Impacts of Incomplete Slag Discharge on Tire Pyrolysis Furnaces

Impacts of Incomplete Slag Discharge on Tire Pyrolysis Furnaces

Residual slag causes long-term damage to pyrolysis furnaces across four key areas: equipment lifespan, production efficiency, safety risks, and product quality, as detailed below:

I. Damages Equipment Structure and Shortens Service Life

Furnace Wall Corrosion and Reduced Thermal Efficiency

Acidic substances (e.g., hydrogen chloride) in residual slag continuously corrode furnace walls, accelerating the aging and cracking of refractory materials and metal linings. Slag adhering to walls also forms an insulating layer, causing uneven temperature distribution, reduced heat transfer efficiency, and increased fuel consumption.

Equipment Deformation and Blockage

Repeated carbonization and hardening of slag at high temperatures can block the furnace bottom, pipelines, and slag outlets. This may also cause localized stress concentration, leading to deformation or cracking of the furnace shell, which often requires costly shutdowns for major repairs.

II. Reduces Production Efficiency and Increases Operational Costs

Reduced Effective Volume

Residual slag occupies internal furnace space, lowering the single-batch loading capacity and forcing longer pyrolysis cycles, which directly reduces daily production output.

Higher Energy Consumption and Maintenance Costs

More fuel is required to maintain pyrolysis temperatures. Frequent slag cleaning increases labor and equipment maintenance costs, while frequent shutdowns for repairs further reduce production capacity.

III. Triggers Safety Hazards and Increases Accident Risks

Local Overheating and Deflagration

Accumulated slag is prone to local overheating, causing secondary pyrolysis of heavy oil, which generates large volumes of gas and leads to sudden pressure spikes or even deflagration.

Toxic Gas Accumulation

Slow decomposition of residual slag at high temperatures releases toxic gases such as carbon monoxide and sulfides, posing a poisoning risk to personnel. Gas accumulation may also form explosive mixtures.

IV. Impairs Product Quality and Reduces Economic Returns

Higher Impurity Content in Oil Products

Carbon black and metal impurities from residual slag enter the condensation system with pyrolysis gas, contaminating fuel oil. This results in darker color, excessive impurities, lower product grades, and reduced selling prices.

Degraded Carbon Black Quality

Residual slag mixing with newly produced carbon black causes uneven particle size and higher ash content, reducing its application value in rubber, plastics, and other industries.