Technologies

We develop and implement the pyrolysis plants into operation to turn the waste problem into profitable income.

GRENECO plant is intended for utilization of a wide range of hydrocarbon-containing wastes using a modification of a widely used pyrolysis technology,

namely, the Low-temperature ThermoСhemical Decomposition with the innovations, introduced by GRENECO experts.

for today the GRENECO plant is able to recycle:
   - Used Tyres, rubber
                          - High—density polyethylene (HDPE)
                         - Low—density polyethylene (LDPE)
   - Polypropylene (PP)
- Polystyrene (PS)
                             - Acrylonitrile butadiene styrene (ABS)
    - Oil Sludge and Tar

Greneco technology allows to recycle waste into pyrolysis oil, technical carbon, gas, which can be used for the further cemical production, production of heat and electricity.

Our pyrolysis process far exceeds the economic value of the traditional pyrolysis process. During pyrolysis low-polluting/non-hazardous fuel products are formed, which make it possible to reduce the impact on the environment and reduce the cost of energy production compared to traditional types of fossil fuels.

Watch the Video of burning tests of Greneco pyrolysis oil.

Technology benefits

  • The rotating drum technology ensures maximum efficiency of the pyrolysis process. Due to constant mixing of raw materials the active surface area increases, sintering of the raw material is prevented in contrast to retorts with static crucibles;
  • The possibility of control and management at all stages of the technological process provides the completeness of cycle, including the stage of calcining the carbon residue. There are no stringent requirements for the homogeneity of the raw materials, unlike the flow type plants;
  • The possibility to dispose of various types of waste in one installation;
  • Relatively low specific labor and energy costs (the average consumption of electric energy during pyrolysis is about 3 kW/h);
  • Pre-grinding of raw materials is not required for delivery to the installation, which significantly reduces capital and operating costs;
  • The feeding of raw materials by the pressing-in method allows efficient use of the reactor volume;
  • 100% stable quality of the final pyrolysis products.

Our plants usually achieve the following indicators of pyrolysis products:

  • Oil
    40-80%
  • Carbon
    10-40%
  • Burning Gas
    10-12%
  • Steel
    0-12%

Exact percentage of products from Greneco technology will be set up for Customer according its strategy and commercial case. Greneco specialists will be happy fully consult our new Customers from the planning till the Gurantee and support of new plants. We highly recommend you to follow our Projects and News. Please Contact with us if you have any question. Additionally visit our FAQ page.

  • Oil
    Oil
    After the pyrolysis process in Greneco , most of the produced synthesis gases are concentrated back to oil. Depends on partner wish solution might be set up with priority for light / mid or heavy oil. Additionally, it can be refined into Greneco Diesel and other petrochemical products. The main advantage of Greneco Oil is low level Sulphur, which is less then 1%. Labor tests and burning tests confirm ability to use in oil traditional fields, such as heating plants, cargo and passenger vessels. Greneco oil was fully approved by Finland and Estonia.
  • Carbon black
    Carbon black
    Average energy value when technical carbon burned is 30 to 34 MJ/kg comparing to coal with 17 to 24 MJ/kg and wood with 16MJ/kg. Combusted almost without residue. Technical carbon is the main component for rubber production, filtering systems and pigmentation.
  • Steel
    Steel
    The metal yielded from the proposed conversion process has unchanged structure and therefore has the highest value on metal recycling market.
  • Burning Gas
    Burning Gas
    Burning gas is used to run production equipment heating and can be channelled to consumers market to compete with a price advantage compared to current alternatives. Calorific value of Pyrolysis Gas is higher than Natural Gas (38-39 MJ/kg) and energy value comparable to Propane/Butane C3H8/C4H10 with 45-47 MJ/kg.

Technological process stages

1 stage. 
Loading raw materials into the reactor. The end cover of the reactor is opened and through it the raw material loading s performed. Loading is possible in several ways:

  • Tires(and bulky raw materials) are loaded into the reactor without pretreatment through one of 2 windows using a pusher press. The first window has a size of 1500x470mm and is intended for loading medium-sized tires and other raw materials into a given dimension. The force of the pusher is sufficient to load a tire of a larger diameter. In this case, the tire is deformed when passing into the loading window. The second window has an envelope of 900x900mm and is intended for passenger and truck tires and other raw materials. The force of the press pusher is sufficient to push the tire inside with a diameter of up to 1300 mm;
  • For loading mixed types of raw materials of different fractions the loading device has options for interchangeable nozzles. So, the press pusher has a quick-release mechanism for replacing it with another type and there are slots in the floor for installation of boards of various configurations;
  • Liquid raw materials are loaded through the reactor fitting and additionally the Unit can be equipped with a continuous fluid supply system during process of pyrolysis;
  • The pusher press can be supplemented with a briquette press. In this case the press pusher is used as a power drive of the briquette press;

Loading is carried out by 2 people.
After loading is completed the reactor window is closed hermetically hatch. Then workers can start loading / unloading another reactor or briquetting tires, packing products, loading a free tray by other waste. The time required to load the reactor does not exceed 1 hour.

2 stage. 
The active phase of the pyrolysis cycle. The reactor is heated by oil burner for 1.5 hours. If there are several reactors, it is possible to perform the initial heating with excess gases of another operating reactor. Then begins the active phase of pyrolysis. The gas-vapor mixture formed in the reactor is fed to the condensation line, where pyrolysis liquid is separated from it. The noncondensed part of the pyrogas enters the combustion chamber, where it is burned in a gas burner for further reactor heating. The reactor goes to self-supply with maintaining a certain temperature, which is controlled by changing the power of the burner and the pressure - by dropping excess pyrogas (mostly methane) into the flare burner. The duration of the pyrolysis cycle is 6-8 hours.

3 stage. 
Cooling (in the case of liquid or metal-free raw materials, complete cooling is not required). At the end of pyrolysis cycle the operator starts the reactor cooling program on the control panel. After 3 hours of cooling the unit is ready for unloading the dry carbon residue.

4 stage. 
Unloading of dry carbon residue. The operator attaches an outlet tube for carbon unloading in the axis of rotation of the reactor and attaches the Big Bag to the other end, starts the rotation of the reactor in the opposite direction and empties the reactor. The unloading process takes up to 1 hour.

5 stage.  
Unloading of steel cord (if present in the raw material). The twisted bundle of steel cord, remaining after unloading the carbon residue, is extracted through a special end hatch of the reactor using a traction device. Unloading is carried out in a dust-free manner into the receiving tank located indoors adjacent to the reactor. The process of unloading steel cord takes up to 30 minutes.

 The total time of the production cycle is about 16-24 hours and depends on the type, humidity, fraction, age, steel cord condition and other parameters of the feedstock.

Additional production work which performed simultaneously with the main technological operations:

  • preparation of raw materials - cleaning, washing, grinding, etc.
  • briquetting of raw materials on the press (if necessary);
  • packing of the cooled carbon residue in the container, preparation for sale;
  • transfer and filling of pyrolysis fuel tanks, preparation for sale;
  • transportation of the steel cord bundle, preparation for storage and for sale;
  • loading of products / unloading of waste.