Tire pyrolysis is a thermal decomposition process that breaks down waste tire rubber in the absence of oxygen. Unlike burning, pyrolysis converts tires into four valuable products — pyrolysis oil, recovered carbon black (rCB), steel wire, and syngas — without releasing the toxic emissions associated with open combustion.
The process works best with TDF chips (tire-derived fuel) as feedstock. Our standard 2" or smaller TDF chips are the ideal input material for pyrolysis reactors — uniformly sized, consistent composition, and ready to feed directly into the system.
This article explains how tire pyrolysis works step by step — from waste tire collection through final product output — and why it represents the next frontier in tire recycling technology.
The Pyrolysis Process: Step by Step
Tire Collection & TDF Chip Production
Waste tires are collected from tire shops, fleets, municipalities, and property owners. They're transported to a processing facility where they're shredded into TDF chips — 2 inches or smaller, processed through 2-inch screens. These uniformly sized chips are the ideal feedstock for pyrolysis reactors.
Feedstock Preparation
TDF chips are inspected for quality and consistency. Steel content, moisture levels, and chip size are verified to meet reactor specifications. Properly prepared feedstock ensures efficient pyrolysis and high-quality output products.
Thermal Decomposition (Pyrolysis)
TDF chips are fed into a sealed pyrolysis reactor and heated to 400–700°C in the absence of oxygen. Without oxygen, the rubber doesn't burn — instead, it thermally decomposes into its constituent molecules. The process typically takes 4–8 hours per batch depending on reactor design.
Condensation & Product Separation
The gases produced during decomposition pass through a condensation system. Heavier hydrocarbons condense into pyrolysis oil (liquid fuel). Lighter gases that don't condense become syngas. Solid residue in the reactor contains carbon black and steel wire, which are separated mechanically.
Product Collection & Refinement
Each output product is collected separately: pyrolysis oil is stored in tanks, recovered carbon black (rCB) is ground and packaged, steel wire is baled for scrap recycling, and syngas is either flared or recycled back into the reactor as fuel — making the process partially self-sustaining.
What Pyrolysis Produces from Waste Tires
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Pyrolysis Oil (Tire-Derived Oil)
A liquid fuel similar to diesel, used in industrial boilers, furnaces, and generators. Can also be refined into higher-grade fuels or used as a chemical feedstock. A single passenger tire yields approximately 2–3 gallons of pyrolysis oil.
Yield: ~40–45% of tire weight
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Recovered Carbon Black (rCB)
A fine black powder used in rubber manufacturing, ink production, pigments, and as a reinforcing filler. rCB from tire pyrolysis replaces virgin petroleum-derived carbon black — a high-value industrial material with growing global demand.
Yield: ~30–35% of tire weight
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Steel Wire
Steel belts and bead wire from tires are recovered intact and sold as scrap steel. Recycled steel requires 75% less energy to produce than virgin steel, making this a valuable and environmentally beneficial byproduct.
Yield: ~10–15% of tire weight
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Syngas (Non-Condensable Gas)
A combustible gas produced during pyrolysis that can be recycled back into the system to fuel the reactor itself — making the process partially self-sustaining and reducing external energy costs.
Yield: ~10–15% of tire weight
Tire Pyrolysis — Frequently Asked Questions
What is tire pyrolysis?
Tire pyrolysis is a thermal decomposition process that heats waste tires to 400–700°C in the absence of oxygen, breaking them down into pyrolysis oil, recovered carbon black (rCB), steel wire, and syngas — without burning.
What feedstock works best for tire pyrolysis?
TDF chips (tire-derived fuel) at 2 inches or smaller are the ideal feedstock. Uniformly sized chips feed consistently into the reactor and produce predictable, high-quality output. Eco Tire Solutions sells TDF chips to pyrolysis plants.
Is tire pyrolysis environmentally safe?
Yes. Pyrolysis occurs in a sealed, oxygen-free reactor — so there is no open combustion and minimal emissions. The process converts waste into useful products rather than releasing pollutants. Syngas can be recycled to power the reactor.
What is recovered carbon black (rCB)?
rCB is a fine black powder recovered from the pyrolysis of waste tires. It replaces virgin petroleum-derived carbon black in rubber manufacturing, inks, pigments, and coatings. Global demand for rCB is growing rapidly as industries seek sustainable alternatives.
How much oil does a tire produce through pyrolysis?
A single passenger tire yields approximately 2–3 gallons of pyrolysis oil. Oil yield is typically 40–45% of the tire's weight. The oil is similar to diesel and can be used in industrial boilers and furnaces.
Does Eco Tire Solutions operate a pyrolysis plant?
We sell TDF chips to pyrolysis plants as feedstock — we are a TDF supplier, not a pyrolysis operator. Our 2-inch or smaller TDF chips are the ideal input material for pyrolysis reactors producing rCB, oil, steel, and gas.
Need TDF Chips for Your Pyrolysis Plant?
Eco Tire Solutions sells TDF chips (2" or smaller) to pyrolysis plants as feedstock. Contact us to discuss supply volume, specs, and pricing.