1. FORM 2
THE PATENT ACT1970
(39OF1970)
AND
THE PATENTS RULES, 2003
(See section10, rule13)
COMPLETE SPECIFICATION
Title of Invention: “A unique process for recovery of
Low Viscous-Low Suphur-High Pour Point -Fuel Oil by
converting wasted tyres”.
APPLICANT:
a) Name:
b) Nationality: Indian
c) Address:
[1]

2. PREAMBLE OF INVENTION:
The fallowing specification particularly describes the
invention and the manner in which it is to be performed.
FIELD OF THE INVENTION:
The invention relates generally to processes for
economically recovering carbonaceous materials from
used vulcanized articles. More specifically it relates to an
economical pyrolysis process for recovering carbon black,
fuel oil, fuel gas and steel from discarded tires.
BACKGROUND OF INVENTION:
Passenger cars and trucks are normally wear out millions
of tires each year. Disposal of these used tires has become
a major environmental problem. A high proportion (25%-
35%) of the weight of a used tire consists of carbon black
reinforcing of the rubber in both the tread and sidewalls.
This carbon black is prepared by conventional carbon
black production processes and comprises individual
particles one micron or less in diameter. Fifty to sixty
percent (50%-60%) of the weight of a discarded tire is
butadiene-styrene copolymer rubber. Tires also contain
certain amounts of oil and significant quantities of steel
wire and/or fiberglass or polyester cord. All of these
components are expensive and require large amounts of
energy in their manufacture. A process that would allow
economic recovery of these materials from the huge
[2]

3. stocks of used tires piling up around the country would be
very desirable. Unfortunately, the very characteristics that
makes tires long-lasting and safe on the road, i.e.,
durability, resistance to puncture and slicing, and
resistance to decomposition at moderate temperatures,
combine to make tires exceptionally difficult to recycle.
The prior art teaches that rubber can be pyrolyzed in the
absence of air at temperatures of between 842° and 1112°
Fahrenheit in laboratory equipment to produce oil, gas
and a solid residue that is carbonaceous in nature. Large
electrically heated sink reactors and Dewar flasks have
been used for obtaining test data.
The prior art also teaches some pilot plants that were built
to carry tire processing schemes into the commercial
world. Circulating heated ceramic balls have been used as
a direct source of reaction heat. The balls are heated
externally, mixed with rubber feed chips, discharged,
screened, reheated and recycled. These reactions take
place substantially at atmospheric pressure. Other pilot
plants have been designed which make the carbonaceous
solid phase of tire pyrolysis into fuel briquets. These fuel
briquets are much less valuable than the carbon black
produced by the present invention. Still other batch pilot
plants have been built in which the tires are indirectly
heated through the tray walls of multi-tray reactors to
temperatures of between 1400° and 1600° Fahrenheit. At
[3]

4. these temperatures, heavy oils and tar products can be
recycled for further cracking to improve carbon black
yields. Other batch and continuous type process plants
have been built that depend on indirect heating through
the walls of a jacketed screw reactor from a high
temperature molten salt heat sink. These reactors do not
have hollow shafts nor hollow flights and have far less
heat transfer area than the present invention.
When heating rubber as for instance chips for tires, the
rubber at certain temperature, usually 400°-500° F. start
to devulcanize and one gets a soft slicky phase which
adheres to most known heat transfer surfaces reducing
heat transfer and making a continuous operation difficult.
The present invention overcomes this difficulty with a
novel approach which is not taught in the prior art.
It is extremely difficult to physically break tires apart to
obtain individual rubber particles free of reinforcing
materials. Commercially available tire disintegrators
include slicing machines, hammer mills, debeaders and
manglers that have been adapted to tire reduction from
other industries.
The recent introduction of steel reinforcing in both
passenger and truck tires has greatly increased the
difficulty and expense of sufficiently disintegrating a tire
to convert it into a useable pyrolysis feed stock.
[4]

