How Old Tyres Are Recycled into Black Oil, Steel & Carbon | Waste Tyre Recycling Explained

Waste tires are recycled and broken down into black oil, carbon black, and steel primarily through a process called pyrolysis. Pyrolysis is the thermal decomposition of a material in the absence of oxygen. This eco-friendly process prevents the environmental hazards of landfilling or incinerating tires.
⚙️ The Pyrolysis Process
The entire process takes place in a sealed, oxygen-free reactor to prevent the material from combusting. It involves several key steps:
Shredding and Preparation: First, the waste tires are shredded into smaller pieces. This increases their surface area, making the pyrolysis process more efficient. In some advanced plants, the steel wires and textile fibers are removed from the rubber at this stage using magnetic separators and other machinery.
Feeding and Heating: The shredded tire material is fed into a sealed pyrolysis reactor. The reactor is then heated to high temperatures, typically between 400°C and 900°C. Common heat sources include natural gas, coal, or even a portion of the non-condensable gas produced during the process itself.
Thermal Decomposition: As the temperature rises, the organic polymers in the tires (rubber, carbon, etc.) begin to break down into smaller molecules. This decomposition process produces a mixture of gases, liquids, and solids. The absence of oxygen ensures that the material doesn't burn but rather "cracks" or breaks down into its constituent components.
Oil Condensation: The gaseous products, known as "oil gas," are cooled in a condenser. This cooling causes the gas to liquefy, forming tire pyrolysis oil (TPO), a dark, viscous oil with a strong smell. This oil is collected in a storage tank and can be used as an industrial fuel in furnaces, boilers, and other heavy machinery.
Gas Recovery: During the cooling process, some of the gas does not condense. This non-condensable gas, often called "syngas," has a high calorific value and can be recycled to fuel the pyrolysis reactor, making the entire process more energy-efficient and self-sustaining.
Carbon and Steel Extraction: After the oil gas has been extracted, a solid residue remains in the reactor. This residue consists of two main components: carbon black and steel wire. Once the reactor has cooled, the solid residue is discharged. A magnetic separator is then used to separate the steel wire from the carbon black.
🧪 End Products and Their Uses
Tire Pyrolysis Oil (TPO): This black oil can be used directly as a substitute for furnace oil in industrial applications. It can also be further refined through distillation to produce a higher-quality fuel similar to diesel. TPO contains valuable chemicals like benzene, toluene, and xylene (BTEX), which can be extracted and sold.
Recovered Carbon Black (rCB): This fine black powder is similar to the carbon black used in the original tire manufacturing process. It's a valuable filler and reinforcing agent for rubber and plastic products. It can be used to make new tires, pigments for ink, and in various construction materials.
Steel Wire: The recovered steel wire is a high-quality scrap metal that can be sold to steel mills for reuse. It's melted down and recycled to create new steel products, closing the loop on a critical raw material in tire production.
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