Installation for thermal decomposition – working symbol WGW 8EU – of an innovative nature, for recycling and material recovery of all types of organic waste, in particular car tires.
The installation can process the following materials in a closed cycle:
elastomers – a variety of rubber waste and worn-out consumer products, in particular tires,
polymers – a variety of plastic waste and worn-out consumer products made of plastic, polymer composites, etc.,
used oil and other petroleum waste (sludge, shales, filters, oil, industrial cleaning cloth contaminated with oil and grease and other petroleum products, plastic packaging contaminated with petroleum, etc.)
other organic waste including mixed industrial waste such as polymer/elastomer/ cellulose/metal, etc. (eg. packaging of food products and household chemicals, and multilayer composite packaging, Tetra Pak type packaging, tannery waste and post-operational waste, etc.).
biomass, wood waste and post-consumer waste, wood and wood-like materials, including multi-layer materials, eg. combined with polymers,
hospital waste including hazardous materials subject to contamination (cloth such as gowns, bed linen, etc., gloves, syringes, needles, containers made from any type of polymers, which are now collected in sealed containers (buckets with lids) and the like.
waste from electronic and electrical industry including appliances / IT and end of life vehicles
Thermal decomposition is carried out in the WGW – 8 EU device in a specialized installation, under optimal technological conditions which are all the time automatically controlled (control of the process and safety system equipment for thermal decomposition is ensured by appropriate drivers).
Thermal decomposition is carried out in a sealed reaction vessel without oxygen/air and it is therefore an anaerobic process. In addition, the reactor is evenly heated during a slow and continuous rotation.
The anaerobic process of thermal decomposition occurs at a temperature of 320-450°C, depending on the type and nature of organic material being decomposed.
In the process the material (eg. tires) under pyrolisis is decomposed into component parts – oil, gas and solid fractions (in the case of tires it is a steel wire – scrap) and soot/fly ash (charcoal). The ongoing process of thermal decomposition results in the production of vapors of oil and gas character which having left the reactor in a closed and controlled process are passed into appropriate fractionating columns. As a result of this process oil and post-process gas are obtained.
WGW 8 EU device for thermal decomposition of organic waste manufactured by WGW Green Energy Poland consists of the following major components:
• Fully automated process control system of thermal decomposition (using a PLC drive)
• an insulating chamber housing a rotary reactor,
• a closed cycle series of condensing columns and tanks for post-process oil,
• a gas installation with dual-fuel rings for heating the reactor,
• a closed cooling system for condensing columns with an intra-process water tank,
• a complete exhaust removal system
• a parallel, independently functioning system of process and operation safety.
In order to ensure the safety of the process and device operation, the whole process is automatically controlled and monitored, including a self-diagnosis of the device.The yield of the WGW-8 EU installation for the process of thermal decomposition, including a reaction chamber with working space of approximately 8 to 12 Mg of load, whose capacity is 8 to 16 Mg/day (two cycles per day).
- The weight of the entire device, together with the components: approx. 35,000 kg.
- The weight of the shredded tire load: max. 12,000 kg; The load weight recommended by the manufacturer: 10,000 kg.
- Approximate dimensions of the reactor together with an insulating housing (l. x w. x h.): 7,000 mm x 3,000 mm x 3,500 mm.
- Capacity of the tanks for oil products: 2 x 6,000 l.
- Capacity of the tanks for gas products: 1 x 4 m3.
- Approximate dimensions of all the devices and installations (l. x w. x h.): 16 m x 6 m x 5 m.
- The area of the production hall should ensure an unhampered load; the recommended area is 500 m2.
- The maximum permissible noise level in the room operator does not exceed 55 dB and maximum noise level in the room of installation does not exceed 85 dB
- It is necessary to supply power to the electrical switchboard (30 kW, protection 63 A).
- Thermal decomposition is fully controlled and monitored by a computer system, which eliminates such dangers as low qualifications of the operators. The process takes place in an anaerobic environment, so there is no combustion process. This prevents fumes and a harmful impact on the environment! Additionally, the reaction chamber is thermally insulated. The loss of heat to the environment is thus minimized.
The thermal decomposition process generates materials which are in demand on the market as a basis for fully-fledged final products. These advantages of the equipment make it very cost-effective. The payback time on the machine and its launch is just several years, depending on the type of waste treated.
The following products are obtained in a single process that a machine with a load of approx. 10 tons runs from 12 to 16 hours – a full cycle which includes the cooling and cleaning of the reactor chamber and preparations for the next load. The data refers to thermal decomposition of car tires only:
- approx. 45% of pyrolisis oil
- approx. 25% of charcoal (the market price varies depending on the degree of cleaning and treatment of carbon powder)
- approx. 20% of steel scrap
- approx. 10% thermolisis gases that serve to heat the reactor during the process and therefore are used solely for the purpose
The manufacturer of the device is WGW Green Energy Poland Ltd.