5. Aside from the purely physical problems associated with
breaking down used tires before they can be pyrolized, the
prior art also teaches that vapors produced from tire
pyrolysis are loaded with dusty unburned rubber and
carbon black particles. These particles plug vapor lines,
coolers, condensers, and generally gum up equipment.
Further, some of the heavier hydrocarbons driven off
during pyrolysis is composed of tar and pitch. These high
melting point fractions solidify quickly, especially in the
presence of dust and fiber glass and again generally gum
up downstream processing equipment. If the tires are wet,
as happens when they are washed with water to remove
accumulated dust and mud, the water vapor distills and
forms emulsions with the heavy oils and tars. Tire
pyrolysis oils are also contaminated with metals and
solids carryover. This causes them to have greatly
reduced value as fuel oils. The high degree of metallic
impurities also causes significant problems to be
associated with the use of these hydrocarbons for fuel.
The present invention overcomes the physical difficulties
of the prior art in making clean oils and overcome the
problems with the condensation of the vapors.
Solid phase pyrolysis reaction produces taught by the
prior art include partially decomposed rubber, carbon
black particles, fiberglass, steel wires, metallic oxide
ashes and dust. The prior art has never taught any
[5]

6. satisfactory way of converting this conglomerate
carbonaceous mixture into a clean fuel. It is even more
difficult to convert such a mixture of components into
saleable carbon black, which would yield much greater
economic returns. Because of these difficulties and the
environmental restraints placed on such recovery
processes, the prior art does not teach a pyrolysis system
for the conversion of vehicle tires to saleable carbon black
and hydrocarbons.
To produce commercial carbon black from tires, one has
to use a very controlled temperature of the pyrolysis
process. Haphazard changes or systems where the
temperature cannot be well controlled will lead to
intolerable variances in the fuel oil produced.
The present invention overcomes this difficulty in a novel
way not taught by the prior art.
It is an objective of the present invention to teach a
method of and manufacture apparatus for pyrolyzing
used tires economically into commercial quantities of oil
and fuel gas.
It is yet another objective of the present invention to teach
a method of pyrolyzing used tires that is energy efficient
fuel having low viscosity and and sulphar content and
also generates all the fuel gas necessary to operate the
[6]

7. process within environmental regulations from the
process itself.
It is yet another object of the present invention to teach a method
and teach apparatus for pyrolyzing used tires economically and
commercially saleable Low Viscous/Low Sulphur Fuel oil and
Carbon Black.
PRIOR ART:
In existing method as given in patent application no.
6221329, wherein A process and system for the recovery
of desirable constituent materials from vehicle tire pieces
through pyrolysis. The system includes a pyrolysis section
that is divided into a plurality of individual heating zones.
Each of the heating zones is heated to a distinct operating
temperature that is independent from the operating
temperature of the remaining heating zones. Vehicle tire
pieces are fed into the infeed end of the pyrolysis section
by a rotatable feed cylinder that includes a screw-like
flight extending from the inner wall of the feed cylinder.
As the feed cylinder rotates, the flight directs the supply
of vehicle tire pieces into the infeed end of the pyrolysis
section. The pyrolysis section includes a rotary kiln that is
divided into the plurality of heating zones. The vehicle
tire pieces are fed through the plurality of heating zones in
the rotary kiln from the infeed end of the rotary kiln to the
discharge end of the rotary kiln, such that the tire pieces
are pyrolyze...
[7]

8. In another existing method as given in patent application
no. 4463203, wherein A process for the preparation of
fuel oil, fuel gas and pyrolysis coke by heating to a
temperature of 600.degree.-700.degree. C. a mixture of
rubber, synthetic resin, brown coal and bentonite.
In another existing method as given in patent application no. 4648328,
wherein This invention relates to an apparatus and process for the
pyrolysis of used vehicular tires. The apparatus includes a reaction
chamber supported internally of an insulated casing and heated by
heating means interposed between the chamber and the casing. Tire
fragments are introduced into and removed from the reaction chamber
through airlock mechanisms to prevent the ingress of ambient air as the
fragments are conveyed through the chamber by a chain and flight
conveyor scraping any accumulated solids from the chamber and the
conveyor. All portions of the apparatus contacting the pyrolysis reaction
products are clad with a layer of aluminum oxide to prevent corrosion.
The process includes shredding the used tires, preheating the tire
fragments if desired, passing the fragments through the reaction
chamber, separating solid and gaseous products, recycling a portion of
the gaseous product to the heating means, and recoving salable gas, oil
and carbon products.
In another existing method as given in patent application
no. 4235676, wherein An elongated tube is maintained at
a temperature of about 1100.degree. F. throughout its
length. Organic waste material such as shredded rubber
automobile tires or industrial plastic waste or residential
trash which preferably has metal and inorganic matter
removed there from, is moved through the tube at a
[8]

