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GREEN3      CONVERSION®

G3C Technology

  • First Generation 3 Scrap Tire Conversion Technology.

 

  • Addresses both fundamental CB properties (structure & surface) and CB purity for a wide range of applications, including the following:
    • High-Grade Applications
      • ​Cable Coating and other Semi-conductive rubber applications
      • Conductive CB additive for tires
      • Highway Tire Tread 
      • Rubber applications for high abrasive and tensile strength product
    • Medium and Low-Grade Applications
      • Non-Highways Tire Tread
      • Tire Non-Tread
      • Paint
      • Various rubber applications

 

  • Converts the same feedstock into a different grades of carbon black, i.e. same grade of carbon black can be produced from different feedstock of scrap tires.

 

  • Triple GREEN – Environmentally Friendly.

Scaled-up Horizontal G3C Reactor Pilot System with improved thermo insulation

G3C Technology Highlights

G3C Conversion System

  • The feedstock of G3C Conversion System is steel and fluff free crumbed tire rubber.

 

  • Basic G3C Conversion Process is using a single zone reactor which performs the following:
    • Extraction of volotiles.
    • Reduction of the mass of remaining solid material and its conversion to char.
    • The resultant char has high structure and high surface area properties.

 

  • Optimized G3C Conversion Process encompasses two zones and has better performance, scalability and economy:
    • Zone 1: Volatiles Extraction
      • Most of the volatiles are extracted from the material.
      • The mass of the material is reduced significantly.
      • The resultant char has low structure and low surface area properties.
    • Zone 2: Properties Building
      • Remaining volatiles are extracted from the material to achieve the target level.
      • Material mass is somewhat reduced. 
      • Depending on the Zone 2 process parameters (e.g.  temperatures, durations, etc.) desirable properties are achieved.

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  • Chemical reactions involved in the G3C Conversion Process include those typical of a tire pyrolysis process, and in addition, chemical reactions designed to produce the particular product grades.

G3C Enrichment System

  • The feedstock of G3C Enrichment System is the char produced by the G3C Conversion System.

 

  • The G3C Enrichment System encompasses two areas:
    • Milling Area receives char from the G3C Conversion System, cools it down to the room temperature and reduces the char pieces (a.k.a. agglomerates) sizes by processing the material with milling equipment.
    • Impurities Removal Area receives the reduced in sizes char pieces and runs them through a sequence of chemical processing steps to remove unwanted types of impurities to meet the requirements for the specific applications. For example, all impurities are removed when producing rCB used for cable coating. However, in case of carbon black for tires impurities containing silica and sulfur are not extracted.

G3C Plant Control System

Also see Environmental Impact

  • No pollution, reduced carbon footprint
    • Oil and gas, produced as byproducts of the conversion process are used for heat needed for the process and/or power generation.
    • Heavy oil, a byproductof the process that is difficult to handle and to be useful is recycled back to the conversion process to produce more carbon black and oil and gas.
    • The exhaust from burning flammable oil and gases is after-burned to eliminate remaining flammable component (while using resultant heat for the process energy needs) and then scrubbed to remove unwanted gases (e.g. sulfur dioxydes and nitrogen dioxides).
    • Water used in the G3C Enrichment System is recycled for reuse, thus minimizing both water usage and waste water discharge.

 

  • No fossil fuel is used to produce carbon black
    • G3C Technology potentially allows to substitute all major grades of virgin CB with rCB produced by tire conversion.

 

  • No fossil fuel is used for plant internal energy needs
    • The power required for the operation of the conversion system, char milling machine, enrichment system and auxiliary equipment are internally generated as a byproduct of the tire conversion process.
    • The residual fuel released from the rubber, in the form of oil and gas, is used for reactor heating purposes. The remaining fuel is used for power generation.
    • The self-generated power is more than sufficient for in plant use and the surplus power is sold to the grid.
  • The G3C System operation is fully automated by the plant control system.

 

  • A Central Control Room is used to control arrays of production lines containing Reactors and Enrichment Systems.

 

  • The operational flexibility is achieved through pre-programmed process control algorithms.
    • Each production line is configured to produce a specific carbon black grade, which may be different from that of the otherproduction lines.
    • Taylored configurations are made by loading and assigning a grade specific process control algorithm to the individual production lines.

G3C is Developed with the Environment in Mind

Scaled-up Horizontal G3C Reactor Pilot System