Process for the treatment of used rubber and plastics

Abstract: The process aims treatment of used rubber and plastics such as vehicle tyres, car fluff (plastic and rubber residues from shredded automobiles), and RDF (Refused Derived Fuel). A vacuum pyrolysis of cuttings of said rubber and plastics is made in a reactor to yield a non condensable fraction of combustible gas, oil, and a carbonaceous solid residue. A portion of the carbenaceous solid residue is mechanically mixed in the reactor to the rubber and plastics cuttings before and during pyrolysis thereof.

Description: This invention relates to a process for the treatment of used rubber and plastics by vacuum pyrolysis of cuttings of said used rubber and plastics to yield a non condensable fraction of combustible gas, oil, and a carbonaceous solid residue. The treatment of used rubber and plastics such as vehicle tyres, car fluff (plastic and rubber residues from shredded automobiles), and RDF (Refuse Derived Fuel) is a major environmental problem. Vacuum pyrolysis of rubber and plastics cuttings is state of the art. For example, US Patent N° 4,740,270 describes a process for the vacuum pyrolysis of scrap tyres in which tyre cuttings are moved in a multi-tray reactor with conventional transportation system of the tyre cuttings from an upper to a lower tray for subjecting them to pyrolysis. The tyre cuttings are shifted from the top tray to the bottom tray along a temperature gradient starting at 200°C and peaking at 500°C, the tyre cuttings being thus heated up continuously while moving down. The process aims a high oil yield against non condensable gas, and to achieve that result, the document recommends a subatmospheric pressure of less than 35 mm Hg. it is known that rubber undergoes a softening stage before pyrolysis sets on from 200°C onwards. Softened tyre cuttings are sticky and prone to fix to any available surface, thereby choking the equipment. In the multi-tray reactor described, the tyre cuttings will stick in one stand, most likely always the same tray, as long as the speed of transportation, the temperature gradient, and the heat transfer coefficient are maintained constant. The rubber cuttings may therefore choke a tray, whereas the transport of the cuttings is impaired and the pyrolysis gas is trapped. An overpressure is created in the reactor which may explode. Furthermore, to maintain the aforesaid subatmospheric pressure of 35 mm Hg, the reaction rate must be carefully controlled and kept low, which implies a long residence time of the materials in the reactor and therefore the reactor must be large. Still further, large reactors are expensive, and the lower the pressure in the reactor the more powerful and expensive the vacuum pump. All these adverse features make the equipment expensive and hazardous. EP-A-003803 describes pyrolysis of subber and plastic under reduced pressure such that HC vapour and solid residue are produced. A portion of the solid residue is then recycled bacts. It is an object of this invention to overcome these drawbacks by means of a process for the treatment of used rubber and plastics by vacuum pyrolysis which is safe, efficient, and economical. Accordingly, the invention provides for a process for the treatment of used rubber and plastics by low pressure pyrolysis of cuttings of said used rubber and plastics to yield a non condensable fraction of combustible gas, oil, and a carbonaceous solid residue, comprising the step of mechanically mixing in a reactor at least a portion of said carbonaceous solid residue to said rubber and plastics cuttings before and during pyrolysis thereof. The pressure in the reactor being seduced to 0.5-0.9 bar. The mechanical mixing ensures a homogeneous solid mass, a high transfer of heat from a reactor shell into the solid product, and a reduction of the reaction time. The carbonaceous solid residue is a fine powder which coats the rubber and plastics cuttings, thereby preventing them from sticking to available surfaces when undergoing the softening stage. Further, the carbonaceous solid residue enhances the heat transfer and contributes to reduce the reaction time. The carbonaceous solid residue acts as a thermal buffer and levels off temperature variations, which is particularly advantageous where a batch procedure is used. The process is safe. It is economical as it allows using a smaller reactor volume. It has been examined if the carbonaceous solid residue had some adverse catalytic effect, i.e., if it would boost the conversion of pyrolysis oil into non condensable gas; it has been found that the carbonaceous solid residue, which adsorbs the oil, behaves fairly neutral, and no decrease of oil yield was observed by comparison to a process making no use of the carbonaceous solid residue mixing. Typically, the pyrolysis of the rubber and plastics cuttings is made by batches of said rubber and plastics cuttings loaded successively in the reactor wherein each batch loaded in the reactor is mechanically mixed in the reactor before and during pyrolysis thereof to a portion of said carbonaceous solid residue as resulting from pyrolysis of a previous batch. Preferably, a further step is to remove from the reactor after pyrolysis only a part of said carbonaceous solid residue. Still a further step is that the weight of said part of the carbonaceous solid residue removed from the reactor after pyrolysis of a batch is smaller than that of a next batch and adjusted in a way that at the end of pyrolysis of said next batch a substantially constant amount of carbonaceous solid residue is yielded. Preferably, said rubber and plastics cuttings are mixed with said carbonaceous solid residue in a proportion of one part weight of rubber and plastics cuttings to three to one fifth part weight of said carbonaceous solid residue. Preferably, the used rubber and plastics are shredded to 2 x 2 inches (5.08 x 5.08 cm) cuttings or lesser size to make use of the standard cuttings size afforded by state of the art shredders. And said used rubber and plastics cuttings may be shredded without previous separation of cords and steel threads to avoid the expensive separation operation; the cords are transformed into a graphite powder which mixes well with the carbon black contained in the rubber and the steel threads may be easily removed by a magnetic separator after pyrolysis. The pressure in the reactor shell is reduced to 0.5 to 0.9 bar. In an advantageous configuration, the reactor comprises a reactor shell heated from the outside, either by electricity or hot gas, and the reactor shell is heated up to a temperature range from 450°C to 550°C. Pyrolysis temperature is in the range of 350°C to 450°C. Typically, the process yields 50 to 55% oil, 3 to 8% non condensable combustible gas, and the balance of matter is the carbonaceous solid residue containing carbon black, graphite from pyrolysed cords, zinc oxide, sulfur, silicates and other mineral substances, and steel threads. The yields depend on the quality of the pyrolysed materials and possible uses of the resulting products are state of the art of recycling.