9. uniform rate of speed in the absence of air and/or oxygen,
with the material being churned or tumbled as by means
of a screw conveyor. The vapors and gases which are
produced and/or liberated within the tube are quickly
removed there from by means of a vacuum of from about
four inches to about six inches of mercury, with the
vapors being condensed and the gases separated there
from. The char or residue which is a black, powdery,
carbon-type material is also recovered.
In another existing method as given in patent application
no. 5157176, wherein A preferred embodiment of the
process and apparatus for recycling used automobile
rubber tires is described in which small pieces of rubber
tires are progressively fed into a vertical reactor of the
counter-flow type in which the material progressively
descends downward through the reactor with process
gases passing upward through the downwardly
descending material to decompose and volatilize the
rubber material. At the lower portion of the vessel,
oxygen-bearing gas is injected into the reactor to burn a
portion of the rubber carbon to generate hot combustion
gases that ascend upwardly to pyrolitically decompose the
rubber pieces, and to volatilize such material. The amount
of oxygen is controlled in an oxygen-deficient manner to
maintain the temperature in the combustion zone at a
temperature of less than 500.degree. F. The gases and
volatilized rubber materials and oils are removed from the
[9]

10. reactor at a temperature of approximately 350.degree. F.
At an elevation below the top...
In another existing method as given in patent application
no. 5208401, wherein Commercially valuable chemicals
are separated from tire-derived pyrolytic oils by
subjecting the pyrolytic oils to a fractional distillation at a
temperature of up to about 204.degree. C. under
atmospheric pressure to isolate at least one commercially
valuable chemical selected from the group consisting of
paraffins, naphthenes, olefins and aromatics. Particularly
valuable chemicals which can be extracted from tire-
derived pyrolytic oils are benzene, toluene, xylene,
styrene and dl-limonene.
In another existing method as given in patent application
no. 3996022, wherein Heretofore waste rubber, a
substantial amount of it in the form of used automobile
tires, has been buried, burned, or otherwise disposed of in
manners and by means totally inconsistent with good
ecological practices and considerations. Now, such waste
or scrap rubber, both natural and synthetic, can readily be
converted in the presence of molten acidic halide Lewis
salt catalysts to useful products, including fuels
comprising a naptha-like oil, a burnable solid
carbonaceous material, and a mixture of gases. The most
promising salts are zinc chloride, tin chloride, and
antimony iodide. Also, an extremely active catalyst can be
[10]

11. prepared by adding up to about 60 percent by weight of
sodium chloride to the zinc chloride catalyst. The
burnable carbonaceous material has been shown to be a
carbon black of moderate quality and is believed to be
suitable for reuse in tires if blended with high-quality
fresh carbon black.
In another existing method as given in patent application
no. 3978199, wherein Carbon black is recovered from
vulcanized waste rubber such as automobile tires or other
articles by reacting pieces of the rubber with an aromatic
oil solvent in a stirred reactor at 500.degree.-700.degree.F
temperature and about 25-100 psig pressure for 0.5-2
hours residence time. The resulting solids-liquid mixture
is processed to remove solids, and the resulting solid
product is then dried, screened and chemically treated to
recover the carbon black in dry powder form. The
remaining solvent oil is also recovered and a portion
reused in the process.
In another existing method as given in patent application
no. 5976484, wherein A method and device is provided
which is capable of producing gasified substance and
solid-shaped carbonized substances from solid-shaped
wastes such as waste tyres by a series of heating, dry
distillation and splitting decomposition. After discharging
out from the bottom of a splitting decomposition reactor,
the solid-shaped carbonized substances are subject to a
[11]

