Technology

Pyrum’s unique thermolysis process

Pyrum thermolysis involves the thermal decomposition of organic substances or rubber and plastic waste under the exclusion of oxygen. The process enables precision temperature and pressure control, which minimises risk during pyrolysis (spark-​free and airtight) and ensures raw materials of a consistently high quality. These process conditions produce vapours that condense into oil at low temperatures, as well as permanent gas (gaseous hydrocarbon compounds) and coke.

Self-​sufficient system operation with excess energy

A special feature of the patented process is that after the system has been started once with external energy, the gas then generates sufficient energy for the system to operate self-​sufficiently. The system even generates surplus energy, which can then be sold on as thermal or electrical energy.

Pyrum technology can process the following waste and input materials:

  • Used tyres (cars, lorries, motorbikes, construction machinery, etc.)
  • Bitumen mats and insulation (e.g. roofing felt made of bitumen)
  • EPDM and other elastomers, rubber waste (door and window seals)
  • PE/​PET (films, bottles, moulded parts, etc.)
  • Oil shale and oil sands (in test phase)

The process can be used to generate the following products: 

  • Rubber powder
  • Carbon black
  • Coke
  • Activated carbon
  • Crude oils
  • Gas (like natural gas)
  • Electricity
  • Waste heat

An interactive explanation of the thermolysis process

Sustainable and environmentally friendly future technology

The environmentally friendly disposal of rubber and plastic waste will become hugely important over the coming years because current disposal methods are highly detrimental to the environment. The disposal of used tyres in cement works, for example, will be banned by 2025. In addition, tyre manufacturers such as Michelin are aiming to produce the majority of their tyres from recycled raw materials in the future.

In this respect, the innovative recycling process used is the perfect example of a future-​orientated waste management concept. It combines the economic and ecological requirements for a waste concept with low investment and operating costs, helps to recover raw materials and serves as a replacement for fossil fuels.

Pyrum thermolysis: the multi-​stage recycling process flow

The thermolysis recycling process used here involves multiple stages.

Stage 1

  • Crushing (shredding) of the input material into granulates measuring 1 to 12 mm
  • Separation of metal and textile components for reuse

Stage 2

  • Thermolysis of the rubber granulate in the patented vertical reactor
  • Separation of the resulting vapour and coke

Stage 3

  • Condensation of the vapours
  • Separation of oil and permanent gas

Stage 4

  • Cooling the coke
  • Grinding, screening, classification and pelletisation of the coke into commercially available products: carbon black, rCB (recovered carbon black)

Stage 5

Power generation for main and auxiliary units

  • Recuperation (recovery) of exhaust gas energy
  • Generation of electrical energy for self-​supply and sale by means of a combined heat and power (CHP) unit

Stage 6

  • Rectification of the oil
  • Storage of oil types in the tank farm

Stage 7

  • Cleaning of the exhaust air from the CHP unit to legally prescribed limits; the Pyrum thermolysis process itself does not produce any exhaust gases, only the CHP unit produces small quantities

Stage 8

Refinement of intermediate products: heat, oil and coke e.g.:

  • Combined heat and power with neighbours
  • Carbon black production from oil
  • Activated carbon production from coke
procedure-tile

Stage 1

- Crushing (shredding) of the input material into granulates from 1 to 12 mm

– Separation of metal and textile parts for reuse
procedure-tile

Stage 2

- Thermolysis of the rubber granulate in the patented vertical reactor

– Separation of the resulting products vapour and coke
procedure-tile

Stage 3

- Condensation of the vapours

– Separation of oil and permanent gas
procedure-tile

Stage 4

- Cooling the coke

– Grinding, screening, classification and pelletisation of the coke into commercially available products: Carbon black, rCB (recovered carbon black)
procedure-tile

Stage 5

Power generation for main and auxiliary units

– Recuperation (recovery) of exhaust gas energy

– Generation of electrical energy for self-​supply and sale with the aid of a combined heat and power unit (CHP)
procedure-tile

Stage 6

- Rectification of the oil

– Storage of oil types in the tank farm
procedure-tile

Stage 7

- Cleaning the exhaust air from the CHP unit to legally prescribed limit values; the actual Pyrum thermolysis process does not produce any exhaust gases, only the CHP unit produces small quantities
procedure-tile

Stage 8

Refinement of intermediate products: heat, oil and coke, e.g.:

– Combined heat and power with neighbours

– Carbon black production from oil

– Activated carbon production from coke

Pyrum thermolysis: the recycling process at a glance

Legend

  1. Shredding of rubber granulate to a grain size of 12 mm
  2. Pyrum thermolysis reactor: separation of the rubber granulate into vapour and solids
  3. Vertical cooler for solids
  4. Vapour condensation to oil and gas
  5. CHP unit for power generation

Pyrum thermolysis: a boon for industry and the environment 

Thanks to its outstanding sustainability and economic efficiency, Pyrum’s patented thermolysis process is a technologically sophisticated, environmentally friendly and profitable solution to the increasingly acute problems faced by the recycling sector in almost all industrialised nations. In principle, this represents a secure and high-​yield investment with an ROI of up to 25%.

