Pyrolyzed rubber products and processes

A pyrolysis system, comprising:

• a pyrolysis thermal processor holding at least one porous container having a waste under a sealed, substantially anaerobic atmosphere, the at least one porous container removable from the pyrolysis thermal processor, the pyrolysis thermal processor having an internal baffling;
• a heater in communication with the thermal processor to heat at least one anaerobic gas stream to a temperature sufficient to pyrolyze the waste and produce a carbonaceous char;
• at least one variable speed fan in communication with the thermal processor, wherein the variable speed fan and the internal baffling regulate a circulation rate of the at least one anaerobic gas stream in the pyrolysis thermal processor;
• a condenser in communication with the pyrolysis thermal processor to collect an oil product from the at least one anaerobic gas stream circulated through the pyrolysis thermal processor, wherein the condenser has a substantially open internal pathway formed by a plurality of side-to-side plates disposed in a condensation tower, each of the side-to-side plates having a downward sloping angle with reference to a plane perpendicular to the condensation tower, wherein the condenser provides intimate contact between the at least one anaerobic gas stream coming from a bottom of the condenser and a cooling oil coming from a top of the condenser, thereby cooling the at least one anaerobic gas stream and heating the cooling oil, wherein condensable components in the at least one anaerobic gas stream are thus transferred into the cooling oil and recovered at the bottom of the condenser, and
• a sludge handling system in communication with the bottom of the condenser and receiving the oil product separated from the anaerobic gas stream, the sludge handling system including a sludge settling vessel that facilitates a separation of an immiscible sludge from the oil product, the sludge settling vessel in communication with an oil recovery pump and a sludge recovery pump, the oil recovery pump configured to remove the separated oil product from the sludge settling vessel and the sludge recovery pump configured to remove the immiscible sludge from the sludge recovery vessel.

A pyrolysis system, comprising:

• a pyrolysis thermal processor holding at least one porous container having a waste under a sealed, substantially anaerobic atmosphere, the at least one porous container removable from the pyrolysis thermal processor, the pyrolysis thermal processor having an internal baffling;
• a heater in communication with the thermal processor to heat at least one anaerobic gas stream to a temperature sufficient to pyrolyze the waste and produce a carbonaceous char;
• at least one variable speed fan in communication with the thermal processor, wherein the variable speed fan and the internal baffling regulate a circulation rate of the at least one anaerobic gas stream in the pyrolysis thermal processor;
• a gas compressor in communication with a stream of a product gas from the thermal processor the gas compressor configured to compress the stream of the product gas;
• a bank of process gas storage tanks in communication with the gas compressor, the process gas storage tanks configured to be filled in alternating fashion with the stream of the product gas from the thermal processor and thereby militate against non-uniform pulses of pas flow and gas concentration from the bank of process gas storage tanks;
• a hydrotreater catalyst bed in fluid communication with the bank of process gas storage tanks and receiving a substantially uniform stream of the product gas from the bank of process gas storage tanks, the hydrotreater catalyst bed adapted to hydrogenate at least a portion of the product gas;
• and
• a hydrogen sulfide oxidation system in fluid communication with the hydrotreater catalyst bed and adapted to receive hydrogen sulfide therefrom to produce elemental sulfur, wherein the hydrogen sulfide oxidation system is a wet scrubbing, liquid redox system.