12. series of treatments: water washing, magnetic separating,
alkaline cleaning and acid pickling (treatment) to separate
out iron wire and to remove heavy metal-bearing ash
contents. The carbonized substances are next pulverized
to the desired particle size so that highly purified carbon
black is formed. Subsequently, the carbon black granules
are led into an activation furnace and are heated and
activated at the atmosphere of steam being passed in to
produce powder particulate activated carbon. On the other
hand, from the gasified substance produced by-products
of the combustible oil and gas are respectively formed.
This...
In another existing method as given in patent application
no. 6271427, wherein The invention relates to a method
for the recovery of carbon and combinations of
hydrocarbons from discarded tyres or similar polymeric
material by pyrolysis, using a reactor (3) in which the
material is placed in a preferably largely fragmented
condition, whereby the material is heated to pyrolysis
temperature by the recirculation of previously formed and
heated pyrolysis gas which is led through the material and
where the pyrolysis gas obtained in this way is brought to
condense to condensable products in a condenser (8)
connected to the reactor. In order to improve the
possibilities of control of the process of pyrolysis, a
[12]

13. reactor is used with an inlet (6) and an outlet (7) so that a
gas can be led through the reactor (3) passing over the
polymeric material which is placed in it, whereby at least
a part of the pyrolysis gas which does not condense in the
condenser (8) is heated to a predetermined temperature
and is led by recirculation in a circuit through the reactor
for...
In another existing method as given in patent application
no. 5158983, wherein The present invention is directed to
a process for the conversion of waste plastics and scrap
rubber to a high quality synthetic crude oil which can be
separated by fractionation into gasoline, diesel fuel and
gas oils suitable as a feedstock to a catalytic cracker. The
process generally includes the steps of heating the plastic
scrap and scrap automotive tires in a hydrogen
atmosphere at moderate temperatures and pressures. It has
also been determined that the polymeric waste material
must be present in combination with the scrap automotive
tires to attain conversion of the scrap automotive tires to
liquid hydrocarbon.
In another existing method as given in patent application
no. 5095040, wherein Old rubber tires are physically
shredded and a sized fraction of the shreds is fed into a
heated rotating stainless steel tube in which the
temperature is carefully controlled so that the shreds are
[13]

14. converted to a char and a No. 4 oil product both of which
are separately recovered.
In another existing method as given in patent application
no. 5286374, wherein An economic and safe process
includes a catalytic cracking of the rubber tires and rubber
products in the presence of mica catalyst selected from
muscovite, sericite and biotite at a reaction temperature of
230.degree.-400.degree. C. under a pressure of 1-2.5
atmospheres for forming mixed oils, carbon black,
gaseous products, and other residual products.
In another existing method as given in patent application
no. 4740270, wherein A process for the treatment of used
rubber tires by vacuum pyrolysis in a reactor to produce
liquid and gaseous hydrocarbons and a solid
carbonaceous material is disclosed. According to the
invention, the pyrolysis of the tires is carried out at a
temperature in the range of about 360.degree. C. to about
415.degree. C., under a sub-atmospheric pressure of less
than about 35 mm Hg and such that gases and vapors
produced in the reactor have a residence time of the order
of a few seconds. The process according to the invention
enables one to increase the yield of the liquid
hydrocarbons and lower the yields of the gaseous
hydrocarbons and solid carbonaceous material, and to
thereby produce hydrocarbon oils in substantially
[14]

15. maximum yield. These hydrocarbon oils have a high
calorific value and are thus suitable for use as heating
fuel.
OBJECT OF THE INVENTION:
It is therefore, an objective of this invention is to
manufacture process of carbon black, fuel oil, fuel gas
and steel from used tires. Most particularly the said
invention has unique raw material conveying through
pneumatic conveying system, as soon as it reaches the
jacketed feeding hopper where the raw material powder is
Pre-Heated to 150 Degree Celcius. According to this
system preheating chambers can also be used as a main
Pyrolysis reactor and the Jacketed Screw Conveyors
used as the main reactors in the earlier occasion can be
operational as a carbon black powder coolers and
conveyors.
STATEMENT OF THE INVENTION:
[15]

16. The present invention is basically a process of recovery of
Low Viscous /Low sulphar fuel oil by converting the
wasted tyres. However, waste tyre, a substantial amount
of it in the form of used automobile tires, has been burnt,
or otherwise disposed of in manners and by means totally
inconsistent with good ecological practices and
considerations. Now, such waste or scrap rubber, both
natural and synthetic, can readily be converted in the
presence of Calcium Carbonate and Magnesium Oxide
catalysts mixture to useful products, including fuels
comprising a naphtha-like oil, a burnable solid
carbonaceous material, and a mixture of gases. The
burnable carbonaceous material has been shown to be a
carbon black of moderate quality and is believed to be
suitable for reuse in tires if blended with high-quality
fresh carbon black.
SUMMARY OF THE INVENTION:
The present invention is directed to retrieving from the
500 million plus automobile tires and the like which are
[16]

