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3 authors, including:
Hooshang Pakdel
Christian Roy
Pyrovac Inc.
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Abstract
Various samples of used car and truck tires were pyrolyzed in a batch mode under vacuum
and in a continuous feed reactor. The pyrolysis temperature varied in the range of
440570C. dl-limonene is a major product formed during the thermal decomposition of
rubber under reduced pressure conditions. The pyrolysis oils were distilled to obtain a
dl-limonene-rich fraction. The difficulty of obtaining a pure dl-limonene fraction is discussed.
A high pyrolysis temperature decreases the dl-limonene yield due to the cracking of the
pyrolysis oil. Several secondary organic compounds produced by cracking were identified by
gas chromatography/mass spectrometry (GC/MS) analysis. These compounds had a boiling
point similar to dl-limonene. The dl-limonene yield decreases with an increase of the
pyrolysis reactor pressure. The mechanism of the thermal degradation of tires leading to the
formation of dl-limonene is discussed. A dl-limonene-rich fraction was obtained following a
series of distillation. Sulfur-containing compounds in the dl-limonene-rich fractions were
analyzed by GC using a sulfur specific detector. Several thiophene-derivatives were identified.
Quantitative analysis of the sulfur compounds in the dl-limonene rich fractions was made.
An olfactometry test was performed on a standard thiophene sample in d- and dl-limonene
solutions to establish an approximate threshold value to detect the thiophene odor. 2001
Elsevier Science B.V. All rights reserved.
Keywords: dl-limonene; Pyrolysis; GC/MS
* Corresponding author. Tel.: + 1 418 656 7406; fax: +1 418 656 5993.
E-mail address: croy@gch.ulaval.ca (C. Roy).
0165-2370/01/$ - see front matter 2001 Elsevier Science B.V. All rights reserved.
PII: S 0 1 6 5 - 2 3 7 0 ( 0 0 ) 0 0 1 3 6 - 4
92
1. Introduction
Although used tires represent less than 1 wt.% of the industrial, commercial and
domestic wastes, they give rise to disposal problems. Disposal problems arise from
the extent to which whole tires float back to the surface and become partially filled
with water, which serves as an ideal breeding habitat for many insects. Another
problem associated with used tires is the fact that they are a major fire hazard when
dumped in large numbers. The number of tire fires is increasing and the generated
toxic compounds contaminate soil, groundwater and air. The mutagenic emission
factor of tires burning in open air has been found to be 34 orders of magnitude
greater than the values reported for the combustion of oil, coal or wood in utility
boilers [1]. Polycyclic aromatic hydrocarbons (PAHs) contribute substantially to the
indirect-acting mutagenic activity of the particulate organics emitted from the open
burning of tires while aromatic amines appear to account for much of the
direct-acting mutagenic activity [1]. Composition of PAHs emission is affected by
the conditions under which the combustion occurs [2].
Used tire vacuum pyrolysis is an attractive and clean recycling process solution
which has been the subject of several patents [3]. Vacuum pyrolysis produces useful
liquid hydrocarbons and pyrolytic carbon black. Due to the mild pyrolysis conditions used (e.g. low pyrolysis temperature and absence of a carrier gas), vacuum
pyrolysis produces no hazardous emissions. Vacuum pyrolysis, which operates at a
temperature of about 75 100C lower than atmospheric pyrolysis, produces an oil
with a different chemical composition. PAHs with potential health hazards are
formed from aliphatic hydrocarbons via DielsAlder type aromatization reactions
at high pyrolysis temperature and long residence time in the reactor. Williams and
Taylor [4] reported the formation of individual hazardous PAHs when tire oils were
subjected to secondary cracking reactions in a post-pyrolysis reactor heated to
720C. Furthermore, Cunliffe and Williams [5] reported that the PAHs content of
the pyrolysis oils obtained under a nitrogen purged static-bed batch reactor
condition increases with an increase of the pyrolysis temperature. They also
reported that the total PAHs concentration in the oils increased from 1.5 to 3.5
wt.% as the pyrolysis temperature was increased from 450 to 600C. Due to a lower
pyrolysis temperature, the PAHs content of the vacuum pyrolysis oils is expected to
be lower than atmospheric and high temperature pyrolysis.
