Breaking the 80% Failure Rate: How Smart RCB Integration Transforms Tire Pyrolysis Economics

A presentation by Suhas Dixit (CEO, APChemi) at Recovered Carbon Black Asia Conference at Bangkok 4-5th Sep 2025:

The Problem with Ultra-Pure RCB Obsession

For years, the Recovered Carbon Black Technology sector has chased unattainable <1% ash purity levels, leading to excessive costs and project failures. This pursuit ignores a fundamental truth: RCB isn't a direct replacement for virgin carbon black—it's a new engineered material requiring fit-for-purpose specifications.

Our tire pyrolysis research demonstrates that targeting 8-15% ash content instead of ultra-pure grades slashes processing costs by 40-60% while maintaining commercial viability.

Smart Purification: The Missing Link in RCB Equipment

Traditional Recovered Carbon Black Equipment focuses solely on purity, missing critical revenue opportunities. Our smart purification process recovers $150-250K worth of zinc per 10,000 tons of feedstock while upgrading tire pyrolysis carbon black to market-ready specifications.

The process yields three distinct grades:

- Premium RCB: <7% ash for high-performance applications

- Standard RCB: 8-12% ash for broader market adoption

- Raw RCB: 18-20% ash for specific industrial uses

Real Carbon Footprint: 45-55% Reduction

Market claims of 80-90% carbon reduction often ignore crucial post-processing energy inputs. Our lifecycle analysis reveals the actual reduction: 45-55% compared to virgin carbon black, with energy consumption at 9 kWh/kg versus 15 kWh/kg for virgin production.

The Path Forward: Phased Integration

Success in Recovered Carbon Black Technology requires a pragmatic three-phase approach:

1. Phase 1 (Current): 5-10% RCB integration for market validation

2. Phase 2 (1-2 years): 15-20% integration at commercial scale

3. Phase 3 (3-5 years): 25-30% integration as industry standard

This strategy, proven across our ISCC Plus certified facilities, transforms tire pyrolysis from a waste management solution into a profitable circular economy model.

Tyre Pyrolysis Oil to Virgin-Like Recycled Carbon Black

While the industry traditionally relies on aromatic oils from coal tar like anthracene oil and various coal tar distillates, our fractional distillation technology produces tire pyrolysis oil with BMCI ratings of 77-84, achieving flash points from 130-182°C—specifications that rival conventional carbon black feedstock (CBFS). This approach transforms tire pyrolysis oil into a genuine substitute to petroleum CBFS (Carbon Black Feedstock). For more information, visit: https://www.apchemi.com/pyrolysis-oil

Conclusion

The future of RCB isn't about achieving impossible purity standards—it's about creating fit-for-purpose products that meet real market needs. By focusing on smart purification, zinc recovery, and realistic carbon footprint metrics, the industry can finally deliver on its promise of sustainable tire recycling.

Ready to transform your tire recycling operations? Contact APChemi for validated Recovered Carbon Black Equipment and proven tire pyrolysis solutions.

Tags: Tire Pyrolysis, Recovered Carbon Black, RCB Technology, Carbon Black Feedstock, Sustainable Manufacturing

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rCB CASE STUDIES:

North American Implementations Demonstrate Commercial Viability

Three major North American producers have established industrial-scale operations that produce specification-grade rCB.

Delta Energy Group's Natchez, Mississippi facility stands as the continent's most mature operation. It processes 100 tons of scrap tires daily, yielding 11,000 tons of rCB annually. Their Phoenix Black® and Zephyr Black® products have achieved remarkable commercial success through a partnership with Bridgestone. By 2020, they had supplied 6,800 metric tons, demonstrating an 81% CO₂ reduction compared to virgin carbon black production.

Klean Industries, headquartered in Vancouver, represents the most ambitious North American expansion. They plan facilities with a total tire processing capacity of 225,000 metric tonnes. Their CBk KleanCarbon product line includes grades specifically designed to replace N300, N600, and N700 series virgin carbon blacks. As active voting members of ASTM Committee D36, Klean's leadership has directly contributed to developing the D8474 standard for thermogravimetric analysis of rCB.

The Terre Haute, Indiana facility, originally operated by Pyrolyx and now owned by Bolder Industries following a $55 million investment, showcases the industry's evolution. This facility's four-reactor configuration targets 10,000 metric tons of rCB production annually. The products are refined into semi-reinforcing grades, including N500, N600, and N700. Their jet mill processing achieves particle sizes below 10 μm, enabling an average 30% replacement rate in virgin carbon black applications.

European Producers Lead in Quality Specifications and Partnerships

European companies have achieved the most detailed quality specifications and the strongest partnerships with tire manufacturers. Black Bear Carbon's Nederweert facility in the Netherlands produces 12,000 tons annually of rCB, boasting exceptional quality metrics: greater than 94% carbon content and less than 5 ppm PAH content. This makes it suitable even for food contact applications. Their proprietary post-treatment upgrading technology achieves performance grades equivalent to N300-N600 series, with particle sizes ranging from 7-36 μm in ground form.

Scandinavian Enviro Systems has leveraged its strategic partnership with Michelin to establish commercial credibility. Their Åsensbruk plant, operational since 2019, achieved the world's first ISCC certification for rCB, demonstrating a 93% CO₂ reduction compared to virgin carbon black production. The company's joint venture with Antin Infrastructure Partners aims for 1 million tons of end-of-life tire processing capacity by 2030, with five European facilities planned.