Claims: A process for the treatment of used rubber and plastics by low pressure pyrolysis of cuttings of said used rubber and plastics to yield a non condensable fraction of combustible gas, oil, and a carbonaceous solid residue, characterized by the step of mechanically mixing in a reactor at least a portion of said carbonaceous solid residue to said rubber and plastics cuttings before and during pyrolysis thereof and in that the pressure in the reactor is reduced to 0.5 bar to 0.9 bar. A process according to claim 1, wherein pyrolysis of the rubber and plastics cuttings is made by batches of said rubber and plastics cuttings loaded successively in the reactor, and wherein each batch loaded in the reactor is mechanically mixed in the reactor before and during pyrolysis thereof to a portion of said carbonaceous solid residue as resulting from pyrolysis of a previous batch. A process according to claim 2, comprising the step of removing from the reactor after pyrolysis only a part of said carbonaceous solid residue. A process according to claim 3, wherein the weight of said part of the carbonaceous solid residue removed from the reactor after pyrolysis of a batch is smaller than that of the next batch and adjusted in a way that at the end of pyrolysis of the said next batch a substantially constant amount equal to the amount of carbonaceous solid residue of the previous batch is yielded. A process according to any of claims 1 to 4, wherein said rubber and plastics cuttings are mixed with said carbonaceous solid residue in a proportion of one part weight of rubber and plastics cuttings to three to one fifth part weight of said carbonaceous solid residue. A process according to any preceding claim, wherein the used rubber and plastics are shredded to 5.08X5.08 cm (2 x 2 inches) cuttings or lesser size. A process according to any preceding claim, wherein the used rubber and plastics cuttings are shredded without previous separation of cords and steel threads. A process according to any preceding claim, wherein the reactor comprises a reactor shell heated from the outside. A process according to claim 8 wherein the reactor shell is heated up to a temperature range from 450°C to 550°C. A process according to any preceding claim, wherein the pyrolysis temperature is in the range of 350°C to 450°C.

Inventors: AFFOLTER JEAN, BOVEY RICHARD, VUILLE JEAN-PIERRE, AFFOLTER, JEAN, BOVEY, RICHARD, VUILLE, JEAN-PIERRE
Applicants: ALCYON S A, ALCYON S.A.
Application year: 1997
Main classification: C10G1
IPC codes: C10G1, C10B53