EPROTECH’s microwave pyro-gasification technology is an industrial solution developed to convert end-of-life tyres and other compatible materials into solid, liquid and gaseous fractions intended for subsequent recovery and valorisation processes.
The process takes place in an inert atmosphere, without combustion of the material inside the treatment chamber. Microwave energy is transferred directly to the material, promoting its thermal decomposition and enabling the recovery of carbon black, steel, liquid fractions and process gases.
Each plant is sized according to the input material, the required production capacity and the customer’s recovery objectives.
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Microwave pyro-gasification enables the treatment of end-of-life tyres by separating and recovering their main components.
The form of the input material, the level of preparation and the feeding system are defined according to the characteristics of the ELTs and the production objectives.
The technology is also compatible with the treatment of plastics. A specific pyro-gasification project is underway for this application.
The process can generate fractions suitable for valorisation in different industrial sectors:
The technology applies the principle of pyrolysis: the thermal decomposition of material in an oxygen-free environment.
In microwave pyro-gasification, the material absorbs electromagnetic energy and converts it into heat. Controlling the operating conditions and energy distribution contributes to process management and the quality of the recovered fractions.
Microwave technology can be combined with electric resistance heating systems, adjusting the contribution of the different energy sources according to the material and the desired result.
The material is prepared and introduced into the system through a feeding configuration defined according to the product characteristics and the required capacity. Different loading methods can be considered, including continuous feeding configurations.
Microwaves, optionally supplemented by electric heating, provide the energy required for pyrolysis. The material is treated in the absence of oxygen, preventing direct combustion inside the process chamber.
The liquid and gaseous fractions are directed to their respective handling and recovery sections. The solid fraction is cooled and subjected to subsequent separation operations, also enabling the recovery of the metal component.
In the reference process for the treatment of end-of-life tyres, the recoverable fractions can be approximately distributed as follows:
High-quality dry recovered carbon black (rCB), with reported characteristics up to 95% comparable to those of virgin carbon black for the parameters considered.
Potential applications: tyres; technical compounds; pigments; toners.
Separable metal fraction that can be sent to steelworks for recovery and reuse in the steel industry.
Liquid fraction with an estimated sulphur content below 1%.
It can be considered for energy applications compatible with the required specifications or sent for subsequent refining stages.
A mixture of gases belonging to the LPG family and hydrogen that can be utilised through cogeneration systems.
In the reference process, energy recovery can contribute up to approximately 70% of the plant’s electricity requirements.
The values provided are indicative and must be confirmed according to the material being treated, the plant configuration and the process conditions.
Plant sizing begins with an analysis of the material to be treated and the industrial objectives of the project.
The choice of configuration allows the best balance to be sought between investment, productivity, operational management and maintenance.
EPROTECH defines the following together with the customer:
Every project starts with the material.
Tell us the type of ELTs or material to be treated, the expected quantity and the recovery objectives: we will analyse the process and identify the most suitable configuration for your application.
Request a process assessment
Download the brochure with descriptions, technical specifications and further information.
Click to downloadInput material and fractions recovered from the microwave pyro-gasification process.
