US 9,809,754 B2
Pyrolysis systems with enhanced solids handling
Chuck Schneider, Ralston, NE (US)
Assigned to Blizzard Energy, Inc., Great Bend, KS (US)
Filed by Blizzard Energy, Inc., Great Bend, KS (US)
Filed on Feb. 3, 2016, as Appl. No. 15/14,894.
Claims priority of provisional application 62/197,432, filed on Jul. 27, 2015.
Prior Publication US 2017/0029708 A1, Feb. 2, 2017
Int. Cl. C09C 1/48 (2006.01); C10B 53/07 (2006.01); C10B 57/02 (2006.01); C10B 7/14 (2006.01); C10B 21/12 (2006.01); C10B 27/06 (2006.01); C10B 41/00 (2006.01); C10B 45/00 (2006.01); C10B 47/06 (2006.01)
CPC C10B 53/07 (2013.01) [C09C 1/48 (2013.01); C09C 1/482 (2013.01); C10B 7/14 (2013.01); C10B 21/12 (2013.01); C10B 27/06 (2013.01); C10B 41/00 (2013.01); C10B 45/00 (2013.01); C10B 47/06 (2013.01); C10B 57/02 (2013.01); Y02P 20/143 (2015.11)] 20 Claims
 
1. A method of pyrolyzing a rubber-containing material, said method comprising:
(a) heating at least one crucible at least partially filled with a first quantity of said rubber-containing material under conditions sufficient to pyrolyze at least a portion of said rubber-containing material to thereby form pyrolysis vapors and pyrolysis solids, wherein said pyrolysis solids comprise carbon black, carbon black fines, and metallic elements;
(b) cooling said pyrolysis solids within said crucible to provide cooled pyrolysis solids;
(c) emptying said cooled pyrolysis solids from said crucible into a solids transfer zone;
(d) transferring at least a portion of said pyrolysis solids from said solids transfer zone to a solids cooling zone;
(e) further cooling said pyrolysis solids in said solids cooling zone to provide further cooled pyrolysis solids, wherein at least a portion of said cooling is performed using a fluidized bed cooler;
(f) separating said further cooled pyrolysis solids into carbon black and metallic elements in a solids separation zone;
(g) loading at least a portion of said carbon black into one or more storage containers in a loading zone, wherein at least one of said emptying, said transferring, said further cooling, said separating, and said loading causes at least a portion of said carbon black fines to be emitted into the surrounding environment;
(h) capturing at least a portion of said carbon black fines emitted into said surrounding environment during at least a portion of said emptying, said transferring, said further cooling, said separating, and/or said loading to provide captured carbon black fines; and
(i) introducing at least a portion of said captured carbon black fines into one or more storage containers in said loading zone.