Pyrum begins large-scale production of rCB grade co-developed with Conti

Pyrum Innovations has commenced industrial-scale production of a new grade of recovered carbon black (rCB), developed in collaboration with Continental, at its tire pyrolysis facility in Dillingen, Germany. This follows modifications to the reactors at the site.

Pyrum CEO Pascal Klein discussed the development in a podcast on November 5, noting that the new rCB grade, termed 'new standard', was the result of a joint development agreement (JDA) with Continental initiated in 2022. The collaboration aimed to create a 'golden rCB', achieving a significant milestone by the end of 2024 with the development of this new material. A patent application for the new rCB has been jointly filed by the two companies.

Klein explained that Pyrum's existing basic rCB grade is used in passenger car and truck tires, albeit in limited quantities. The JDA's goal was to develop new grades for broader applications, focusing on materials that could replace larger volumes in car and truck tires. This effort has led to the creation of two new grades: 'new standard' and 'advanced', with the latter still under development.

Pyrum will continue to produce its basic rCB, which is utilized in bicycle, forklift, and construction machinery tires. To facilitate the production of the new standard grade, Pyrum modified its reactors during the summer shutdown, adjusting insulation, operating conditions, temperature profiles, and residence times.

"After the summer break, we turned it on for the first time, hoping that the new standard comes out of the reactors," Klein stated. "And lucky us, it worked." Currently, two reactors are operational: one producing the basic quality rCB and the other running with the new settings for the new standard material.

The modifications have also increased oil output and reduced energy consumption due to lower reactor temperatures and faster processing times. The new grade is softer and requires less electricity during milling.

In a separate update, Klein reported progress in resolving throughput issues at Pyrum's second milling and pelletising plant in Dillingen. After modifying the dosing system, the line's output has improved to 1,250–1,300kg/hour, occasionally reaching 1,350kg/hour, up from 750kg/hour previously. However, this is still below the contracted capacity of 1,600kg/hour.

Klein noted that while the mill and pelletiser are functioning correctly, the static dosing system remains a "bottleneck" due to differences in how rCB flows through the equipment. This issue is particularly pronounced for the 'new standard' grade, which has different flow characteristics compared to basic rCB.

"Having a static dosing system is not a solution," Klein remarked, especially as Pyrum plans to develop additional rCB grades. The company intends to replace the gravity-fed equipment with a forced dosing system using screws and agitators to better control material flow.

The equipment supplier has acknowledged the limitations of the current system and is contractually required to meet the full specified throughput. Additionally, Pyrum has received approval from regional authorities to operate the line continuously, rather than the previous 16-hour daily limit. Klein stated that the extended operating hours would help offset the remaining shortfall in hourly throughput.