Systems and methods for processing pyrolyzable materials in order to recover one or more usable end products are provided. Pyrolysis methods and systems according to various aspects of the present invention are able to thermally decompose carbon-containing materials, including, for example, tires and other rubber-containing materials, in order recover hydrocarbon-containing products including synthesis gas, pyrolysis oil, and carbon black. Systems and methods according to aspects of the present invention may be successful on a commercial scale, and may be suitable for processing a variety of feedstocks, including, but not limited to, used tires and other types of industrial, agricultural, and consumer waste materials.

The present invention relates to a rotary kiln made of a metal alloy. The alloy is preferably chosen from the group of Alloy 321, Alloy 321H, Alloy 347, Alloy 347H, Alloy 348 and Alloy 348H. An object of the present invention is to provide a rotary kiln that can be operated under the reducing gas conditions to be experienced by the kiln in a pyrolysis process of scrap rubber. The present invention furthermore relates to the use of such a rotary kiln in a process for the pyrolysis of tyres.

The invention relates to a process for producing hybrid carbon black particles (12), which comprises the steps: a) production of first carbon black starting particles (16); b) production of second carbon black starting particles (22); c) milling of the second carbon black starting particles (22); d) mixing of the second carbon black starting particles (22) into a particle stream (48) of the first carbon black starting particles (16); and d) pelletization of the first and second carbon black starting particles (16, 22) to form hybrid carbon black particles (12). The invention further relates to an apparatus (10) for producing hybrid carbon black particles (12) and to hybrid carbon black particles (12) produced by means of the process or the apparatus (10).

A system and method for preparing a pelletized carbon black product is provided. The system includes a source of a carbon black product from a pyrolysis process. A mixer is in communication with the source of the carbon black product. A binder oil storage tank is in fluid communication with the mixer. The binder oil storage tank is configured to inject a desired amount of a binder oil into the mixer to form the pelletized carbon black product.

Systems and methods for processing pyrolyzable materials in order to recover one or more usable end products are provided. Pyrolysis methods and systems according to various aspects of the present invention are able to thermally decompose carbon-containing materials, including, for example, tires and other rubber-containing materials, in order recover hydrocarbon-containing products including synthesis gas, pyrolysis oil, and carbon black. Systems and methods according to aspects of the present invention may be successful on a commercial scale, and may be suitable for processing a variety of feedstocks, including, but not limited to, used tires and other types of industrial, agricultural, and consumer waste materials.

The invention relates to a process for producing hybrid carbon black particles (12), which comprises the steps: a) production of first carbon black starting particles (16); b) production of second carbon black starting particles (22); c) milling of the second carbon black starting particles (22); d) mixing of the second carbon black starting particles (22) into a particle stream (48) of the first carbon black starting particles (16); and d) pelletization of the first and second carbon black starting particles (16, 22) to form hybrid carbon black particles (12). The invention further relates to an apparatus (10) for producing hybrid carbon black particles (12) and to hybrid carbon black particles (12) produced by means of the process or the apparatus (10).

The invention relates to a process for producing hybrid carbon black particles (12), which comprises the steps: a) production of first carbon black starting particles (16); b) production of second carbon black starting particles (22); c) milling of the second carbon black starting particles (22); d) mixing of the second carbon black starting particles (22) into a particle stream (48) of the first carbon black starting particles (16); and d) pelletization of the first and second carbon black starting particles (16, 22) to form hybrid carbon black particles (12). The invention further relates to an apparatus (10) for producing hybrid carbon black particles (12) and to hybrid carbon black particles (12) produced by means of the process or the apparatus (10).

Aspects of the present disclosure are directed to a method for converting rubber waste to a functionalized activated carbon (AC). The method includes pyrolysis of waste/scrap tires to produce activated carbon; (ii) chemical activation of the activated carbon using an oxidizing agent; and (iii) and functionalization of the chemically activated carbon with 1,2,3,4,6-pentagalloylglucose (pentagallic acid ester of glucose) to produce the AC. The method of the present disclosure converts waste-to-value-added products, thereby enhancing profitability by recycling the waste products. Such processes are the source of renewable energy (gas and oil) and valuable by-products.

A reactor for converting scrap tire material into output products, while allowing controlling the characteristics of the products within certain ranges, includes a pre-processing zone maintained at a first average temperature, at least one primary processing zone maintained at a second average temperature, at least one secondary processing zone maintained at a third average temperature, a post-processing zone that cools scrap tire material to a fourth temperature, at least one water injector that introduces water into the interior of the secondary processing zones, and potentially also the primary zone, and a transport mechanism that moves, and may mix, scrap tire material across the pre-processing zone, primary processing zone, secondary processing zone, and post-processing zone.

The present invention relates to a method for recycling scrap rubber comprising the steps of pyrolyzing scrap rubber to obtain a char material and milling the thus obtained char material. The present invention also relates to carbon black powders and carbon black pellets obtained by the method according to the invention. Moreover, the present invention relates to the use of said carbon black powder and to compositions comprising said carbon black powders.