Consecutive recovery of recovered carbon black and limonene from waste tyres by thermal pyrolysis in a rotary kiln

End of life tyres are one of the most abundant and least recycled waste streams. Material recovery processes that accommodate for the complexity and heterogeneity of waste tyres, such as pyrolysis, require urgent development. Examples of recycled tyre pyrolysis products include recovered carbon black (RCb), a recycled filler, and limonene, a solvent, although investigations reporting the recovery of both are limited. In this study the pyrolysis of waste tyres was investigated in a batch rotary kiln under varying conditions (temperature, gas flow, sample mass). Characterisation analysis was then applied to selected samples of RCb (BET surface area, transmissibility of toluene extract, proximate analysis) and tyre pyrolysis oil (yield, limonene content, FTIR). The best RCb (77.7 m2/g, 0.2% volatile matter, 17.0% ash, 94.8% transmissibility of toluene extract) was produced at 550 °C with a high ratio of purge gas flow (2000 mL/min) to rubber sample mass pyrolysed (100 g), minimising the recondensation of tarry volatiles on the RCb. The highest oil and limonene yield (38.4% and 17.4 g/kg waste tyres respectively) was produced at a temperature of 550 °C with a low ratio of purge gas (400 mL/min) to rubber sample pyrolysed (200 g), as these conditions prevented the decomposition of limonene to less valuable products and improved the oil trap condensation efficiency. These findings demonstrate the importance of pyrolysis processing conditions when considering the consecutive production of RCb and solvents from waste tyre pyrolysis, which shows significant future potential to valorise waste tyres, incentivising recycling