A. Project Description

In the environment where the state vigorously advocates the optimization of the environment and the utilization of solid waste, in recent years, the traditional projects, the deep processing of waste tires, have been paid more and more attention by people, by the rubber, plastic and other industries, there is a shortage of the situation. In order to respond to the national call, our company has been studying the tire pyrolysis and carbon black deep processing equipment for more than ten years, under the guidance of“China Tire Recycling and Utilization Association”, in-depth research, scientific exploration, the waste tire was further treated by“Eating dry and pressing clean”: the tire was crushed to produce rubber powder and steel wire; The additional value is increased by the utilization of the carbon residue as regenerated carbon black after grinding and granulation, each of which can be operated individually to achieve economic value. According to the characteristics of tire, with the continuous efforts of our scientific researchers, the production equipment is continuously upgraded and the process is continuously optimized The production line is stable in operation, low in energy consumption and high in yield.

1. Advanced production technology and related requirements

1.1. In the raw material transportation, the company adopted the full-closed dilute-phase pneumatic transportation, the whole process without any dust leakage

1.2. According to the characteristics of tire carbon black, the product quality is improved by magnetic separation before superfine grinding

This machine adopts high-strength drum magnetic separation, steel wire magnetic separation efficiency can reach 99.5% , can improve the quality of carbon black, can extend the life of crushing equipment, reduce equipment wear.

1.3. According to the characteristics of carbon black, grinding equipment selected by the new patented powder grinding equipment: ultra-micro impact mill

1.4. The whole comminution production line adopts frequency conversion regulation, fineness adjustable, rotational speed adjustable, PLC central chain control, avoid full or reduced load operation, product particle size more stable.
The carbon black produced by the pulverizer is triangular under a high power microscope, which strongly promotes the combination with other materials, and the dispersal force is increased by two times compared with the products of other grinding equipment, can effectively separate impurities other than carbon black, product quality is more stable, the company has made a lot of technical modifications in the equipment: the equipment made wear-resistant protective treatment and increased the number of grinding block and liner hardness, the service life of the wearing parts is increased by 2-3 times, the fineness of the products is better, the particle size is more concentrated, the output is higher, and the efficiency is nearly doubled.

2. Technical Parameters of different Grinding and Granulating Production Lines:

3. Granulation Equipment:

Pyrolysis carbon black pelletizer by the Patented Powder Pelletizer, This machine uses 304 stainless steel material made of stirring teeth, improve service life and particle pelletizing rate. Because of the impurities such as oil, a lot of antioxidant, reinforcing agent and so on, especially in the process of tire pyrolysis, the toluene transmittance of carbon black varies greatly due to the different pyrolysis temperature of different manufacturers, few pyrolysis plants can reach more than 80 carbon black methyl through, so the carbon black is very unstable in the combination with water is also very different. In view of this situation, the company boldly developed a quantitative carbon black pelletizing system, the equipment is the first in China, not heating, not adding any adhesive particles smooth standard, can be large or small, stable quality; The equipment runs stably and can be adjusted on line according to the raw material condition. The equipment has been in normal operation in many enterprises.
Granulating system includes: carbon black feeding system, water quantitative system, granulating machine, drying system, conveying system, dust removal equipment, finished product silo and packaging machine
PLC set the carbon black granulator in the expected period of low-speed operation, the discharge period of medium-speed operation, only in the material and water into the granulator within 500 seconds of high-speed operation, so the whole machine is very energy-saving, only half of its full capacity: 2.5-3 tons per hour of total pelletizer power: 110kW (The coefficient is 0.6)

4. Drying Equipment

The burner uses special equipment (both oil and gas) ; it can switch back and forth between natural gas, pyrolysis gas and pyrolysis oil; and when the pyrolysis gas is used as much as possible, it can be supplemented with natural gas or pyrolysis oil, the drying machine adopts 304 stainless steel in-cylinder plate form to dry, so that materials and hot air fully contact, reduce energy consumption, and can reduce particle breakage, increase the rate of finished products.

