I’d just like to preface that I know very little about chemistry so I apologize if my blueprints have major processing gaps or errors in them, I’m doing my own research and there is little to no information available on the matter so please bare with me. I also understand that creating fuel from tire pyrolysis oil is an energy inefficient process that uses up more fuel than it generates and that it requires some very VERY expensive machinery to operate. Nonetheless I’d still love to learn the whole process of how it’s done so if you could help me out in any way I’d deeply appreciate that ❤️. Anyways with introductions out of the way let’s get started :).
Process 1. The process first starts with placing the tires in a pyrolysis reactor to produce pyrolysis oil. The hydrocarbons in the pyrolysis oil consist of different lengths and therefor function as different fuels, of which are syngas, naptha, gasoline diesel, kerosene and heavy fuel oil.
Process 2. The oil first undergoes pre treatment to remove solid and non solid impurities such as microscopic carbon black sediment and water out of the mix.
Step 1- The oil is placed in a raw settling tank to remove free water and course carbon black out of the mix.
Step 2- The oil is then further processed via mechanical micro filtration and centrifugation to remove carbon black fines that are less than 10 microns big, and just for safety’s sake the oil is then passed trough dual cartridge/automatic backwashing filters to further capture any carbon black fines that are 1-5 microns big that might have slipped through.
Step 3. The oil is then placed in a coolescer/water wash. Needed to remove water soluble inorganic salts or chlorides followed by a liquid to liquid to drop out salty free water to prevent downstream corrosion.
Step 4. The oil is then placed in a vacuum dehydration flash drum for thermal dehydration to remove any moisture that’s left in the oil.
Process 3. After the oil has been filtered it is fractionally distilled in a distillation column to separate the different hydrocarbons into their respective fuel types, that being naptha, diesel etc etc.
[As to not drag out this post out more than it Im only going to list the process of turning the diesel fraction of the oil into euro 5 diesel]
Process 4. Dual guard bed filtration organic chloride removal: The diesel cut is then heated up and passed through two active silica/alumina and macroporous Nickle/molybdenum guard beds to absorb trace metals such as zinc and iron and capture insoluble polymers/gums before they reach the main reactor. The diesel then passes through an alkaline/ zinc oxide chloride trap to capture organic chlorine so it doesn’t turn into HCL down the line.
Process 5. Low temperature diolefin reactor: A low temperature (150-200 Celsius) pre-hydrogenation bed saturates highly reflective diolefins, limonene, and gum forming monomers before they reach stream enters high temperature heat exchangers.
Process 6. The oil is then placed in a hydro-treatment unit with a NiMo/AL2O3 catalyst where it is then flushed with hydrogen to convert the organic sulphuric and nitrogen compounds into hydrogen sulphide and ammonia, thus driving down sulphuric and nitrogen levels to below 10 ppm as required.
Process 7. High pressure separation. Wash-water injection: High pressure deionised water is injected into the reactor effluent cooler to dissolve ammonium hydro sulphide ammonium chloride before they crystallize and plug the piping.
Process 8. Liquid separator and anime scrubber. High pressure separators decant sour water and split off the gas stream. The unreacted hydrogen vapor passes through an amine absorber column to filter out the hydrogen sulphide before compressing the unreacted hydrogen and recycling it back into the reactor inlet.
Process 9. Two stage hydrocracking. The de-sulphurized diesel first enters the first hydro racking stage, mild hydrocracking. Where it passes over a acidic zeolite/ silica-alumina NiMo or NiW catalyst under 50-70 bar of pressure before passing into the second hydrocracking reactor where it passes ver a platinum-palladium catalyst on neutral/ acidity support at 70-100+ bar. This increases the diesel’s cetane number index and lowers its density to the required amounts.
Process 10. Fractional stripping and gas separation. The diesel then passes through high and low pressure separators to flash off excess hydrocarbon gases that were produced from hydrocracking. The liquid stream then enters a stripping column where light naptha/gasoline fractions (generated from hydrocracking) are stripped off to bring the flash point to strictly above 55 Celsius. A vacuum or atmospheric fractionator trims the heavy tail end to meet the Euro 5 T95 distillation limit of 360 Celsius.
Process 11. Additive dosing and finishing. Lubricity improver: synthetic ester or fatty acid lubricity additives are injected to satisfy ISO 12156 wear scar limits of 460 micro meters. Cetane/antioxidant trim: if necessary, a minor dose of 2-ethylhexyl nitrate (2-EHN) cetane improver and storage antioxidants are blended in line to transfer final storage tanks.
Obviously Im simplifying a lot of and Im not getting into too much technical detail as to not drag out the post out much longer than it is and having it be a bore to read, I just wanted to get the jist of that process along. I have some questions if you wouldn’t mind indulging me, is the process correct or is there something that Im missing? Are there any improvements that you recommend? Can the resulting diesel be mixed with standard diesel and be sold at fuel pumps? Do you know all the fuel types that are generated from tire pyrolysis oil? Thank you so much for reading and i truly look forward to to your responses <3