Εγκατάσταση πυρόλυσης ελαστικών στη Γερμανία

Εγκατάσταση πυρόλυσης ελαστικών στη Γερμανία

On 24 October, we received an inquiry from a German client about waste tyre pyrolysis recycling plant in Germany. The client wants to know more about YSX waste tyre pyrolysis machines. Because Germany offers financial subsidies and incentives for recycling, and Germany produces millions of tyres a year, so they have a big waste tire management problem. Pyrolysis, a form of WtE, could be the answer. The client wants to know if pyrolysis technology can be used for tire recovery and how. The following is what we talked about with the German client.

How to build a tire pyrolysis facility in Germany in 3 steps?

The German tire market is huge and is expected to grow at a CAGR of 3.80% during 2024-2032. With sufficient supply of scrap tires as raw materials, our German customers are interested in setting up a tire pyrolysis plant. They asked about the details of setting up a plant to start the business as they are considering using it for scrap tire management and recycling projects. To answer their questions about scrap tire pyrolysis, let’s start with three steps.

preparations for the tire pyrolysis plant

Environmental Permits

Pyrolysis plants must meet EU and German emission standards (e.g., TA Luft for air quality). Apply for a waste management license under the Kreislaufwirtschaftsgesetz (Circular Economy Act) to legally process tires.

Zoning and Land Use

Ensure the site is zoned for industrial use and complies with local planning laws (BauGB). Secure approval from the municipality (Bauamt) for construction.

Market Study

Analyze feedstock availability (waste tire supply) and market demand for outputs (pyrolysis oil, carbon black, steel).

Assess competition and logistics (proximity to tire collection networks).

Business Planning

Decide on plant capacity (e.g., 10–50 tons/day).

Secure funding (grants, loans, or investors). Germany offers subsidies for circular economy projects (e.g., via KfW Bank).

Step 2 to build a tire pyrolysis plant in Germany

Technology Selection for Your Tyre Pyrolysis Facility

Choose pyrolysis reactor type (continuous vs. batch) and verify compliance with EU standards (e.g., CE certification).

Tyre Recycling Equipment Procurement

Source pyrolysis reactors, condensers, gas scrubbers, and shredders from certified suppliers (e.g., German/European manufacturers or reputable Chinese providers like Kingtiger or Beston).

Ensure equipment meets German safety norms (e.g., DIN standards) and includes emission control systems (e.g., activated carbon filters for VOCs).

Infrastructure Setup of Tire Pyrolysis Plant

Build facilities for tire storage (fireproof), pyrolysis reactors, and product storage tanks.

Install safety systems: fire suppression, explosion-proof electrical systems, and gas detectors.

Workforce and Training for Pyrolysis Plant

Hire engineers with pyrolysis experience and operators trained in waste tire handling.

Conduct safety drills compliant with Gefahrstoffverordnung (Hazardous Substances Ordinance).

Step 3 to build a tyre pyrolysis facility in Germany

Operations and Testing

Perform trial runs to optimize pyrolysis parameters (temperature, retention time).

Validate emissions (dioxins, NOx, SOx) with third-party testing to meet 17. BImSchV (Federal Emission Control Act).

Ongoing Compliance

Submit regular reports to authorities on emissions, waste residues, and product quality.

Renew permits annually and adapt to evolving EU regulations (e.g., REACH for chemical products).

Tire Pyrolysis Product Marketing

Sell pyrolysis oil to cement plants or refineries; carbon black to rubber/plastic industries.

Obtain sustainability certifications (e.g., ISCC PLUS) to enhance marketability.

What are the products of tire pyrolysis?

pyrolysis-products-SUNRISE Gaseous products pyrolysis oil Solid products

How to Choose Pyrolysis Furnaces for Tire Pyrolysis Plant?

Then we keep discussing with the German client. The client wants to set up a pyrolysis plant to recycle tyres and other rubber waste. They inquire which pyrolysis furnaces are best for their recycling plant.

Actually when choosing a tire pyrolysis furnace, it’s essential to consider different operating modes such as Batch, Semi – continuous, and Fully continuous.

