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Article history:
Received 14 July 2009
Accepted 2 October 2009
Available online 6 November 2009
a b s t r a c t
The aim of this work is to assess the behaviour of a moving bed reactor, based on a screw transporter
design, in waste tyre pyrolysis under several experimental conditions. Waste tyre represents a significant
problem in developed countries and it is necessary to develop new technology that could easily process
big amounts of this potentially raw material. In this work, the influence of the main pyrolysis process
variables (temperature, solid residence time, mass flow rate and inert gas flow) has been studied by a
thorough analysis of product yields and properties. It has been found that regardless the process operational parameters, a total waste tyre devolatilisation is achieved, producing a pyrolytic carbon black with
a volatile matter content under 5 wt.%. In addition, it has been proven that, in the range studied, the most
influencing process variables are temperature and solid mass flow rate, mainly because both variables
modify the gas residence time inside the reactor. In addition, it has been found that the modification
of these variables affects to the chemical properties of the products. This fact is mainly associated to
the different cracking reaction of the primary pyrolysis products.
2009 Elsevier Ltd. All rights reserved.
1. Introduction
In the developed countries, approximately one used tyre per capita and per year is produced. Scrap tyres suppose a special challenge for their disposal or reuse because of their size, shape and
physicochemical properties. In order to deal with residues disposal,
the European Commission in the Landfill of Waste Directive (European Commission, 1999) proposes the following routine: to reduce,
to reuse, to recycle and, finally, to perform an energy valorisation
process. Although it would be desirable to implement only the
three first strategies, waste tyre generation is so high that it is
unavoidable to make use of the energy valorisation processes.
Scrap tyres have high-volatile, moderate sulfur content and lowash contents with a calorific value greater than that of coal or biomass. These properties make it an ideal material for thermochemical treatments (combustion, pyrolysis and gasification). Among
these processes, pyrolysis would be very interesting because not
only valuable products can be obtained but low emissions are also
generated, since approximately only 20% of the raw material is finally burnt (Murillo et al., 2006) to provide the internal energy
demand.
In the pyrolysis process, the organic volatile matter of tyres
(mainly the rubber polymer/s) is decomposed to low molecular
weight products, liquids or gases. The inorganic components and
the non-volatile carbon black remain as a solid residue which is
relatively unaltered, and therefore can be recycled in worthwhile
applications. The derived oils can be used as fuels or as a source
* Corresponding author. Tel.: +34 976 733977; fax: +34 976 733318.
E-mail address: ramonm@icb.csic.es (R. Murillo).
0956-053X/$ - see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.wasman.2009.10.001
assembly with two cyclone separators, a cooling system and a gascirculating pump and preheating system. This system is used to
process 5 kg/h of tyre powder. Diez et al. (2005) compared results
obtained at two different working scales, laboratory batch experiments with 50 g of ground tyre shreds and bench scale experiments of batches of 20 kg. The bench plant consists of a
discontinuous feeding system and an electrically heated chamber
containing a wormscrew that pushes the shredded tyre material
through the reactor. Galvagno et al. (2002) utilised a pilot scale
experimental pyrolysis plant to treat scrap tyres which consists
on a rotary kiln reactor externally heated working with a maximum feeding rate of around 50 kg/h of tyre.
The present study used a pyrolysis system for rubber tyre loading up to 15 kg/h in a moving bed reactor. The main objective of
the research work in progress is to evaluate both, process performance and chemical characteristics of the products obtained, while
varying the main operational parameters. Scrap tyre samples used
for the treatment, solid and liquid by-products and the produced
gas were analysed and the results are discussed in the present
paper.
2. Experimental
The raw material used for the pyrolysis experiments was a sample of tyre rubber shreds (without steel core) supplied by Negrell
Residus SL, a Spanish waste tyre recycling company. These tyre
shreds were a mixture of tyres from trucks, tractors and cars. The
average particle size was 5 mm approximately and had the following ultimate and proximate analyses: C (ar) 81.72%; H (ar) 6.54%; S
(ar) 1.87%; N (ar) 0.55%; moisture (ar) 0.71%; ash content 6.64% and
volatile matter (ar) 62.58% where ar means as received. The ultimate analysis was determined with a Carlo Erba EA1108 instrument. The moisture was determined by ISO-589-1981, the ash
content by ISO-1171-1976 and the volatile matter by ISO-56231974.
