The Technology

With our patented Chemical Recycling through Pyrolysis of Rubber waste and End-of-Life Tires (CRPR) technology we are able to recycle rubber waste and End-of-Life Tires (ELTs) in a sustainable and renewable way into products with high added value.

This process, based on a proper separation of waste, is characterized by high efficiency, continuous operation, low-temperature (high energy consumption is not required), with minimum residence time (very fast pyrolysis), and without producing new waste (waxes and/or tars).

From the environmental point of view, it is important to mention that products or recycled materials and/or obtained results from this process fully comply with European legislation REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), resulting in healthy products that are safe for the environment, meeting the objectives of the circular economy.

The implementation of our technology allows certifying according to ISO (International Organization for Standardization) 9000 and 14000, which determines our industrial facility as a “zero emission plant” in environmental perspective.

According to the EU Renewable Energy Directive (RED) waste has a zero carbon footprint.  Since rubber waste and End-of-Life Tires (ELTs) will be the feedstock for our CRPR process and its installation is a zero emission plant, all products produced in this facility are classified as sustainable, renewable and green products.

The process reduces toxic waste, with consequent environmental benefits, resulting in different new products or secondary raw material, with high added value:

  • “Green” Limonene.
  • “Green” Carbon Black / Active Carbon.
  • “Green” Liquid and gaseous fuels.

Pyrolysis is the chemical decomposition of all materials, except metals and glasses, caused by heating in the absence of oxygen.

In our Pyrolysis process Rubber waste and End-of-Life Tires (ELTs) turn into liquids, pyrolysis gases and a solid fraction by thermal flash pyrolysis and secondary reactions. Its yield and properties vary primarily with operating temperature and residue characteristics.

The process of chemical recycling through flash pyrolysis, as such, is carried out in a spouted bed pyrolysis reactor, which is a static body consisting of an upside down truncated-cone that extends at the top end as a cylinder with the purpose to collect the solids carried by the gas flow through the center of the bed. The inlet conical section is specially designed for maximum efficiency of the gas – solid contact (optimal heat transfer), minimum pressure drop and uniformity of the solids to be processed.

The different fractions obtained are separated. The separation methods used in this process are based on the different volatility of the components.

The yield by weight of the different components in the liquid fraction depends on operating temperature and temperature control in de pyrolysis reactor. Therefore we distinguish two types of operating modes or types of production units, both with different outcomes.

Production Unit Type I:

  • The liquid fraction obtained is of suitable quality and contains its largest single component, Limonene, reaching yields of 20 to 22% by weight.
  • From this liquid fraction dipentene (DL-Limonene) is separated and purificated.
  • Another part of the liquid fraction is Fuel Oil. This oil may be characterized, based on its properties, between a light and medium Fuel Oil.

Production Unit Type II:

  • The liquid fraction obtained with a yield of 55% is of suitable quality for use as fuel.
  • The liquid fuel need separation of the two different fuels Diesel and Gasoline through fractional distillation reaching yields of 36% Diesel and 19% Gasoline.

The solid fraction of both operating modes can potentially be used as carbon black, smokeless fuel as well as Activated Carbon, or can be gasified to produce gaseous fuels. In any case these applications require subsequent activation processes.

Comparison with other Pyrolysis Technologies

Pyrolysis is a technology that exists for over more than 100 years and there are more than 80 patents worldwide. Mostly we are talking about pyrolysis at high temperature, with very poor performance and generation of polluting waste and emission during the process.

Our patented CRPR technology however is the only pyrolysis technology in the world, that is internationally approved using a process that is technically and economically superior profitable, without any polluting emission, which offers the following results:

  • The chemical transformation of waste gases is total, not generating waste ashes, or wax and tars.
  • Carbon black obtained is clean of oils, being of high quality. Its subsequent treatment allows to remove residual sulfur, getting a high quality active carbon.
  • It is the only technology of this kind that will produce Limonene of a high purity out of rubber waste.
  • Obtain liquid fuels in a very high quality percentage, allowing to obtain fuel homologated for vessels and for the automotive industry and/or usage for the generation of electricity.

Production Process

Our production process is a true Circular Economic process.

  • As feedstock for our technology we use toxic End-of-Life Tires and other rubber waste.
  • The first fraction obtained is a gas with a yield of 10% for type I and 15% for type II.
  • This gas is used as fuel for the production units.
  • The second fraction obtained is a liquid with a yield of 60% for type I and a yield of 55% for type II.
  • This liquid is stored for post-processing.
  • The final fraction is a solid one with a yield of 30%. This is our carbon black.
  • The carbon is activated to Activated Carbon with a final yield of 12 to 19%.
  • The liquid fraction of unit type I is separated and purified. This results in a 20 to 22% yield of Limonene of high purity and a 34 to 40% yield of Fuel oil.
  • The liquid fraction of unit type II is separated and homologated. This results in a 17 to 18% yield of Gasoline and a 32 to 34% yield of Diesel.
  • The part of the liquid fraction that is commercially unsuitable is used as fuel for the production units.

In loving memory of our friend,

José Leandro “Lalo” Martinez Camus.

Rest in peace.

© 2017-2021, El Toro Verde. All rights reserved