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Striving to become the UK’s premier green oil producer

Since 2018, the Carlton Forest Group has invested over £5m in research and development to treat end-of-life-tyres (ELTs) and develop a unique modular pyrolysis plant which converts ELTs into green oil and carbon char. The group secured a UK patent on its globally unique designs in December 2020 and has PCT Patent Pending status globally. Following on from this, the group commenced manufacture of a full commercial scale plant in March 2021 – operations will start in December 2021 in Worksop, UK.
 
Each module recovers 4,000,000 litres of oil and 2,500 tonnes of carbon char from approximately 1,800,000 million tyres / 12,000 tonnes – modules can be linked together, providing a truly scalable solution to handle any amount of ELT. The patented process not only removes ELT from disposal streams but also prevents the need for virgin sources of oil and char to be pulled from the ground. Each module saves over 5,700 tonnes of CO2 per year, showcasing the benefits of zero-to-landfill and making the Carlton Forest Group a substantial decarbonisation partner towards helping the UK meet COP26 goals. 
 
The oil has a relatively low sulphur level (c.0.8%) and can be directly blended with marine fuel specifications RMG380/3.5% and RMG180/1.5%. The carbon char provides a green alternate to coal and coke (low moisture level <1.5%). Both the oil and char can be further refined to increase the number of applications.
 
The group’s strategy will see deployment of over 25 modules in the UK to achieve our target of producing 100,000,000 litres of green oil, 62,500 tonnes of green carbon char per year.

 
 

How our technology works

The word is derived from the Greek pyro "fire" and lysis "separating".


Pyrolysis is the thermal decomposition of materials – taking something and turning it into its base components. In the case of tyres, pyrolysis generates carbon char, oil and a gas. The gas that is released is used to fuel the reaction, and excess heat is used in a steam generator to produce electricity – the plant operates as an island. The oil and char that are produced can go on to be used in hundreds of applications – just the same as virgin sources.


A significant portion of our design efforts were invested in ensuring that the plant meets all UKCA/CE marking requirements and abides by all UK Environment Agency legislation. The plant is approved under HAZOPS, DSEAR and ATEX safety requirements. All of this adds up to make Carlton Forest Renewables pyrolysis modules the only fully permitted kit in the UK market.


The plant is designed to be operated continuously 24x7, with downtime scheduled every 3 months for preventative maintenance purposes only - giving circa 7,600 operational hours per year. The plant is fully automated and controlled by a PLC/SCADA – meaning safety is built in and operational efficiency can be delivered with minimal intervention from people.

 

P1.1 Tyre crumb feed

Crumb spec: 8 - 15mm tyre crumb @ 99% steel free, 85% fibre free.

P1.2 Rotating Kiln x2

Operating temp 450 - 500°C. Throughput 500kg per hour per kiln.

P1.3 Carbon Char Storage

Operating temp 20°C. 2 x 500kg bag station, Discharge temp 20°C@350kg/h.

P1.4 Condensing Array

X4 Water cooled condensers in series 7.3m high. Discharge oil at 30°C.

P1.5 Thermal oxidiser

6m long. 25m diameter. Refractory lined. Operating 850°C and 2 second residence time.

P1.6 Exhaust Gas Scrubbers

Ceramic type dry scrubber using sodium carbonate and powdered AC. (Ceramic)

P1.7 Cooling Tower 

Wet - type cooling tower.

P1.8 Exhaust Stack

150mm Diameter. Height dependent on air dispersion modelling on each site. Output temp 110°C.

P1.9 Interim Oil Tank

1Capacity 1000ltr. Temperature 30°C at discharge into tank prefiltering.

 
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