Except for the Onahama plant in Japan [6], to our knowledge there is no other
proven large scale, continuous feed industrial tire pyrolysis system operating at
present. Common problems include feeding and handling the tire shreds inside the
reactor and finding end-use applications to the pyrolysis products [7]. Pyrolysis
process economics is greatly influenced by the quality and yield of the pyrolysis
products, especially carbon black.
Vacuum pyrolysis of used tires produces approximately 55 wt.% pyrolysis oil.
This oil typically contains 20 25 wt.% of a naphtha fraction with a boiling point
B 200C. The naphtha fraction typically contains 2025 wt.% dl-limonene. The
pyrolysis oil is also composed of unsaturated branched chain hydrocarbons and
volatile sulfur and nitrogen-containing compounds [8]. The presence in the oil
93
derived from the vacuum pyrolysis of used tires of single-ring nitrogen compounds
(PANH) such as aniline, pyridine and alkylated pyridine and alkylated quinolins
and sulfur-containing compounds (PANSH) such as benzothiasol has been reported
[8,9]. Tire pyrolysis oil has a high calorific value, typically 40 MJ kg 1, and a
sulfur content of 0.8 1.6 wt.% depending on the tire source and pyrolysis
process conditions used. Unlike crude oil, tire-derived pyrolysis oil sulfur-containing compounds are generally volatile thiophenic derivatives.
A high proportion of the volatile aromatic hydrocarbons found in pyrolysis oils,
BTX in particular, can be used as an octane booster if the pyrolysis naphtha
fraction is separated and blended with petroleum naphtha. However, the unsaturated nature of the pyrolysis oil is the main obstacle to refining and handling [10].
dl-Limonene (dipentene) is a major component of the pyrolysis oil and is derived
from the thermal decomposition of polyisoprene [11,12]. Limonene is the chief
constituent of citrus oil and is mainly obtained by expression from the fresh peel of
grapefruit, lemon, and orange. Limonene exists in three forms: d-limonene, the
most naturally abundant, l-limonene and dl-limonene, a racemic isomer. Except for
its optical activity, dl-limonene has the same physical properties as d- and llimonene. Limonene has extremely fast-growing and wide industrial applications
[11]. Furthermore, the biological activity of limonene, such as its chemopreventive
activity against rat mammary cancer, has been recently investigated [13,14]. The
market demand for limonene fluctuates considerably. Its price was about 1 US$
kg 1 during the period 1986 1988 and increased up to 9 US$ kg 1 in 19951996.
Its sale price was 10 US$ kg 1 as of November 1999.
Polyisoprene or natural rubber compose approximately 5060% of a typical
truck tire formulation [15]. Both represent an ideal source of limonene [16]. Tire
elastomers other than polyisoprene are not the main source of dl-limonene.
However, Madorsky et al. [17] examined the pyrolysis of polybutadiene rubber, and
found that butadiene, vinylcyclohexene and dipentene were formed in high concentrations. Pure polyisoprene yields oil with a wide range of hydrocarbon compounds
upon pyrolysis. Under similar conditions, regular tires yield more solid residue,
which is partially due to the presence of carbon black added during tire manufacture. It has been shown that SBR (styrene and butadiene rubber) and BR
(butadiene rubber) are non-charring rubbers and that extender oil has no effect on
the carbon residue [16]. However, extensive charring and condensation reactions
may occur during pyrolysis owing to poor heat transfer throughout the sample,
slow heating rates, and long residence times of the products in the pyrolysis reactor
[18]. The thermal decomposition of different rubbers has been studied earlier by TG
and DTG to predict the behavior of rubber mixtures and their compositions under
atmospheric nitrogen [19,20] and oxygen [21]. Conesa and co-workers indicated a
weight loss of about 65% at 500C temperature under nitrogen atmosphere [22]
while a stronger heat effect was observed under oxygen atmosphere with a weight
loss over 80% [21]. Since pyrolysis degradation mechanism largely involves intramolecular free radical reactions which take place in the rubber section of the
product, the polymeric structure and sulfur crosslinking in particular tend to
change the pyrolysis product distribution and oil yield. Pyrolysis gas chromatogra-
94
2. Experimental
2.1. Pyrolysis
A schematic diagram of the large scale pyrolysis experimental unit used in this
study (runs c H018, H036 and H045, Table 1) is illustrated in Fig. 1. The
pyrolysis unit is a semi-continuous pilot plant reactor 3-m long with a diameter of
600 mm. The reactor is equipped with two horizontal heating plates, one on top of
the other, each 350-mm wide. Commercial eutectic molten salts circulate countercurrently with the feedstock through tubes below the heating plates supporting the
bed of tire particles. The salt leaving the reactor is collected in a tank, which is
equipped with a vertical pump to circulate the molten salts through the system and
to the salt reheating unit. During the pyrolysis experiments, the temperature was
534c510570d
500a570b
546
42
500
153
21
14.4
0.8
250
25
10
13
40.9
11.7
38.4
Bed temperature.