17. annually discarded in this country and abroad, a
hydrocarbon fuel substitute with a liquid oil equivalent of
over 800 million gallons per year to help meet this
nation's energy needs and at the same time to improve its
physical environment. Additionally, the conversion
process herein disclosed also recovers a residual material
consisting primarily of carbon black, which may be
recycled into new tires, thereby further reducing the
demand for natural gas from which carbon black is now
made.
These desirable objectives, as well as many others, are
obtained in the present invention by means of a process
wherein relatively large pieces of scrap rubber including
whole tire carcasses are shredded and the powder of 30
mesh size is pre dried and in the first pyrolysis chamber it
is mixed with mixture of Catalyst, whereby the resulting
extremely rapid reaction produces the following three
basic products: The first product is a mixture of non
codensable hydrocarbon gases; the second product is a
low-sulfur fuel oil; and the third product is a
carbonaceous residue. According to the present invention
it has been observed that the amounts of these three
products. Yields of the oil run as high as 60 percent under
conditions that dictate that on a scale of commercial size
expectations for the amounts of these products should be
45% oil by weight (about 1.5 gallons per tyre), 45 percent
carbonaceous residue, and about 10 percent gases. The oil
[17]

18. product meets the requirements of a No. 2 fuel oil without
further treatment. For purposes of operating the process,
the heating values in the gaseous product from the present
invention are quite sufficient to provide the necessary
makeup heat for maintenance and continuance of the
reaction, and finally and equally importantly, the present
process proceeds rapidly with rubber introduced into the
catalyst. Thus, a process has been developed which can
recover very rapidly the hydrocarbon values of used tire
carcasses and the like which operate in a time period of a
matter of minutes. If even shorter times are required, or
desirable, the reaction proceeds in a matter of seconds on
diced pieces of waste tire.
DETAILED DESCRIPTION OF INVENTION:
Disposed vehicle tyres and other rubber materials have in
recent times become a major environmental problem
partly because such material is in itself not simply
biodegradable and thus currently requires extremely large
stores and dumping areas, and partly because combustion
of the material to ash in special combustion plants forms
environmentally dangerous substances such as sulphur-
containing acids and other gases which smell of fuel.
[18]

19. Since the material of which the tyre is composed itself
contains a large fraction of substances which are valuable
for the petrochemical industry, it has proved interesting to
find efficient methods for recovering these valuable
substances. Tyres consist of, among other things,
approximately 35% carbon black as reinforcement in the
walls and wearable surface of the tyre, approximately
60% styrene-butadiene-rubber (SBR) and considerable
amounts of oil, together with cord in the form of steel
wire and/or glass fibre polyester. All of these substances
are valuable and expensive to produce by conventional
methods from current raw materials. On the other hand,
unfortunately, the substances which are elements of the
tyre material and which give the tyre its desirable
properties are also primarily those substances that make
the possibilities of efficiently recycling the tyre more
difficult.
The present invention now proposes a new and novel
apparatus and process for the pyrolysis of used vehicular
tires. The pyrolysis reactor possesses several unique
characteristics which solve the problems of continuous
pyrolysis of shredded tire fragments on a continuing,
commercially viable basis.
Process:
[19]

20. Generally the wasted tyre is shredded into smaller cubes,
after the removal of bead wire, steel wire, and nylon cord.
The shredded pieces undergo further size reduction
through set of pulverizes and once the size is brought out
to 30 mesh size through a unique pneumatic conveying
system. Automatically it reaches very quickly the jacketed
feeding hopper where the raw material powder is Pre-
Heated to 150 Degree Celcius.
Due to gravity it passes through an Air Lock System and
gets inside the First stage of Pyrolysis. Reactor having
Jacketed, Finned, Screw Conveyor system. The Jacket is
externally insulated using Ceramic fiber wool. (The
temperature range is in between 300 to 400 degree
celcius.).The catalyst and Hydrocarbon cracking solutions
are dosed through a metering device. The evolving
mixture of hydrocarbon gases have been sucked out of the
reactor using a blower and the hot mixture of hydrocarbon
gases pass through a cyclone filter, where all the solid
particles are separated and then passes through a shell and
tube condenser, where the condensable Hydrocarbon
gases are condensed to form oil and non condensable
gases are scrubbed through a packed column scrubber and
[20]

