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In this technology the tyres are mechanically cut to about 20mm to 50mm size and
feed into reactor . This reactor processes the tyres and never needs to be opened. The
oil phase is extracted with blower and condensed. The carbon phase is conveyed via
closed conveyors into a carbon and steel separator. Inthis system the entire system is
a closed circuit. The reactors run continuously and are never opened to remove steel
or carbon from the system causing no carbon pollution or discharge in the air. This
system is generally known as the continuous pyrolysis technology.
The continuous plants operating in the country do not suffer from most of the
environmental and safety problems encountered in the existing batch plants. However,
even for the continuous pyrolysis plants the following facilities have been ensured for
the reliable continuous operation:
i. The feed to the reactor is screw conveyor.
ii. The feeding system provided with air-lock arrangements so that no air enters the
reactor during feeding.
iii. The initial heating of the reactor is done by liquid fuel or gas. The flue released to
the atmosphere through a chimney of at PCB norms height (max 30 mtrs).
iv. After initial heating, during the pyrolysis process, the pyro gas is generated within
the plant and it is burned as a fuel.
v. Excess pyro gas has to be flared through properly designed flaring system of
adequate capacity considering the emergency situation in which the entire gas may
have to be flared. The flaring should be done at a minimum height of 30 metre.
vi. Adequate instrumentation for measurement and control of temperature and
pressure along with safety interlocks to cut off heating of the reactor in case of
increase of temperature or pressure will be provided. Automatic control systems such
as Programmed Logic Control (PLC) shall be adopted. It should be ensured that the
reactor is under positive pressure all the time.
vii. In order to control fugitive emissions from the reactor during operation, proper
sealing will be provided.
viii. The collection of the oil from the condensers shall be in closed vessel and storage
also should be in closed tanks with suitable vents. There should be no manual
handling of oil. Transfer of oil shall be through pumps.
ix. The removal of carbon will be through a mechanized system and it will be ensured
that no spillage takes place during the collection of the carbon in the bags. Moreover
an air-lock will be provided to ensure no entry of air into the reactor.
xii. The adequate plot size for storage of cut tyres, oil and carbon black in addition to
the pyrolysis plant and accessories as well as enough space for movement of fire
tender in case of any emergency. A minimum indicative size of small plant is about
3000 square metres.