Reactor inside wall temperature.
c
Molten salt temperature.
d
Registered from different locations of the reactor inside wall.
e
Not available.
H45
Truck
A120
Truck
Batch, 1 l
A121
Truck
Batch, 1 l
A122
Truck
Batch, 15 l
G45
Polyisoprene
23.7
3.6
53.7
7.0
39.3
230
33
480c431471d
12.0
n.a.
3.3
60
3.6
36.4
0.2
480
1.3
n.a.
3.3
43.4
3.2
53.4
0.2
440
1.3
n.a.
2.8
n.a.e
n.a.
n.a.
0.2
480
1.3
30.7
9.8
90.3
5.9
3.8
500
28
Granules B3.8 Granules B3.8 Granules B3.8 Granules B3.8 Granules B3.8 Granules B3.8 Granules 2
Product Yields
Oil
Gas
Solid residue
H036
Truck
Horizontal
Horizontal
Horizontal
Batch, 1 l
semi-continuous semi-continuous semi-continuous
pilot
pilot
pilot
H018
Truck
12
Multiple
hearth
semi-continuous
pilot
Cylindrical
form 2.7
Reactor type
Average
particle
volume
(cm3)
Total pressure
(kPa)
Temperature
(C)
Total feed (kg)
Feed rate (kg
h1)
D014
Car
Exp. c
Type
Table 1
Product yields under various pyrolysis conditions
96
97
2.2. Distillation
The pyrolysis oil fractions from experiments D014, H18, H036 and H045 were
distilled batchwise in a 300 l capacity pilot column to recover the naphtha fractions.
The distillation was performed in a 750 mm long and a 45 mm i.d. glass column
with 25 theoretical plates at a 1:30 reflux ratio and packed with a metallic material
(GodloeTR). The naphtha fractions were further distilled in a batch mode in a 5 l
capacity column to recover a concentrated dl-limonene fraction.
2.3. Solid liquid chromatography on dual silica gel and alumina column
The limonene rich fractions were fractionated to simple sub-fractions to analyze
their compositions. Details of the fractionation technique can be found elsewhere
[8].
2.4. Analysis
2.4.1. GC analysis for the sulfur containing compounds
A Hewlett Packard model 5970 GC equipped with a flame photometric detector
(FPD) was used to scan the oil fractions to detect the sulfur-containing compounds.
The analytical conditions were as follows: detector temperature 230C, air flow rate
100 ml min 1, hydrogen 75 ml min 1, nitrogen 30 ml min 1, capillary column
HP-5MS with dimensions 30 m 0.25 mm i.d. and 0.25 mm of film thickness. The
column temperature was maintained at 30C for 3 min, then the temperature was
98
raised to 90C at 5C min 1, then finally to 250C at 30C min 1. The column
temperature was maintained at the final temperature for 10 min.