5. Dedusting Equipment, Finished Product Silos and Packers:

Carbon black particles or powder, through a hoist or pneumatic conveying, conveying to the finished product silo. The equipment has its own dust removal system. After the dust is filtered and purified by the filter bag in the dust collector, the clean air is discharged into the atmosphere through the fan. The material filtered by the dust catcher enters the silo, and the finished products are packed by the ton packing machine, the small packing machine, the vacuum packing machine, and the palletizing machine. The whole packing process is highly automated and free of dust pollution.

6. PLC Control Cabinet

PLC control cabinet is the core and soul of modern industry, which can complete the automation of equipment and process and realize the perfect network function. Users can design PLC control cabinet, frequency converter cabinet according to their own needs, and can match the human-machine interface touch screen to achieve easy operation.

The whole set of equipment is scientific, environmental protection, intelligent, energy-saving requirements, workshop only 2-3 people to operate, in the current field of recycled carbon black equipment, our products have been recognized by customers, and widely used.

B. Grinding and Granulation Requirements:

1. Raw Materials: Tire Pyrolysis Carbon Black
2. Raw Material Particle Size: 0-5mm, the light transmittance of toluene was ≥60%
3. Grinded Particles Size Requirements: 325mesh ≥99.9%
4. Grinded Particles Output: 600kg/hr±5%
5. Granulation Requirements:
   • Fine Rate ≤10%
   • Granulated Particle Size (0.25mm-2.0mm)±0.5mm, Proportion ≥80%
   • Granulated Particles Hardness: 50-80cN, Max. 160cN
   • Granulated Particles Heating Reduction: ≤2%

C. Technical Indicators:

1. Particle Size Requirement: 325mesh ≥99.9%
2. Granulation Yield: 600kg/hr±5%

D. Equipment Name:

1. Mechanical CJ Series grinding and grading production line: Model CJ120
2. JXZL granulator production line: Model 650

E. Grinding and Granulating Technical Requirements

1. Particle Size: 325mesh ≥99.9%
2. Output: 600kg/hr±5%
3. Powder Content ≤10%
4. Granulated Particle Size (0.25mm-2.0mm)±0.5mm, Proportion ≥80%
5. Granule Hardness: 50-80cN, Max. 160cN
6. Heating Reduction: ≤ 2%

F. Process Description:

1) Process Route

2) Process:

1. The set of production line as a whole negative pressure production, to prevent dust pollution.
2. The pulverizing equipment is a horizontal axis reflective pulverizer, which can complete the two processing processes of micro-pulverizing and micro-particle sorting at the same time, the pulverizer is composed of a moving disc and a gear ring, which revolves at high speed through a special shape of the moving disc, and the material particles are repeatedly squeezed, collided and sheared between the moving disc and the stationary gear ring, thus achieving the pulverization, the material is transported to the pulverizing cavity by the quantitative feeding system, the material is impacted and sheared between the high-speed rotating rotor and the stator of the gear liner, the crushed material enters the classification area under the drive of the airflow, the qualified material is collected by a cyclone and a dust collector, the unqualified material returns to the pulverizing area again to carry on the pulverization, according to the characteristics of carbon black easy to catch fire, the production line designs the automatic slag discharge process.
3. The pelletizing system includes: carbon black feeding system, water quantitative system, pelletizing machine, drying system, conveying system, dust removal equipment, finished product silo and packaging machine.
   • Feed: the carbon black powder is placed in the hopper and may be supplemented with liquid regulators through the feed pump to accommodate the different uses and characteristics of the carbon black.
   • Wet granulation: under the action of carbon black and water in the mixing ruler, carbon black powder and atomized water meet, forming a strong small collision and impact, resulting in carbon black powder dispersion, grinding and pilling reaction. This process promotes the formation of particles, the shape and porosity of which depend on the physical and mechanical composition of the black itself. In short, mechanical granulation is the combination of the black with other substances, the formation of particles by physical forces such as rotation and friction.
   • Drying: wet granulation completed, the particles contain more water (50%) , the need to be removed through the drum dryer moisture. In this process, the particles in the dryer kept rotating, through the way of air drying, gradually reduce the moisture content, until the moisture content ≤2% state. Heat source: pyrolysis gas, pyrolysis oil, natural gas, tire pyrolysis waste heat.
     

