Recycling shredded used tyres and rubber waste into personalized recovered Carbon Black to limit use of fossil fuels and carbon dioxide emission

Project Information

CBreCYCLE

Grant agreement ID: 101009283

DOI

10.3030/101009283

Project closed

EC signature date 5 October 2020

Start date 1 September 2020

End date 31 July 2023

Funded under

• PRIORITY 'Societal challenges

Total cost

€ 3 569 375,00

EU contribution

€ 2 498 562,50

Coordinated by

SYNTOIL SPOLKA AKCYJNA
Poland

Periodic Reporting for period 2 - CBreCYCLE (Recycling shredded used tyres and rubber waste into personalized recovered Carbon Black to limit use of fossil fuels and carbon dioxide emission)

Reporting period: 2021-09-01 to 2023-07-31

Summary of the context and overall objectives of the project

Rubber tyres have been with us for the last 130 years. Manufactured and used on a massive scale, they have a significant impact on our economy. But they also generate global problems related to handling over 1.5 billion used tyres every year and consuming fossil fuels (mostly crude oil) to produce new ones. Only a small fraction of used tyres is rethreaded, while most end their life generating electricity or producing heat in steelworks or cement kilns, although generating high volumes of CO2.
At Syntoil, we aim to change it by overcoming the limitations of existing technologies and bringing to the market continuous pyrolysis and clean recovered carbon black which can fully replace virgin carbon black made from fossil fuels. Syntoil S.A. has developed a process of cleaning the contaminated soot from used tires recycling into a valuable product called recovered carbon black and also the continuous pyrolysis process that limits the usage of fossil fuels and minimises waste and carbon dioxide emissions. The EU-funded CBreCYCLE project focuses on the main products of pyrolysis by developing a unique method that recovers carbon black (CB) from the char and replaces traditional CB in tyre production and other applications.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

We have introduced a revolutionary Milestone in a recycling technology. Our state-of-the-art plant has been designed and assembled to efficiently process 2,000 tonnes of pure material per year, setting a new standard in eco-friendly production. The existing facilities had been expanded to create an industrial-scale pilot plant.
This innovative plant seamlessly integrates two distinct installations: one dedicated to the continuous pyrolysis of rubber granules, and the other focused on contaminated soot cleaning. Both procedures culminate in the production of recovered carbon black, an alternative to the virgin carbon black currently derived from fossil fuels, showcasing a significant advancement in sustainable practices. Sustainability is at the core of our design, with energy derived from the pyrolysis process powering the plant.

Our installation follows a modular approach, allowing each device to operate independently. The entire system is linked to a central system, overseeing device control and monitoring crucial parameters such as raw material inventory status.
Following thorough testing and integration, our pilot plant is now operational. Our rCB samples have garnered attention from industry leaders in the pigment and rubber market ensuring that our recovered carbon black met the stringent requirements and expectations of the market's leading players.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

We developed a unique method able to recover Carbon Black (CB) from the char (different name: contaminated soot) and replace traditional CB in rubber, paints, and tire manufacturing, and other applications. We do it at a price level lower than the market price of CB produced out of crude oil. Additionally, our cleaning technology allows for personalizing recovered CB which opens highly profitable applications in various industries.
With our solution, we can not only mitigate the use of fossil fuels but we minimize generated amounts of CO2. With support from the EIC Accelerator, we plan to develop an industrial-scale demonstrator to confirm the scalability of our solution and prepare the foundation for post-project commercialization addressing the new and rapidly growing rCB market worth nearly EUR 450M in 2023.

Syntoil founders

Company's logo

Syntoil's factory building

Syntoil founders