21. the purified gas is utilized as fuel for the burner located in
our Hot Air Generator.
Once the first pyrolysis step is completed the partially
converted material passes through the second stage
pyrolysis reactor through an Air Lock System where the
temperature of reaction is maintained throughout between
400 to 500 degree Celcius. The evolving hydrocarbon
gases have been sucked out of the reactor using a blower
and the hot m`oture of hydrocarbon gases pass through a
cyclone filter, where all the solid particles are separated
and then passes through a shell and tube condenser, where
the condensable Hydrocarbon gases are condensed to
form oil and non condensable gases are scrubbed through
a packed column scrubber, and the purified gas is utilized
as fuel for the burner located in our Hot Air Generator.
Other reactors where the main body of the reactor rotates
like a cement kiln, wherein the agitation inside will too
little due to improper material size and rate of heat
transfer will be less. Consuming lot of heat energy30%
more heat energy.
[21]

22. Moreover feeding cannot be continuous. Also the carbon
black removal will be consuming lot of time and huge
production loss. Few other conventional designs have
vertical reactors having an agitator. Here the feeding of
non uniform raw material sizes is a big challenge and
every time the lid has to be manually opened and closed.
It is not safe to open the lid for every batch since
entrapped air inside the reactor may cause explosion.
Inside the present reactor Agitation given to the waste
tyre powder is the maximum due to the revolving Paddles
fixed on the Rotating Screw. The Heat Transfer
Coefficient rate is the maximum.
Due to that agitation not only the Catalyst is uniformly
mixed but also the rate of pyrolysis .is increased. This
design is unique where in preheating chambers can also
be used as a main Pyrolysis reactor and the two sets of
Jacketed Screw Conveyors used as the main reactors in
the earlier occasion can be operational as a carbon black
powder coolers and conveyors.
The first aim of the present invention is therefore to
achieve a method which improves the best opportunities
for controlling the process of pyrolysis and which makes
[22]

23. it possible to recycle significant components such as
carbon black and condensed oils from discarded tyres in a
more efficient way and with a higher quality. To be more
precise, what is aimed at is a method which makes it
possible to control the pyrolysis process based on a
schedule which is predetermined, using parameters set
depending on economically reducing the size of raw
material as a result the cost of size reduction does not
exceed 0.07 US$ /kg which is used and on which final
product is desired, and the method according to the
invention is based in principle on the introduction of tyre
material for continuous treatment in the reactor, that
heating of the reactors are carried out using a hot air
heated by the scrubbed non-condensable gas evolving
from the pyrolysis reaction.The composition and relative
amount of the pyrolysis gas which is produced by the
reactor is measured, whereby the information obtained is
used to control and regulate the process.
A second aim of the invention is to make the handling of
the processed tyre waste continously, and in this way
make it possible to rapidly and simply exchange the
material through the pneumatic conveying sysrem.
[23]

24. The current invention is not limited to that described
above and shown in the figure, but can be changed and
modified in a number of ways within the scope of the
concept of the invention as stated in the following claims.
ABSTRACT
The present invention relates to a method and process for
the recovery of Low viscous /low sulphur fuel oil, carbon
black and fuel gas conversion of wasted tyres or similar
polymeric material by pyrolysis. Discarded tyre is
shredded into smaller cubes, after the removal of bead
wire, steel wire, and nylon chord. The shredded pieces
undergo further size reduction through set of pulverize
and once the size is brought out to 30 mesh size through a
unique pneumatic conveying system.and passed on to a
specially manufactured Finned Jacketted, Screw
Conveyors.The heat energy required for the pyrolysis
reaction is supplied by a hot air generator fuelled by the
non-condensable gases evolving from the pyrolysis
reaction.
[24]