Pyrum Innovations in Germany has gained remarkable commercial traction since starting operations in May 2020. Their Dillingen facility has processed over 7,000 tons of end-of-life tires, with plans to expand to a 20,000 tons annual capacity. Key partnerships include Continental AG for long-term rCB supply and BASF SE as both a 7.9% shareholder and pyrolysis oil customer. Pyrum holds the distinction of achieving the first REACH registration in the tire recycling sector in 2018.

The Circtec-Birla Carbon partnership represents the largest planned European capacity. Their Delfzijl, Netherlands facility targets 200,000 tons of tire processing annually. By partnering with Birla Carbon, the world's largest carbon black producer, Circtec gains access to technical expertise for producing their Continua™ Sustainable Carbonaceous Materials that meet ASTM specifications.

Asia-Pacific Operations Scale Rapidly with Technical Innovation

Asian producers are demonstrating significant scale and technical capabilities. Enrestec's Taiwan facility processes 36,000 tons annually with a remarkable 99% conversion rate using patented continuous pyrolysis technology. As the first commercial chemical plant in Asia certified with ISCC Plus, Enrestec has expanded to Thailand with a 100,000-ton capacity facility, producing rCB that meets stringent standards for plastics and industrial rubber products.

Epsilon Carbon in India operates 115,000 metric tons of virgin carbon black capacity and recently entered the tire-derived rCB market. Their January 2025 launch of Terrablack is a sustainable product line that uses recovered carbon black and tire-derived oil. After 24 months of development, Epsilon Carbon is constructing a fully integrated tire recycling facility in Karnataka. This facility will be operational by FY26, processing 30,000 tons of end-of-life tires annually to produce 9,500 tons of rCB and 12,000 tons of TDO. Their commitment to reducing global warming potential by 40-50% aligns with India's extended producer responsibility standards.

Multiple Korean producers, including OCI Company Ltd., operate facilities with combined capacities exceeding 420,000 metric tons annually. However, specific rCB production volumes require further differentiation from virgin carbon black operations.

Process Parameters and Purification Methods Achieve Specifications

Industrial implementations utilize various reactor configurations and process parameters to meet ASTM D8474 specifications. Continuous rotary kiln systems operate at controlled pyrolysis temperatures, with residence times optimized for carbon black recovery. Higher heating rates shift production toward oil yield, while controlled temperature profiles maximize fixed carbon content in the rCB product.

Critical purification innovations enable the achievement of N300-N600 specifications. RCB Nanotechnologies' wet chemical treatment achieves 96% carbon content with sub-10 micron particle sizes, matching virgin carbon black quality. Acid-base demineralization using HCl treatment reduces ash content from 15% to 4.9%, qualifying products for N550 substitution. Advanced microwave-assisted processing with HCl/HF dual reagents achieves 92.10 m²/g surface area, qualifying for N326 replacement applications.

Commercial Validation Through Tire Manufacturer Adoption

Major tire manufacturers have validated rCB quality through commercial implementation. Continental began using rCB in SC20+ solid tires in 2023, achieving 60% renewable/recycled content. Bridgestone's multi-plant usage across Des Moines Agriculture, Aiken County Passenger, and Cuernavaca facilities demonstrates broad applicability.

Michelin achieved 63% sustainable materials in Le Mans 2023 racing tires and maintains a 20% stake in Enviro Systems.

Schwalbe's bicycle tire success represents the most complete implementation, with 70% of their product range now using Pyrum rCB. This closed-loop system recycled 940,000 bicycle tires while achieving an 80% CO₂ reduction compared to virgin carbon black.

Published Documentation Confirms Technical Achievements

Technical validation appears in numerous peer-reviewed publications and industry reports. A 2025 paper by Bogdahn et al. in Advanced Materials & Sustainable Manufacturing confirms rCB properties comparable to N500 and N600 series using ASTM D8474-23 thermogravimetric analysis. Industry reports from Smithers (2023-2024) indicate that 65% of tire makers cite rCB as the "best material to achieve sustainability goals." Typical passenger tire rCB performs close to N700 specifications, and partial replacement is possible for N300-N600 grades.

Conference presentations at the International Rubber Conference series, Recovered Carbon Black Asia Conference, and Tire Technology Expo demonstrate ongoing technical advancement and commercial implementation strategies.

Market Transformation Accelerates Toward 2030

The global rCB market has grown from $259.3 million in 2024 to a projected $890.6 million in 2025. This represents a compound annual growth rate of 35.12%. Current global production of approximately 20,000 tons annually is expected to expand to over 250,000 tons by 2030 based on announced capacity additions. While current market penetration remains below 1% of global carbon black usage, long-term supply agreements and tire manufacturer sustainability commitments are driving rapid adoption.

Bottom Line

The recovered carbon black industry has successfully demonstrated commercial production that meets ASTM D8474 specifications for N300-N600 grades through multiple industrial implementations. Advanced purification technologies, strategic partnerships between rCB producers and established carbon black manufacturers, and validation through tire manufacturer adoption confirm that specification-grade rCB represents a commercially viable sustainable alternative to virgin carbon black. The transition from pilot programs to industrial-scale production marks a fundamental shift in tire manufacturing sustainability.

Ready to transform your tire recycling operations? Contact APChemi for validated Recycled Carbon Black Equipment and proven tire pyrolysis solutions.