What is the continuous pyrolysis machine?

What is the continuous pyrolysis machine?

1. Introduction: Why can't batch type pyrolysis machine meet customer needs?

2. What is the continuous pyrolysis machine?

3. Core technological principles of the continuous pyrolysis machine

4. Unique advantage of the JINZHEN continuous waste tyre pyrolysis machine

5. Continuous pyrolysis machine vs. Batch pyrolysis machine: Technical differences

6. Continuous pyrolysis machine's Technical parameters and performance indicators

7. Continuous pyrolysis machine's Detailed explanation of core components

8. Continuous pyrolysis machine's success case

Are you looking for the most effective pyrolysis solution for your business? This article can advise you an advance pyrolysis technology for you.

Pyrolysis solution can pyrolyze a wide range of materials with different type machines. In the past years, customers liked the batch-type pyrolysis machine because of its easy operation and convenient installation. But in recent years,  batch-type pyrolysis machines have not met customer needs.

First, the daily capacity of the batch-type pyrolysis machine is small. The biggest daily capacity of a batch-type pyrolysis machine is 15tons, if you want to pyrolyze above 15tons, you need to add the quantity of the machine. Such as when you want to pyrolyze 35tons waste tires, you need to prepare at least 3sets of this pyrolysis plant. Our Shandong province's customer pyrolyze 240tons waste tires, there are 16sets of waste tire pyrolysis machines.

Second,  a batch-type pyrolysis machine can not meet the environmental demands, because it often needs to open and close the pyrolysis reactor door. When pulling the steel wire from the pyrolysis reactor, there will be some carbon black powder flying in the air if we do not add the dust cover.

Third, there is often a need to start and stop the pyrolysis reactor. It is bad for the pyrolysis reactor.

With the emergence of the continuous pyrolysis machine, the above three problems can be solved perfectly.

The continuous pyrolysis machine is the most advanced pyrolysis technology. It can continuously run 24hours without stopping the machine. This continuous pyrolysis machine adopt automatic feeding system and a discharge system. The waste materials can be pyrolyzed in a sealed environment, and the products have higher economic value.

Compared with batch type pyrolysis machine, when you are feeding the materials, you can discharge the carbon black at the same time; moreover, you can also discharge pyrolysis oil at the same time. This operating style can strengthen the daily capacity of the machine. Until now, we have done a single continuous pyrolysis machine for customers, which machines are still running. Its daily capacity is 50tons. It is 4times that of batch type pyrolysis machine.

The most advanced technological advancements in the continuous pyrolysis machine are reflected in the sealing of the entire process.

The Working process of the continuous pyrolysis machine:

1. Tyre pretreatment

Waste tyres need to be crushed, reduce their water and solid impurities, and obtain 2.8-5 mm rubber powder.

2. Feeding

Rubber powder will be put into the continuous pyrolysis reactor through the feeding system. This feeding system can control the quantity of rubber powder, and it can adjust the feeding speed. The whole pyrolysis process is under sealed conditions.

3. Continuous Pyrolysis process

The continuous pyrolysis reactor adopts indirect heating, heating module is distributed in the furnace. The heating output is controlled by a PLC to ensure uniform heating of the pyrolysis reactor. This provides uniform heating and extends the reactor's lifespan. The rubber powder decomposes under high-temperature heating, producing oil and gas. The whole pyrolysis process is controlled by PLC, with fully automatic operation,  reducing manual operation.

4. Cooling

The continuous pyrolysis machine adopt two-stage cylindrical condensation system, and the cooling pipe use" S" route. The cooling area and cooling distance are big enough so that the oil gas can be fully cooled down. Ensure the high oil yield.

5. Pyrolysis oil collection

The pyrolysis is collected in an oil tank.

6. Waste gas recovery

There are some oil gases that can not be cooled down but are combustible; these oil gases will pass through the safety water seal, waste gas recovery pipeline, and gas spray gun to reach the furnace of the continuous pyrolysis reactor for secondary heating. This can save operating costs.

7. Carbon black discharge

After pyrolysis, the carbon black is discharged from the outlet at the rear of the pyrolysis reactor via the automatic slag discharge device.

1. Continuous seal feeding ensures that the entire pyrolysis process remains closed.

2.It adopt variable frequency feeding style. It is easy to control the amount and speed of feeding.

3. The three-pass design results in a long pyrolysis distance and a small equipment footprint.

4.PLC intelligent control system, high degree of automation;

5. Real-time equipment monitoring, high safety factor.

6.It can continuously run for 60 days, stopping the machine to maintain 1 time.

7. Oil and gas can be cooled down to achieve a high oil yield.

8. We Jinzhen can customize the environmental device to meet different countries' emission standards.

Customers do not know which kind of pyrolysis machine is suitable for them. In most cases, it's because they don't understand the fundamental difference between continuous and batch methods. Indeed, it has a huge impact for investor when they chose different operating style of the pyrolysis machine.

In the chart below, we show you the detailed differences in the main aspects between the continuous pyrolysis machine and the batch pyrolysis machine.

Model	Continuous pyrolysis machine	Batch pyrolysis machine
Feeding style	Fully automatic continuous feeding	Manual/mechanical single-feed
Heating style	Indirect heating	Direct heating
Operation style	24-hour uninterrupted operation, continuous feeding, and continuous slag discharge	Each furnace requires heating and must be shut down for cooling and slag removal.
Environmental benefits	No dust leakage, emissions meet standards	Dust is easily generated during loading and unloading.
Daily capacity	35-50tons/set	1-15tons/set
Core features	No furnace shutdown required for cooling; high degree of automation	The equipment is simple and requires low investment, but each batch needs to be cooled.

The chart below is the technical parameter of the  Continuous pyrolysis machine:

Raw material	Waste tyre, plastic, oil sludge;
Single daily processing capability	30tons-50tons
Pyrolysis temperature	280-400℃
Work pressure	Micro-positive pressure
Pyrolysis rate	＞99.999%
Equipment lifespan	＞5years
Equipment operation mode	Automatic feeding, automatic slag removal, continuous production;
Control method	PLC color touch screen control;
Cooling method	Circulating water cooling;

One set of production lines of a continuous pyrolysis machine includes many small systems:

1. Fully automatic variable frequency feeding system: Convey the material into the pyrolysis reactor fully automatically, ensure whole process is sealed.

2. Three-pass continuous pyrolysis system: Unique design of our company,  ensuring the area of the machine is small; In an anaerobic environment, organic macromolecules are broken down into smaller molecules of oil gas.

3. Constant temperature heating system: Many small heating module is distributed by the continuous pyrolysis reactor,  ensuring constant temperature heating.

4. Cooling system: Indirect heat exchange is used, avoiding contact with oil and gas and producing no wastewater.

5. Waste gas recovery system: Non-condensable gases will be transported to the combustion chamber to provide heat for the reaction.

6. Safety system: Ensure the whole process's safety

7. Pyrolysis oil collection system:  Pyrolysis oil will be collected in an oil tank, then packaged by workers.

8. Fully automatic carbon black collection system: While maintaining a sealed state, the carbon black is continuously discharged and cooled. Then it will be packaged by workers.

10.PLC intelligent control system: Real-time data acquisition via the PLC system enables automatic control and fault alarms.

 

We Jinzhen has more than 17 years of experience in the pyrolysis industry, whether you are finding batch type pyrolysis machine or a continuous pyrolysis machine, we can customize this pyrolysis plant depending on your running conditions and your raw material. Of course, welcome you visit our factory do the testing of your raw material.