0 %
environmentally neutral
0 %
energy self-​sufficient
0 %
modular
Endless
material cycle

1. recycling of used tyres

Environmentally friendly tyre recycling

New raw materials are obtained from old tyres using the patented pyrum thermolysis process: In addition to steel wire and fabric fibres, mainly Oil, gas and carbon – energy self-​sufficient and environmentally friendly. Compared to the used tyre disposal mix in Germany, this means that 72 % CO2 saved (according to the Fraunhofer UMSICHT study 2022).

2. shredding the used tyres

Shredding three tonnes of used tyres per hour

The used tyres are first shredded. The Pyrum plant in Dillingen has a capacity of three tonnes of used tyres per hour.
Fabric fibres and Steel wire are filtered out and added to the
production cycle of the industry.

Learn more

3. filter out steel wire

Pyrum steel wire: sustainable raw material for the steel industry

One tonne of used tyres can be turned into up to 750 kg Pyrum steel wire filtered out. By post-​treatment of the steel wire, Pyrum achieves a Purity of over 96 per cent. The wire can be purchased at the current mixed steel scrap price.

Learn more

4. filter out fabric fibres

Pyrum fabric fibres: Sustainable raw material for the construction industry

Three tonnes of used tyres are turned into up to 300 kg Pyrum tissue fibres filtered out. These are used as a valuable secondary raw material for the production of new Insulation material for the construction industry.

5. pyrum rubber granules

Pyrum rubber granulate: the material for top recycled products

The rubber granulate produced using the pyrum thermolysis process is a valuable and sought-​after secondary raw material for the production of sustainable recycled products that meets the highest standards. The granulate is available in four different grain sizes from 1 to 6 mm for different applications and almost every customer requirement.

Learn more

6. thermolysis of the tyre rubber

Pyrum thermolysis: Sustainable raw materials from tyre rubber 

Three tonnes of used tyres are turned into up to 2,100 kg Rubber filtered out. The granulated rubber (grain size 12 mm) is fed to the thermolysis process in the patented Pyrum vertical reactor. In the process, the rubber is Steam and Solid (coke) separated. In the process, sufficient Energy for the self-​sufficient operation of the system.

With pyrum thermolysis, in addition to Exhaust and heat energy valuable Raw materials for the sustainable manufacture of new products:

7. pyrum thermolysis oil

Pyrum thermolysis oil: Sustainable raw material for the chemical industry

The vapours generated during pyrum thermolysis are condensed and stored in Permanent gas and Thermolysis oil separated. Pyrum thermolysis oil is a unique crude oil that is produced to the highest quality and consistent grade.

The REACH-​certified recycled oil is used as a raw material in various industries: chemical industry, refineries, carbon black production (CB) etc.

Practical applications

Pyrum thermolysis oil is used, for example, in combination with biomethane as a raw material in the production of virgin plastics for Mercedes-​Benz vehicle components.

Learn more

Pyrum thermolysis oil is used, for example, as a raw material for the production of polyamide for Outdoor clothing from the VAUDE brand used.

Learn more

8 BASF relies on pyrum thermolysis oil

BASF relies on pyrum thermolysis oil

The Chemicals group BASF has invested in Pyrum Innovations AG as part of the ChemCycling™ project. With the REACH-​certified thermolysis oil, BASF is securing a Pioneering source of raw materials and at the same time improves its own carbon footprint. BASF is already using the oil at its Ludwigshafen site for new plastics for the production of Vehicle components from Mercedes-​Benz.

9. pyrum thermolysis permanent gas

Pyrum thermolysis permanent gas: energy self-​sufficient operation

A special feature of the patented Pyrum thermolysis process is that after starting up the system once with external energy, sufficient energy is generated by the gas obtained in the condensation process to enable the system to operate independently. A surplus of energy is even generated, which can be sold on as thermal or electrical energy.

10. pyrum thermolysis coke (carbon black)

Pyrum thermolysis coke (carbon black): High-​tech raw material

The coke produced in the pyrum thermolysis process can be used unground, with a grain size of up to 4 mm, as a soil improver, substitute fuel or filler. However, a large proportion of the pyrum thermolysis coke is used for the production of recovered carbon black (rCB).

Learn more

11. pyrum-​recovered carbon black (rCB)

Pyrum-​recovered Carbon Black (rCB): The raw material for new tyres

Through further processing in a grinding plant, Pyrum produces high-​quality recovered carbon black (rCB), which is an increasingly sought-​after raw material in the tyre industry for the production of sustainable new tyres. This closes the material cycle sustainably. Pyrum-​recovered Carbon Black (rCB) can be supplied in ground form in sizes from 7–36 µm.

Practical applications

The recovered carbon black (rCB) obtained from the rubber of old bicycle tyres using pyrum thermolysis is fed back into the manufacturing process for new bicycle tyres.

Learn more

In the medium term, the particularly high-​quality pyrum carbon black (rCB) is to be used for Continental’s tyre production.