Furnace Performance and Efficiency

Batch pyrolysis furnace is a good option for small to medium-scale operations with diverse raw material requirements. It can handle many different raw materials, such as tyres and plastics. It can process anything from 100 kg to 20 tonnes a day, which is ideal for facilities with fluctuating demand. You can process different batches of materials with different characteristics. The horizontal rotation structure and the choice of reactor materials ensure durability and proper heat transfer. It uses less power (≤ 30KW) and cools itself, so it’s more energy-efficient. The internal gearing transmission type provides reliable operation. The weight of the batch furnace can be accommodated in facilities with appropriate space.

The semi-continuous pyrolysis furnace is a good choice for operations that need to be productive and flexible. It can handle 10-20 tonnes a day, which is suitable for medium-sized recycling plants. A continuous feed is more productive than a batch furnace. It can process tyres and other raw materials efficiently while controlling the pyrolysis process. The horizontal rotation design and similar reactor specifications ensure reliable performance. The pyrolysis reactor operates at 0.4 rpm and has an internal gearing transmission. The water cooling system with a condenser cooling area of 100 square metres helps in effective condensation of the pyrolysis products. The weight and power requirements are within a range that can be managed in a medium-scale industrial setup.

A fully continuous pyrolysis furnace is the best option for large industrial operations that process a lot of waste tyres. It can process 15-50 tonnes of raw materials continuously, 24 hours a day. The horizontal rotation structure and durable reactor ensure long-term, stable operation. The normal operating pressure and cooling system keep the pyrolysis process going. The 100-square-metre condenser cools the pyrolysis products. The gears and the power support continuous, high-throughput operation. It costs more to run and needs more maintenance, but it produces a lot of pyrolysis oil and other useful products. This makes it a good choice for large waste tyre recycling facilities.

Pyrolysis Plant Installation

German tire Pyrolysis plant installation_SUNRISE

Tyre pyrolysis machine

Parameters of YUSHUNXIN pyrolysis furnace

Item Waste pyrolysis unit
Equipment type Batch Semi-continuous Fully continuous
Raw materials Rubber tyres, plastics, oil sludge, coal tar, aluminium plastics, etc.
Structure form Horizontal rotation
24-hour capacity 100 kg-20 tonnes 10-20 tonnes 15-50 tonnes
Oil yield From 30-70 per cent
Operating pressure Normal
Pyrolysis reactor material Q245/345R, boiler plate, stainless steel
Thickness of pyrolysis reactor 14, 16, 18, 20 mm
Speed of pyrolysis reactor 0.4 rpm
Total power ≤ 30KW
Cooling mode Circulating water cooling
Condenser cooling area 100 square metres
Type of transmission Internal gearing
Weight Depending on size

Average oil yield in the waste tyre pyrolysis plant featuring with auto-feeder

Waste tyre to oil
Waste plastic to oil
Waste rubber to oil

How much profit can you make from tire pyrolysis recycling?

The client wants to invest in a tyre-recycling plant now. Therefore, they asked about the profit from tyre pyrolysis recycling. “We wanted to know how much money this recycling production line could make.” This is also a question that most customers are very concerned about. Actually this depends on many things.

Scale of Your Pyrolysis Plant

Plant that processes 10,000 tons of tires annually

From these 10,000 tons of tires, it is estimated to produce around 4,500 tons of fuel oil, 3,500 tons of carbon black, 1,000 tons of steel wire, and 1,000 tons of combustible gas.

Let’s do the math. If the fuel oil (pyrolysis oil) is sold at a price of $500 per ton, carbon black sold at $300 per ton, steel wire at a price of $800 per ton, and the combustible gas is sold at $100 per ton. The total revenue from the sale of all these products would be approximately $4,200,000. Next, let’s estimate the cost of raw materials and labor to $2,000,000. Therefore, the annual profit of this plant would be $4,200,000 – $2,000,000.

It is worth noting that this is our estimate of the customer’s situation after discussion and is for reference only. If you need specific information, please contact us.

