wherein the amount of collected product blended with the unreacted tires is at most 10 % by weight of the unreacted tires.

67. A method for transitioning a tire pyrolysis system comprising a first pyrolysis reactor and a second pyrolysis reactor to recover carbon black rather than activated carbon, comprising:

Adjusting the temperature of the second pyrolysis reactor to a temperature sufficient to recover carbon black,

Collecting the product produced from the second pyrolysis reactor while the second pyrolysis reactor is adjusted to a temperature sufficient to recover carbon black, and

Blending the collected product with unreacted tires and feeding the blend to the first reactor once the second reactor has reached the temperature sufficient to recover carbon black.

68. The method of claim 67, wherein the temperature for the second pyrolysis reactor to recover carbon black is in a range of from about 750 to about 900 °F.

69. The method of claim 67 or 68, wherein the amount of collected product blended with the unreacted tires is at most 15 % by weight of the unreacted tires.

70. The method of claim 69, wherein the amount of collected product blended with the unreacted tires is at most 10 % by weight of the unreacted tires.