The experimental system has been described in detail elsewhere (Ayln et al., 2008) and consists of four main parts: the feeding system, the reactor, the solid collecting system and the
condensing system. The feeding system presents a total capacity
of 10 kg approximately and allows carrying out the process continuously under inert atmosphere by using nitrogen as carrier gas. The
reactor is a continuously operated moving bed reactor and designed to process up to 15 kg/h of waste tyre. The tyre shreds move
through the reactor and, at the same time, they decompose into a
gaseous product and a solid residue. The solid residue leaves the
reactor by gravity falling into a solid collecting system and the gas
reaches the condensing system by natural convection helped by
the carrier gas. Eventually, the non-condensed pyrolysis gas is
pipelined to a burner before it reaches the atmosphere. Several
experiments were carried out under the same conditions to determine the plant reproducibility. It was observed an excellent process reproducibility and stability. In the present work, four series
of experiments have been carried out in order to study the main
operation variables: reaction temperature, solid residence time,
mass flow rate and inert gas flow. The pyrolysis conditions for
these experiments are collected in Table 1.
Yields to solid and liquid products were directly obtained by
weight. The gas fraction percentage was calculated through a mass
balance. The pyrolysis products obtained in all the experiments
have been characterized as follows: permanent gases were analysed in a Varian 3800 CP gas chromatograph equipped with a
thermal conductivity detector (TCD) and HAYESEP Q and Mole
Sieve HP-Al/KCl columns. Hydrogen was analysed in a Hewlett
Packard 5890 series II model, equipped with a TCD detector, a Mole
Sieve column and argon as carrier gas. For C1C4 compounds the
1221
Table 1
Experimental pyrolysis conditions.
Experiment
T (K)
Solid residence
time (min)
T 873
T 973
T 1073
SRT 1
SRT 2
SRT 3
SRT 4
SRT 5
MFR 1
MFR 2
MFR 3
INERT 1
INERT 2
INERT 3
873
973
1073
873
873
873
873
873
873
873
873
873
873
873
3.7
3.7
3.7
5.3
3.7
2.5
1.9
1.5
3.7
3.7
3.7
3.7
3.7
3.7
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
6
8
3.5
3.5
3.5
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
68.4
144.0
Table 2
Product yields, proximate analysis of the solid and gas residence time at different
reaction temperatures (3.5 kg/h, solid residence time = 3.7 min, N2 = 11.4 l N/h).
Reaction temperature (K)
873
973
1073
Product yields
Solid (wt.%)
Liquid (wt.%)
Gas (wt.%)
40.6
41.5
17.9
39.0
31.3
29.7
41.0
27.5
31.5
1.26
4.41
97.3
16.7
0.86
2.15
98.8
14.9
0.45
1.33
99.2
13.5
1222
16.0
14.0
(g /g tyre)*100
12.0
600 C
700 C
800 C
10.0
8.0
Table 3
Ultimate analysis, thin layer chromatography and simulated distillation of the
pyrolysis oil obtained at different reaction temperature (3.5 kg/h, N2 = 11.4 l N/h,
solid residence time = 3.7 min).
Reaction temperature (K)
873
973
1073
Ultimate analysis
Carbon (wt.%)
Hydrogen (wt.%)
Nitrogen (wt.%)
Sulfur (wt.%)
88.58
10.40
1.43
1.05
91.00
8.17
1.39
1.12
90.56
7.66
1.28
0.93
4.8
67.8
27.5
2.2
68.5
29.4
0.0
72.8
27.2
46.5
36.5
17
55.5
33.7
10.8
59.3
33.4
7.3
tr
L
rpm P
C p DT 2 DE2 =4 P rpm q 1 U a 60
6.0
4.0
2.0
0.0
H2
COx
H2S
CH4
C2
C3
C4
where C is the mass flow rate (kg/h), DT is the screw diameter (m),
DE is the core diameter (m), q is the particle density (kg/m3), U is
the free volume percentage inside the screw, a is the section reduction due to screw inclination (horizontal screw, a = 1).
The increase of the gas residence time would favour the cracking of the primary pyrolysis products and would promote a change
in the gas/liquid ratio. However, experimentally, these variations
seem not to be important enough to change the yields to the three
6.0
5.0
(g /g tyre)*100
3.5 kg/h
6 kg/h
8 kg/h
4.0
3.0
2.0
1.0
0.0
H2
3.3. Mass flow rate influence on the reaction product yields and
properties
Results of a set of three experiments (3.5, 6 and 8 kg/h) have
been analysed in order to study the influence of this variable.
The product yields obtained are shown in Table 4, where it is observed that this variable affects considerably to the gas/liquid ratio
obtained, while the solid yield remains constant. According to Eq.
(2), the higher the tyre flow rate, the lower the free volume inside
the reactor and, on the other hand, as a consequence of a higher
tyre flow rate, there is an important increment in the volatile matter released. Both effects make that the gas residence time inside
the reactor decreases considerably (from 17 to 3 s). This remarkable decrease of the gas residence time when the tyre flow rate
is increased, limits the cracking of the gas fraction. Therefore, a bigger amount of liquid is obtained in the process. It must also be
pointed out that the proximate analysis of the solid product indicates a volatile content lower than 5 wt.% in all the experiments.