Pyrolysis Product Prices and Market Demand

carbon-black
Analysis of Tire Pyrolysis Oil

Pyrolysis oil

The price of used tire pyrolysis oil obtained through pyrolysis fluctuates with the oil market. In times when oil prices are high, the profit from selling pyrolysis oil can be substantial. For instance, if the price of pyrolysis oil is $500 per ton and a plant can produce, say, 2,000 tons of oil from recycling tires in a year, the revenue from oil sales alone would be $1 million. But when German oil prices are low, the profit margin may shrink.

Carbon black

High-quality carbon black has a stable market demand in the German rubber and plastic industries. If the carbon black produced through pyrolysis meets the quality standards of these industries, it can be sold at a good price, which can significantly contribute to the overall profit. The price of carbon black can vary from $300 to $800 per ton or even higher depending on its quality and market conditions.

Steel wire

Steel wire recovered from tires can be sold as a scrap metal. The price of scrap steel also fluctuates but generally provides an additional source of income. If the plant can produce 1,000 tons of steel wire per year and the scrap steel price is $300 per ton, the revenue from steel wire sales would be $300,000.

Combustible gas

The combustible gas produced during pyrolysis can be used for heating the pyrolysis reactor itself, which reduces the energy cost. If there is an excess of gas, it can be sold to other industrial users or for power generation, adding to the profit.

Is there any customized scrap tire pyrolysis solution reference?

oLet’s differentiate based on processing capacity. The following we’ll provide you with German waste tire pyrolysis recycling production line of different scales for reference. Customers can make adjustments as needed:

Small tire pyrolysis recycling production line proposal (suitable for start-ups or experimental production)

The daily processing volume of waste tires is about 1-2 tons, mainly producing rubber particles, some steel wires, and pyrolysis oil.

Before pyrolysis

tire-shredder
Tire shredder

Use a powerful rotating knife roller to crush tire blocks into 1-3 cm pieces, with a power of 15-20 kilowatts and a processing efficiency of 0.8-1.2 tons per hour. There is a simple screening net inside to initially separate large-sized impurities.

Magnetic Separator
Magnetic separator

Placed on the crushed material conveyor belt, it recovers steel wire through strong magnetic adsorption, with a separation efficiency of more than 90%, and the purity of the recovered steel wire can exceed 85%.

tire crusher
Tire crusher

further crushes the primary crushed materials into 0.5-1 mm rubber fine powder, with its own air cooling system to prevent overheating and bonding, and an hourly output of 0.5-0.8 tons.

Pyrolysis machine(optional)

Tire Recycling Line

Small intermittent tire pyrolysis furnace

Processes part of the rubber powder after fine crushing, produces 50-100 liters of pyrolysis oil and recovers 30-50 kg of carbon black per day, uses electric heating or small gas heating, is easy to operate and low cost.
Read More

Other aspects of the pyrolysis solution

The site area is 200-300 square meters, including equipment placement, raw material and product storage areas; the staffing is 4-6 people, covering equipment operation, raw material handling, quality inspection and other positions.

The dust collection system collects crushed dust and discharges it after bag dust removal and purification; the pyrolysis exhaust is treated by simple condensation and activated carbon adsorption.

Medium tire recycling production line solution (regional market)

The daily processing volume of waste tires is 5-10 tons, and high-quality rubber particles and high-quality carbon black are produced for tire retreading or high-end rubber production, and recycled steel wire is sold. The pyrolysis oil meets the industrial fuel standard and is partly used for self-use and partly sold.

Before pyrolysis

Dual-axis shredder (primary)
Dual-axis shredder (primary)

Strong torque shreds tire blocks, the output is 2-5 cm, the power is 30-50 kilowatts, the processing efficiency is 3-4 tons per hour, and it is equipped with overload protection and intelligent monitoring.

Magnetic separation machine
Magnetic separation machine

The steel wire is magnetically attracted synchronously during material transmission, and the material is automatically transmitted to the next step after separation. The steel wire recovery rate exceeds 92% and the purity exceeds 90%.

