Production of Low-Sulfur Fuel Distillates from Waste Tyres via Pyrolysis and Their Application in Petroleum Refining
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This study investigates the conversion of end‑of‑life tyre rubber into liquid fuel distillates and the subsequent upgrading of the products to meet key motor‑fuel quality requirements. Thermal behavior of tyre rubber was assessed by thermogravimetric analysis to justify process conditions, and pyrolysis parameters (temperature, residence time, and crumb size) were systematically evaluated to maximize distillate yield. Under the established optimum conditions (400 °C, 60 min, 0.5–6 mm), the liquid distillate yield reached up to 50%. The tyre‑derived distillate exhibited a density of ~870 kg/m³ at 20 °C and a boiling range of approximately 65–360 °C. GC–MS analysis revealed a complex mixture dominated by naphthenic and aromatic hydrocarbons with minor sulfur‑containing species (notably benzothiazole and benzo[b]thiophene derivatives). The total sulfur content of the untreated distillate was ~0.798 wt.%. A practical low‑temperature upgrading route based on sulfonation with concentrated H₂SO₄, followed by neutralization and isolation of sulfonates as salts, was developed, reducing sulfur to ~0.07 wt.% under severe treatment. Co‑processing feasibility was demonstrated by blending 5% (v/v) of the tyre‑derived distillate into an atmospheric‑distillation feed (crude oil/gas condensate mixture), which increased gasoline and gasoil fractions while decreasing the kerosene cut without deteriorating key properties. The proposed approach provides a resource‑efficient pathway for tyre‑waste valorization and supports refinery integration of upgraded tyre‑derived distillates.