Thus, it can be concluded that the material devolatilisation has
been achieved even for the highest tyre flow rate studied.
The effect of a lower cracking when the tyre flow rate is increased can be also observed in the product characteristics. Fig. 2
shows the composition of the gas fraction expressed in terms of
gas compound yields. When the mass flow rate is increased, the
gas fraction obtained presents a higher percentage of the heaviest
compounds. It is worth to highlight that the increase of the yield in
light compounds is doubled in the case of the lowest tyre flow rate
(3.5 kg/h).
Regarding to the liquid fraction characteristics the variations
are not so noticeable. It has not been found any difference in the
ultimate analysis data and only a very slight decrease of the aromatic hydrocarbons percentage has been observed when the tyre
flow rate is increased. However, some differences have been found
in the simulated distillation curves. In Table 5 it can be observed
that when the tyre flow rate is increased, the gasoline percentage
in the liquid yield decreases, varying between 25% and 47% in
the studied range.
Table 4
Product yields, proximate analysis of the solid and gas residence time at different
mass flow rate (T = 873 K, solid residence time = 3.7 min, N2 = 11.4 l N/h).
Mass flow rate (kg/h)
3.5
6.0
8.0
Product yields
Solid (wt.%)
Liquid (wt.%)
Gas (wt.%)
40.6
41.5
17.9
39.9
46.4
13.6
39.9
48.4
11.7
1.26
4.41
97.3
16.71
1.58
3.87
97.8
6.74
1.54
4.41
97.4
3.23
1223
COx
H2S
CH4
C2
C3
C4
Fig. 2. Composition of the gas fraction obtained at different mass flow rate
(T = 873 K, N2 = 11.4 l N/h, solid residence time = 3.7 min).
Table 5
Ultimate analysis, thin layer chromatography and simulated distillation of the
pyrolysis oil obtained at different mass flow rate (T = 873 K, solid residence
time = 3.7 min, N2 = 11.4 l N/h).
Mass flow rate (kg/h)
3.5
6.0
8.0
Ultimate analysis
Carbon (wt.%)
Hydrogen (wt.%)
Nitrogen (wt.%)
Sulfur (wt.%)
88.58
10.40
1.43
1.05
85.81
10.78
4.61
0.98
83.52
10.66
0.90
0.91
4.8
67.8
27.5
5.5
65.2
29.3
5.8
64.7
29.5
46.5
36.5
17
38.9
32.7
28.4
25.9
33.3
40.8
3.4. Inert gas flow rate influence on the reaction product yields and
properties
The last variable that has been assessed is the inert gas (nitrogen) flow rate. Three experiments have been carried out to check
the influence of this variable on product yields and properties:
5 vol.% N2, 20 vol.% N2 and 35 vol.% N2 in the gas fraction inside
the reactor (these percentages correspond to an inert gas flow of
11.4, 68.4 and 144 l N/h, respectively). It could be expected that
the residence time of the gas phase produced by pyrolysis would
decrease at increasing inert gas flows. High nitrogen flow rates removed the products quickly from the reaction zone and hence minimised secondary reactions such as cracking. However, according
to the experiments performed, no influence of the nitrogen flow
rate has been detected. Both, the product yields and product properties are similar to those reported in Table 2 for the experiment
performed at 873 K. Probably, no change has been found because
the variation of the gas residence time as a consequence of the inert gas increment is almost negligible (the gas residence time only
changes from 17 to 15 s although the inert flow rate has been notably increased). Nevertheless, it has been considered that higher
percentages of nitrogen in the final gas would suppose an excessive
dilution of the gas fraction and therefore these gases may not have
enough calorific value to satisfy the process energy requirement.
4. Conclusions
According to the results shown in this paper, the total conversion of waste tyre has been achieved under all tested experimental
1224
conditions. It has been found that the volatile matter yield in the
produced char is lower than 5 wt.% in all the runs. Therefore, it
would be possible to select the most appropriate operational
parameters in terms of desired product distribution. The maximum
oil yield is obtained working at low temperatures (around 873 K)
and high mass flow rates (8 kg/h). Moreover, it has been proven
that the solid residence time needed to achieve the total conversion is <1.5 min. This residence time is clearly lower than other reported in literature for different reactor geometries. That would be
a remarkable asset of this experimental system compared to other
bench-scale reactors and the scaling up of the technology could be
performed taking into account the obtained experimental results.
Acknowledgements
Authors would like to thank to Negrell Residus SL the tyre sample supply and to the Spanish Science and Education Ministry the
FPU Pre-Doc grant (E. Ayln).
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