Cone crusher (intermediate)
Cone crusher (intermediate)

The primary crushing material is finely crushed to 0.5-2 mm, with a processing capacity of 2-3 tons per hour, and the particle size is controlled by hydraulic adjustment of the discharge port.

Vibrating screen combination machine
Vibrating screen combination machine

The vibrating screen then classifies the rubber particles to ensure that the product particle size is uniform and the quality is excellent, and the classification accuracy rate exceeds 95%.

Pyrolysis machine(optional)

Continuous tire pyrolysis furnace: It produces 1-2 tons of pyrolysis oil and 0.8-1.2 tons of carbon black per day, uses natural gas or biomass particles as fuel, has a thermal efficiency of more than 70%, and is equipped with waste heat recovery for drying and other links.

Other aspects of the pyrolysis solution

The site is 800-1200 square meters with clear divisions; there are 10-15 people, with dedicated personnel for each process, and a technical and quality control team.

Advanced bag dust removal and cyclone dust removal combined with dust capture; recycl and treat pyrolysis tail gas by desulfurization, denitrification, and condensation; wastewater treatment reaches the third-level emission standard for circulation or standard emission.

Large-scale tire recycling production line plan (industrial cluster)

Daily processing of 20 tons or more of waste tires, large-scale production of high-quality rubber product raw materials, carbon black, and steel wire, and pyrolysis oil for park energy or external sales.

Equipment layout before pyrolysis

Heavy-duty double-shaft shredder (primary)
Heavy-duty double-shaft shredder (primary)

high power, high torque, processing capacity of 6-8 tons per hour, 1-3 cm discharge, sturdy and durable body, suitable for high-intensity continuous operation.

Multi-stage magnetic separation and air separation integrated system
Multi-stage magnetic separation and air separation integrated system

multi-channel magnetic separation ensures high wire recovery rate of over 95%, high purity of over 92%, air separation removes impurities such as fibers, and material flow is automated.

Impact crusher (intermediate)
Impact crusher (intermediate)

crushed to 0.3-1 mm fine powder, output of 4-6 tons per hour, using special wear-resistant materials, low maintenance cost.

Intelligent vibrating screen and airflow classification system
Intelligent vibrating screen and airflow classification system

accurately classify rubber particles, output according to market requirements of multiple specifications, and classification accuracy exceeds 98%.

Pyrolysis and deep utilization cluster

High-efficiency large-scale pyrolysis furnace group: multiple continuous pyrolysis furnaces in parallel, daily output of 5-8 tons of pyrolysis oil and 3-5 tons of carbon black, advanced heat recovery and automatic control to ensure stable operation.
Carbon black modification and granulation production line: Deep modification and granulation of carbon black to meet the needs of tires and high-end rubber, with strong product competitiveness; pyrolysis oil refining device purification reaches the high-quality standard of fuel oil.

Other aspects of the pyrolysis solution

The site is over 2,000 square meters with scientific planning; 30-50 people with fine division of labor, including R&D and process optimization teams to enhance product added value.

Build a complete “three wastes” treatment system, ultra-low dust emission, deep exhaust purification, zero discharge and recycling of wastewater; introduce clean energy such as solar energy to supplement production and practice green circular development.

Why Choose YSX as your Pyrolysis Furnace Supplier?

What Qualifications Do We Have?

At SUNRISE, CE and ISO 9001 certifications are just part of our offerings in this regard. We’ve got a whole slew of other certifications up our sleeve to meet diverse compliance and quality benchmarks as well.

Customer feedback pictures of pyrolysis plant

pyrolysis recycling equipment.
Pyrolysis furnace

Finally, our German customers want to know how pyrolysis works in specific production case studies. This can help them decide if this technology is right for them. Let’s take a look at some great examples. Click here to know more.

YSX team can provide you not only the tire reycling solutions, but also e-waste disposal plan like batteries recycling solutions, circuit board recycling solutions, and solar panel reycling solutions. Feel free to contact us if you wanna start recycling business.

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