25. CLAIMS:
I/We Claim;
1. A unique process for recovery of Low Suphur/Low
Viscous and fuel gas conversion of wasted tyres, the
process comprising the steps of:
a. wasted tyre is shredded into smaller cubes, after the
removal of bead wire, steel wire, and nylon chord. The
shredded pieces undergo further size reduction through
set of pulverize and once the size is brought out to 30
mesh size.
b. transferring the product pieces from a supply into a Air
lock system and gets inside the First stage of Pyrolysis; it
reaches the jacketed feeding hopper where the raw
material powder is Pre-Heated to 150 Degree Celsius.
c. transferring the product powder from the first heating
zone to a second heating zone in the pyrolysis chamber;
heating the product powder between 300.degree to
400.degree in the second heating zone,
d. transferring the product powder from the second
heating zone to a third heating zone to the catalyst and
Hydrocarbon cracking solutions are dosed through a
[25]

26. metering device, heating the product powder at a third
temperature in the third heating zone, the third
temperature being more than the second heating
zone(between 400 to 500degree cel) the evolving mixture
of hydrocarbon gases have been sucked out of the reactor
using a blower and the hot mixture of hydrocarbon gases
pass through a cyclone filter where fine particles of
carbon black powder is separated from the evolving
gases.
2. The process of claim number 1 where all the solid
particles are separated and then pass through a shell and
tube condenser, where the condensable hydrocarbon gases
are condensed to form Low Viscous/Low Sulphur oil and
non condensable gases are scrubbed through a packed
column scrubber and the purified gas is utilized as fuel for
the burner located in our hot air generator.
3. The process of claim number 1 where in once the first
pyrolysis step is completed the partially converted
material passes through the second stage pyrolysis reactor
through an Air Lock System where the temperature of
reaction is maintained throughout between 300 to 400
degree Celsius.
[26]

27. 4. The process of claim number 1 wherein the tire
powders are transferred into pneumatic conveying system
by a rotatable feeding vane,radially formed along an
inside wall of the feed valve, the flight being constructed
to direct the tire powder from a first end of the feed
hopper to a second end of the feed valve as the feed vane
rotates.
8. The process of claim number 3 wherein the evolving
hydrocarbon gases have been sucked out of the reactor
using a blower and the hot mixture of hydrocarbon gases
pass through a cyclone filter, where all the solid particles
are separated and then passes through a shell and tube
condenser, where the condensable hydrocarbon gases are
condensed to form oil and non condensable gases are
scrubbed through a packed column scrubber, and the
purified gas is utilized as fuel for the burner located in our
hot air generator.
9. The process of claim number 3 due to gravity it passes
through an air lock system and gets inside the First stage
of pyrolysis. Reactor having jacketed, finned, screw
conveyor system. The Jacket is externally insulated using
[27]

28. Ceramic fiber wool. (The temperature range is in between
300 to 400 degree Celsius.)
10. The process of claim number 2 wherein the other
reactors where the main body of the reactor rotates like a
cement kiln, where in the agitation inside will too little
due to improper material size and rate of heat transfer will
be less. Consuming lot of heat energy30% more heat
energy.
11. The process of claim number 10 wherein
preheating chambers can used as a main pyrolysis
reactor and the sets of jacketed screw conveyors
used as the main reactors in the earlier occasion
can be operational as a carbon black powder
coolers and conveyors.
12. The process of claim number 10 wherein
inside these reactor agitation given to the waste
tyre powder is the maximum due to the revolving
paddles fixed on the Rotating Screw. The heat
transfer coefficient rate is the maximum. Due to
that agitation not only the catalyst is uniformly
mixed but also the rate of pyrolysis is increased.
[28]

29. 13) Any waste shredded material like Rubber, Tyre,
Plastics, Rice husk, Alge , fed continuously
through an extruder fixed at an angle in a
Reactor filled with Lead material Kept at a
temperature between 250 degree to 1000 degree
Celsius, will be pyrolysed and the evolving
hydrocarbon gases will pass through a condenser
where condensable gases will be converted into
fuel oil and non- condensable gases is passed
through a gas generator to drive an alternator to
generate power.The generating capacity will be in
the range of 5kw to 5megawatt.The heating
system of the reactor can be Infra Red Or
Induction Heating .
Otherwise we can use the Non condensable gas can
be used to heatup the water circulated through a
Boiler and generate steam inturn will drive the
Turbine and generate Power from (5 K.Watt) to(
5 Mega Watt)
[29]