Recovered Carbon Black Processing

The Hosokawa Group has developed a complete process for the sustainable recovery of carbon black (rCB) from used tyres. By performing a number of steps after pyrolysis, the process results in dust-free granular material that can be dosed accurately. It is immediately suitable for reuse in tyre production and other rubber-based applications.

Many recyclers that handle car tyres are keen to find a way to recover carbon black from the rubber. Our integrated rCB processing line transforms this ‘black gold’ into consistent, top-quality rCB—ready for dosing, storage and downstream use—supporting circular manufacturing and reducing reliance on virgin carbon black.

Integrated Process

This process was developed through close cooperation between several companies in the Hosokawa Group – including Hosokawa Alpine, Hosokawa Micron and Hosokawa Solids Solutions – in combination with proven equipment and many years of experience. Thanks to the close coordination of all machines and process steps, recycling companies benefit from a consistently efficient complete system with only one point of contact.

rCB-finishing

After tyres are shredded and treated by pyrolysis, oils and gases are recovered for reuse, while the remaining solid fraction forms the basis for rCB finishing. To meet the strict requirements of tyre manufacturers, the particle structure of this material must be precisely modified. Hosokawa’s rCB process converts the pyrolysed material into a granular product with controlled particle size, improved flowability and minimal dust formation, making it suitable for storage, transport and downstream use.

Fine Grinding of rCB

Fine grinding is a key step in achieving the desired rCB quality. Depending on the target fineness, ash content and abrasiveness of the material, Hosokawa Alpine offers different milling technologies. Fluidised bed opposed jet mills enable ultra-fine grinding with sharp particle size distribution while facilitating the removal of residual metallic impurities. For coarser rCB grades, mechanical classifier mills provide an energy-efficient alternative with reliable performance. The choice of technology ensures an optimal balance between product quality and operating costs.