The Pyrolyx Technology

The cycle closes

Large amounts of raw materials are required for tire production. Every year, more than 20 million tons of crude oil are used for the production of Carbon Black, one main component of tires. During this production crude oil (the feedstock) is introduced into a hot gas stream where it vaporizes and then pyrolyzes in the vapor phase to form microscopic carbon particles. The recovery of the carbon black from the end product was not possible until just now. Once bound in the end product, it was no longer available for the cycle until very recently. Many developers and engineers tried in vain to recover this valuable component from scrap tires, to feed it back into the production of rubber products, and thus to close the cycle.

Pyrolyx technology: groundbreaking

For this reason we are proud to develop the world’s first and only market-ready technology for a closed recycling loop which breaks the waste-tire granules down into industrially usable raw materials, producing high-quality carbon black: the Pyrolyx technology. With this method, organic compounds in the vulcanized rubber granules are broken down in the absence of oxygen at temperatures between 350 °C and 700 °C. In addition to oil and pure gases, which can be used for energy and heat recovery, the residue is Pyrolyx carbon black, the world’s first carbon black that is produced in an environmentally friendly way. Pyrolyx carbon black meets the highest quality standards and contains no toxic or carcinogenic components in any significant concentration (e.g. the PAH values of Pyrolyx carbon black are below the detection threshold and are hence at least 1,000 times below those of conventionally produced carbon black) – the perfect basis for the production of new tires.

The Pyrolyx technology can fundamentally change the manufacture of many rubber products, as it closes the cycle for the first time: the waste tire is almost completely utilized for the new tire, only a small amount of additional raw materials is required – which signifies enormous ecological and economic progress! 

The first closed recycling loop for carbon black

Ready for the market

Pyrolyx AG holds the rights to the Pyrolyx technology and has financed the fundamental test and pilot reactors. The task is now to establish this method on a global scale. After the completion of the first large industrial plant we will start selling our turnkey systems worldwide, jointly with Zeppelin Systems GmbH, an internationally leading plant construction company.

The Only Sustainable Method of Waste-Tire Recycling

For a long time experts have considered pyrolysis to be the future of used-tire recycling. The method of heating waste materials in the absence of oxygen to such high temperatures that the organic compounds are broken down, has already proven to be effective in many areas. Unfortunately, when it came to reprocessing rubber granules, no one was able to develop a satisfying method until now.

Entering the profit zone with the Pyrolyx technology

The Pyrolyx technology for the first time makes it possible to utilize rubber granules made from scrap tires in a way that is economically feasible and sustainable. The method has been successfully tested in various pilot plants: the analyses renowned institutes, such as the Fraunhofer Institute and the German Institute of Rubber Technology as well as the previous extensive tests of leading tire manufacturers have verified the high quality of the carbon black gained in this manner. Therefore we are very confident, that also the final tests of the tire industry will reaffirm these results.

What is new about the Pyrolyx technology is the combination of the two methods of pyrolysis and depolymerization. Only regular waste-tire granules from established suppliers are used in this process whose availability in all industrialized markets is guaranteed for the long term.

Conventional carbon black production

Gas, oil, and carbon black

The Pyrolyx technology not only releases process-related carbon black but also gases with organic compounds which condense into oil when cooled down. The ratio and the composition of this fraction depends on the temperature, retention time, and specific process parameters.

The material stays in the system, which is divided into zones with different temperature and process states, for several hours. When the gases which are released there are directed through a condenser, their vaporous organic components liquefy and are discharged in different fractions. These can be sold as a valuable basic material, processed further, or used as energy carriers in the manufacture of additional carbon blacks. The gases which have been released from the condensable components have a natural gas-like quality and are used for power generation. What remains at the discharge point of the device is the solid coke fraction, carbon black. The cycle has closed. 

The Pyrolyx cycle