99
dipentene. This depends on the reactor configuration and heat transfer limitation
inside the reactor. If the reactor temperature is too high and the vapor residence
time is too long, then the dl-limonene molecules will decompose to isoprene along
with many other compounds. The high energy mechanism then starts to predominate following a free radical pathway which will lead to the formation of pyrolysis
oil. It is very unlikely that ideal conditions will be achieved in a large scale pyrolysis
unit. It is believed that all mechanisms occur during the course of pyrolysis to some
extent. Analytical pyrolysis-GC is a suitable technique to perform a controlled
pyrolysis reaction. Groves and Roy [31] used the pyrolysis-GC/MS technique to
study the natural rubber pyrolysis mechanism. The authors indicated that if the
monomer residence time increases in the melt, the relative yield of dimer would be
greater for the thicker samples. They postulated a DielsAlder mechanism for the
formation of dl-limonene. In contrast, it is believed that dl-limonene will decompose above 450C if it is not quickly removed from the reaction zone.
The mechanism of thermal degradation of tires and tire rubber components
suggests that the major initial products of pyrolysis are isoprene and dl-limonene
and other dimers. Further reaction results in the formation of a wide variety of
compounds, such as aromatic compounds, directly by polymer chain scission or via
degradation products of isoprene and dl-limonene or partially at higher temperatures or long residence times via secondary reactions. Due to their structural
differences, natural rubber decomposes at lower temperatures than styrene and
butadiene rubbers.
Earlier results from the authors laboratories indicated that dl-limonene formation ended below 450C [12]. Napoli et al. [32] reported that dl-limonene is the
main component of sidewall rubber pyrolysis under a flow of nitrogen at 450C but
the authors provided no quantitative results. dl-limonene was formed in trace
quantities as the pyrolysis temperature was increased to 550C. Furthermore, Roy
et al. [30] reported an increase of about 3040% in the dl-limonene yield as the
pyrolysis pressure of polyisoprene was reduced from 28 kPa to 0.8 kPa. Bhowmick
et al. [33] reported that dl-limonene starts to form at a temperature of about 300C.
Earlier results of the authors indicated that the six hearth vacuum pyrolysis vertical
reactor operating at 250, 300, 350, 400, 450 and 510C yielded six fractions of oils
[12]; dl-limonene was mainly found in the oil fractions of hearths 35 corresponding to the temperature range of 350450C. At any temperature higher than
450480C, dl-limonene is believed to decompose to trimethylbenzene, m-cymene
and indane (see Tables 2 and 4). A reaction mechanism for the formation of
trimethylbenzene from the degradation of limonene has been proposed earlier
[34,35]. The A121 experiment was performed at a lower temperature than experiment A120, resulting in a decrease in oil yield. However, the overall dl-limonene
yield in the oil was not affected. As the pyrolysis pressure increased in experiment
A122, the total dl-limonene yield immediately dropped. Similar results were obtained earlier by the authors during the pyrolysis of polyisoprene [30].
Tables 2 4 show the chemical composition of three dl-limonene rich fractions.
Trimethylbenzene, m-cymene and indane are believed to arise from the thermal
decomposition of dl-limonene and other compounds and inhibit the purification of
100
Table 2
Principal compounds in the dl-limonene concentrated fraction (run D014)
Tentative Structure
2,7,7-trimethylbicyclo(2.2.1)heptane
4-methyl-1-isopropylcyclohexene
1-methyl-3-isopropylbenzene (m-cymeme)
dl-limonene
Butylbenzene
4-ethyl-1,2-dimethylbenzene
3-tert-butylthiophene
2,5-diethylthiophene
a
b
176
175176
183
169a,b
181a,b
Concentration (wt.%)
2
3
2
92
0.5
0.5
Trace
Trace
dl-limonene. Fig. 2 illustrates the gas chromatograms of the four naphtha fractions
obtained under different conditions (see Table 1). Peaks 14 in Fig. 2 were
identified as trimethylbenzene, m-cymene, dl-limonene and indane respectively. As
shown in Tables 2 4, those three compounds have a boiling point similar to that
of dl-limonene and are difficult to separate from dl-limonene by distillation without
substantial additional operating costs. The ratio of dl-limonene in D014 (Fig. 2a)
and H045 (Fig. 2b) to trimethylbenzene, m-cymene and indane is lower than that
of H018 and H036 oils (see Fig. 2c and d). Oils D014 and H045 were obtained at
lower pyrolysis temperatures than oils H018 and H035 (see Table 1). The total
dl-limonene yield also decreased in H018 and H036 pyrolysis oils compared with
D014 and H045. Thus, it can be concluded that dl-limonene undoubtedly has
degraded to form trimethylbenzene, m-cymene and indane when subjected to a
pyrolysis temperature higher than 500C.
