The manufacturing industry contributes significantly to CO2 emissions and the global problem of climate change. That’s why we’ve developed a novel technology to recover Carbon Black, oil, and steel from end-of-life tires (ELTs) through the pyrolysis process of waste tires.
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Technology
The Contec Process
State-of-the-art rubber pyrolysis technology
Our tire pyrolysis technology enables manufacturers to source cleaner and more sustainable product substitutes for various applications. At Contec, we’ve spent more than five years perfecting a technology that meets the quality, efficiency, and safety required for the industry.
We’ve been involved in the technology’s development from the beginning. Contec has facilitated the R&D process with the Warsaw University of Technology, technology design with internal and external engineers, the construction of the pilot plant, and the startup of the entire system.
This intensive research and development have resulted in a pilot plant in Szczecin, Poland and a perfected pyrolysis process. We now have two pyrolysis lines in full operation at the plant.
These combined experiences have given us a strong foundation for further expansion and capacity increase.
Safe and efficient pyrolysis process of waste tires
We’re committed to developing a sustainable solution for the manufacturing industry. Our pyrolysis process of waste tires is designed for three impactful advantages.
Efficient and stable production
Consistently high-quality products from pyrolysis
Safe and secure pyrolysis plants
Quality products depend on best-in-class technology
01. Striving for quality excellence
The future of manufacturing depends on sourcing viable reuse commodities from recovered materials with a lower carbon footprint.
We ensure that the materials we use, and the end products we make, are of the highest quality and produced under optimal conditions.
Quality is checked and managed at every stage of the manufacturing process – from the initial tire shredding and pyrolysis process to the testing of the end product in our dedicated in-house lab.
The quality assurance process is robust, and we recognise the importance of maintaining high standards. All of our industrial processes comply with relevant standards and regulations.
At first, we manage quality by checking the condition of the tires and cleaning them if needed. The quality procedures ensure that only the highest quality feedstock is used in the pyrolysis process.
In order to ensure the premium quality of our rCB and recovered oil and steel, we employ a team of technicians at our in-house laboratory to perform regular quality checks.
The preventative maintenance program and our engineers take immediate steps to identify and rectify the cause of any pyrolysis line needs. We achieve high-quality, thorough, and well-maintained equipment.
Our on-sight team of technicians and engineers undergo regular preventive maintenance schedules and performance checks.
02. Safety & sustainability first
At Contec, we put safety and sustainability in full focus.
Our plant provides a safe working environment, and a high-performing track record in avoiding accidents and injury. We regularly perform operator training, supported by process engineers 24/7, and have safety procedures in place. Automated safety systems are in place at the plant.
The recovered Carbon Black we produce is a sustainable alternative to several grades of virgin Carbon Black that can have less than an 80 per cent carbon footprint (based on the Climate Solutions report).
We use circular methods that turn rubber waste into reusable materials and that comply with the guidance set out by the European Chemicals Agency (ECHA): Guidance on waste and recovered substances document.
Learn how Contec uses nitrogen inertisation to maximise safety during pyrolysis.
Contec’s protected pyrolysis technology
At Contec, we’ve developed a pyrolysis process for waste tires and a sustainable circular solution that helps to manage end-of-life tires (ELTs) waste.
It supports tire manufacturing companies to become climate neutral by enabling them to replace petroleum-based commodities with sustainable alternatives. We approach the pyrolysis process in three phases.
Phase 1
Feedstock Preparation
ELTs are shredded with scrap steel removed and recycled. The rubber granulate is then transported to dedicated silos.
Phase 2
Pyrolysis Process
The rubber granules are fed into the special designed auger-type pyrolysis reactor and decomposed into gas and recovered Carbon Black particles at temperatures of up to 550°C.
The reactors are heated with molten salt, which circulates in a closed loop.
Most of the gas is condensed to become oil, which after treatment, becomes a product. Non-condensable gas is being used as an energy source for the process in the molten salt heater.
Phase 3
Post-Processing
The rCB is refined further, milled, and turned into pellets ready for packaging. The rCB is checked in the on-site laboratory to ensure high quality before being transported to end-partners.
Innovative heating reactor with molten salts
We’re the only company in the world that uses molten salt as a heat transfer medium in the pyrolysis industry.
Molten salt enables a continuous process for a safer, more efficient, and highly economical production method during pyrolysis.
Salt is heated to its molten state in a heating tank and then pumped around the closed-loop system, providing heat to the reactor. The molten salt then returns to the heating tank, completing the loop.
Molten salt usage greatly improves the heat transfer parameters. It provides better control over the process, meets higher safety requirements, and ensures repeatable quality. Also, the thermal stress of the entire system is much lower in comparison with conventional solutions.
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