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Semi-continuous Tire Plastics Pyrolysis Plant 

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Introduction

Semi-continuous Tire Plastics Pyrolysis Plant is an improved thermal decomposition system which is developed to transform waste tires and plastics into useful energy products by a process-controlled heating in the absence of oxygen. This is a new technology that is able to resolve the increasing environmental problem in the form of tire and plastic waste and produce commercially viable products such as pyrolysis oil, carbon black, steel wire, and combustible gas. The plant is operated at temperatures of 250 o C to 450 o c with a semi-continuous feeding system which allows it to have an efficient batch processing with minimum downtime between cycles. Having processing capacities of 6 to 20 tons per batch, these plants are set up to be operated at industrial scale with an aim of finding a sustainable waste management solution and the possibility of generating revenue on the same. Through the pyrolysis process, the long chain hydrocarbon polymers are effectively reduced to short molecules resulting in products that are capable of being used as alternative fuels, industrial carbon supplements as well as raw materials in industrial manufacturing processes.

Why Choose Kerone Semi-continuous Tire Plastics Pyrolysis Plant

Semi-continuous Tire Plastics Pyrolysis Plant by KERONE in the waste-to-energy sector is a remarkable example of the perfect engineering accuracy, guaranteed operating efficiency and devotion to environmental consciousness. Having a history of more than forty years with experience in thermal processing, KERONE has come up with a pyrolysis process which is capable of producing maximum quality of output at minimal costs of operation and the amount of environmental damage. Our plants have high reactor metallurgy that has been specially formulated to survive corrosive behaviour of pyrolysis gases and long operational life to make our plants last long and demand less maintenance. The semi-continuous operation model is the ideal compromise between the fully batch and the continuous system; it gives the flexibility in its operation but has high throughput efficiency.
The KERONE philosophy has been to embrace a holistic approach through proper pre-installation consultation, a tailored system design, which is dependent on the specific characteristics of the feedstock, professional supervision of the installation, operator training programs, and technical support. Our plants have several safety redundancies, auto process controls, and efficient heat recovery systems that save up to 30% of fuel settings as compared to the traditional designs. Moreover, KERONE can go further to provide a service to supply equipment as well as provide support in regulatory compliance, environmental impact assessment and optimization policies that can guarantee maximum returns on investment throughout the operational life of the plant.

Types and Features of Semi-continuous Tire Plastics Pyrolysis Plant

The Semi-continuous Tire Plastics Pyrolysis Plants of KERONE are designed in different formats based on specific needs of the process, feedstock to process and also quantities of production. The typical models are horizontal reactor designs when using mixed waste streams, vertical reactor designs when processing mainly tires, and modular designs which can be expanded as the business expands. All types of plants have individual feeding systems specialty screw conveyors of the shredded material and hydraulic pushers of the whole tire, which assure the uniform flow of material and the optimal loading of the reactor. The reactor vessels are made of high-grade boiler steel and their internal designs are special to enable even distribution of heat and no hot spots. In high technologies, multiple stage cooling is used in condensation systems to recover as much oil as possible and to separate light and heavy fractions adequately. Cycle separators, water scrubbers, and activated carbon filters are added into gas cleaning units to ensure high standards of emission. The semi-continuous operation allows a reactor to be cooled and discharged as the other is heated and this reflects a lot on the productivity of the whole system. Also, the plants may be fitted with automated tire shredding devices, steel separation relying on magnets to recover them, carbon black processors, and advanced SCADA to allow remote monitoring and data recording that will give operators full visibility and control of the processes.

Key Features

  • Advanced Reactor Design

    • Intensive horizontal rotating reactor with specialized internal structure that guaranteed uniformity in heat distribution, maximum material contact and long service life of more than 8-10 years of continuous operation.

  • Semi-continuous

    • The semi-continuous operation type has been developed enabling continuous feeding preparation and operation as long as a batch is being sequenced with 85-90% equipment utilization compared to the traditional batch system 60-65%.

  • Efficient Heat System

    • Multi-fuel friendly furnace with optimized burner system, refractory lining, and heat recovery system which lowers the fuel burn by 25-30 percent, but still provides regular processing temperatures.

  • High Oil Yield Technology

    • New technology based on a high condensation system, three stage cooling tower, high performance heat exchangers, and efficient design of vapor pathways that have a recovery rate of up to 40-45 percent of the tires and 50-60 percent of the plastics.

  • Automated Safety Systems

    • Extensive safety design portion: pressure relief valves, temperature sensors, emergency shutdown, flame arrestors and water seals guarantees operator safety and the compliance with the regulations.

  • Environmental Protection Package

    • Built in pollution control desulfurization towers, dust collection system, activated carbon adsorption system, and tail gas recycle system that satisfy Euro 5 and EPA standards of emission control.

  • PLC-Based Automation include

    • A front office and a back office to handle data files, data analysis package, and heart rate measurement package.

Powered by AI, ML & IoT

Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Semi-continuous Tire Plastics Pyrolysis Plant

These Semi-continuous Tire Plastics Pyrolysis Plants are widely applied in waste management, energy generation, and in the fields of the circular economy, created by Kerone.
The common uses are:
    • Waste Tire Recycling Facilities: Having end-of-life tires of automotive, truck, aircraft, and industrial equipment sources, they are converted to profitable energy products and useful steel components are recovered by utilizing them.
    • Municipal Solid Waste Management: Plastic-laden municipal waste streams such as packaging, agricultural films and mixed plastic waste will be treated, resulting in less reliance on landfills and the generation of alternative energy sources.
    • Petrochemical Industry: Transformation of polymer production waste and off-spec plastic materials, contaminated plastic materials, and polymerization residues into feedstock which can be reused in chemical production processes.
    • Steel Processing Plants: Inclusivity scrap tires collected during heavy machinery will be utilized to produce thermal energy used in various industry processes as well as carbon black that can be used to supplement the metallurgical carbon needs.
    • Production of Alternate Fuel: Commercial production of pyrolysis oil as alternative fuel to power boilers, furnaces and generators in industries like cement production, brick kilns and thermal power production.
The Semi-continuous Tire Plastics Pyrolysis Plant by KERONE is a technologically advanced, economically viable, and environmentally responsible solution to the problem of management of tires and plastics waste in the world. The plants will allow enterprises to be a part of the circular economy by turning waste materials into some of the highest-valued commodities, including pyrolysis oil, carbon black, steel wire, and combustible gas. The dedication of KERONE to engineering quality, business performance, and client success will make sure that each installation achieves the best performance, compliance with regulation, and profitability in the long run. The semi-continuous design has the best combination of operational flexibility and production efficiency thus it can be used by both the upcoming waste management businesses as well as the established recycling businesses that want to increase their size.
KERONE is a comprehensive and enthusiastic partner of its clients to optimize the returns of their investments with continuous support starting with consultation services until the end of its operations, in addition to bringing about environmental sustainability. As the global regulations gradually bring responsibility to waste disposal and industries are considering cost effective alternative sources of energy Semi-continuous Tire Plastics Pyrolysis Plant by the KERONE is a proven technology that is capable of making sure that demands are met with reliability, cost effectiveness, and quantifiable outcomes.

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Frequently Asked Questions (FAQ)

  • Kerone Company has semi-continuous tire pyrolysis plants in different capacities 6 tons to 20 tons per batch. Under the model of semi-continuous operation, it is also possible to process about 20-25 tons of material in a day through a 10-ton reactor system, one reactor will be cooling and discharging, the other undergoes pyrolysis, which is much more productive than the conventional batch system.

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