Table 3
Principal compounds in the dl-limonene concentrated fraction (run H018)
Tentative Structure
Concentration (wt.%)
1-methyl-3-isopropylbenzene
Trimethylbenzene
dl-limonene
Indane
1-propynylbenzene
Butylbenzene
2-tert-butylthiophene (2 isomers)
2,5-diethylthiophene
2-methyl-5-propylthiophene
Others
175
175
175176
176
13
19
50
8
1
3
0.4
0.2
Trace
5.4
a
b
183
169a,b
181a,b
\181
101
Fig. 2. Gas chromatograms of the four naphtha fractions obtained under different pyrolysis conditions.
102
Table 4
Principal compounds in the dl-limonene concentrated fraction (run H036)
Tentative Structure
1-methyl-4-isopropenylcyclohexene
Trimethylbenzene
1-methyl-3-isopropylbenzene
dl-limonene
Indane
1-ethyl-3,5-dimethylbenzene
1-propenylbenzene
1-methyl-3-propylbenzene
4-ethyl-1,2-dimethylbenzene
2-tert-butylthiophene
2,5-diethylthiophene
Others
a
b
175
175
175176
176
169a,b
181a,b
Concentration (wt.%)
3
5
22
62
1
2
0.38
0.31
3
103
Dimethylethylbenzene
Trimethylbenzene
Ethyl-3,5-dimethylbenzene
104
the incomplete separation of the sulfur compounds from the hydrocarbons and
non-linearity of the detector response. Preliminary separation of the oil fractions
can significantly reduce the quenching effect for a meaningful quantitative analysis.
If the peak area (S) and sulfur concentration (C) is expressed as ln S/ln C, the
response/concentration curve becomes linear. The sulfur compounds concentration
can then be calculated from the following equation:
Csulfur =Csulfur compound N 32.06/M
where N is the number of sulfur atoms in the sulfur compound and M is the
molecular weight of the compound. ln S values of three standards, namely thiophene, dimethylthiophene and dodecanethiol, were plotted in various concentrations versus ln C by linear regression. These compounds did not give a single curve
as demonstrated by Zoccolillo et al. [38], but the following equations were derived.
Any of the following equations could be used to calculate the sulfur content in the
dl-limonene enriched fraction.
Y=2.0738x +1.5170, R 2 =0.9977
for thiophene
for 2,5-dimethylthiophene
for dodecanethiol
105
4. Conclusion
The maximum yield of dl-limonene (3.6 wt.%) was obtained from truck tires in
a pilot plant pyrolysis reactor.
dl-Limonene is formed by the dimerization of isoprene units following a low
energy reaction mechanism. Intramolecular cyclization to form dl-limonene is
also possible.
A pyrolysis temperature higher than 500C tends to crack the limonene
molecules to trimethylbenzene, m-cymene and indane which have boiling points
similar to dl-limonene.
The dl-limonene yield increases as the pyrolysis pressure decreases.
Any heat and mass transfer limitations during the pyrolysis hamper dl-limonene
formation and favor a secondary degradation of the pyrolysis products.
Dimethylthiophene, diethylthiophene and tert-butylthiophene found at a concentration of about 228 ppm are the major source for the unpleasant odor in the
dl-limonene rich fraction.
The quantitative determination of the total sulfur content of a dl-limonene rich
fraction with GC/FPD can be made using thiophene, dimethylthiophene or
dodecanthiol as the external standards.
106
The sub-fractionation of the oil samples eliminated the quenching effect for
reliable GC/FPD analysis.
A proven and economical method to deodorize dl-limonene-enriched fractions is
needed.
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