G. Application Direction of Pyrolysis Carbon Black

1. In response to the national call for recycling of used tyres, pyrolysis carbon black is widely used in the tire industry to replace some of the original carbon black, reducing the cost of use; The regenerated carbon black can be used as reinforcing agent to recycle in automobile tires, motorcycle tires, electric tires and bicycle tires.
2. As a kind of low pigment carbon black, pyrolysis carbon black is widely used in paint, ink, color masterbatch, plastic raw materials, cement mortar creasing agent, activated carbon and other industries.
3. Used in the production of rubber products, as a filler to increase the hardness, strength and wear resistance of rubber products, improve weather resistance and chemical corrosion resistance, such as: rubber strips, rubber sheets, conveyor belts, sealing ring, gasket, rubber strip, hose, sole, conveyor belt, asphalt, waterproof agent.
4. For electronic products, cables and batteries, as a conductive agent, improve conductivity and heat resistance.

H. Equipment Configuration and Parameters:

1. Feeding system: the carbon slag is uniformly and uniformly transferred to the magnetic separator through the screw transportation, the carbon slag is transported to 20 cubic raw materials through the negative pressure transportation, the material bin (can be customized according to the site height) , the negative pressure transportation crushing system.
2. The host: the use of frequency conversion speed control, to achieve the ability of adjustable crushing, the host power: 90kW
3. The classifier: the use of frequency conversion speed control, to achieve the classification of adjustable fineness, the adjustment range of 50-2000 mesh. Classifier power: 30kW
4. Cyclone collector a set of φ750
5. Chamber dust collector: Filter area 160 square meters, electric pulse automatic dust, bag 136mm*2500mm
6. Induced draft fan: Power 37kW
7. Pneumatic conveyor: one set, adjusted to the granulator carbon black content, with carbon black raw material silos and quantitative silos (20 cubic meters)
8. Quantitative Water Supply System 2 sets: water pump 3kW, flowmeter according to carbon black quantitative add water quantity.
9. One pelletizer, power 45kW
   The pelletizer is completed and enters the drying system; heat requirement:
   - Natural gas 60-100 cubic /tons
   - non-condensable gas 55-65 cubic /tons
   - Pyrolysis oil 50-55 kilograms per ton
10. Dry particles through the cooling system dust removal system: filter area of 160 square meters, induced draft fan power 22kW. After cooling, the carbon black particles enter the sieving system through the bucket elevator, and the qualified finished products enter the silo; the large particles enter the finished product silo together through the crushing system, and the dust is uniformly collected and transported to the carbon black powder silo through the environmental dust collector.
    
11. The finished products entering the finished goods warehouse are packaged by the ton-charter machine or by the open packing machine.
12. Electric Control Cabinet: all electrical control is completed on one electric cabinet.

I. Production Line Power composition:

1. Host: 90kW
2. Grader: 30kW
3. Five sets of discharge valves:1.1kW
4. Three sets of roots fan: 15kW * 2, 7.5kW * 1
5. Feeder: 1.1kW
6. Induced draft fan: 37kW
7. Granulator: 45kW * 1
8. Drying converter: 7.5kW
9. Drying dust collector 37kW
10. Two sets of Type Z Hoist: 3kW * 2
11. Ton charter: 3kW
12. Vacuum packaging machine: 3kW

J. Plant area requirements: the process flow diagram is for reference only. The connecting position and direction of the equipment can be arranged according to the requirements of the plant

K. Equipment production cycle: 90 days, installation and commissioning cycle 60 days

L. Pyrolysis carbon black grinding granulation equipment supply details

1. The motor is CHNT dust explosion-proof motor. The standard of dust explosion-proof motor is Ex TD A21 IP65 T130℃, explosion-proof solenoid valve, dust with explosion-proof vent
2. Consumable parts: crushing disk, liner, hammer head
   • The replacement cycle of the hammer head is 800-1000 hours,
   • The replacement cycle of the liner is 1600-2000 hours,
   • The crushing disk maintenance after 800 hours of use, and can continue to be used after maintenance.

Crushing Hammer Head	Lining Plate	Crushing Disc

M. Customer case:

1. Customer cases of grinding and granulation production line
2. Grinding production line customer cases

N. Production line pictures display