12/28/2016 5TypesOfTireRecycling::RecycleRubberTireProcess

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5TypesOfTireRecycling

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Shreddingandgrindingtires:
Byshredding,thevolumeofscraptirescanbereducedtoabout,thusreducingspacerequirementandshippingcosts.Tireshreddingcanbe
consideredamaturetechnologynowinNorthAmerica.

Products:RubberCrumb(sellableproductservesasrawmaterialtomanymanyindustries)
Finersyntheticandnaturalrubber(obviouslyaftertreatments)whichcanbeusedinTilesandtileadhesives,mixingwithasphalt,sports
surfaces,carpetunderlay,noiseandvibrationinsulation,playgroundsandmatting.Rubbercrumbisalsousedinnewtyres,devulcanisationfor
lowtechpressedorextrudedrubberproducts,commercialflooring,trafficcontrolproductsandplentymore.

AmbientScrapTireprocessing
Theprocessiscalledambient,becauseallsizereductionstepstakeplaceatornearambienttemperatures,i.e.nocoolingisappliedtomake
therubberbrittle.

Thetiresarefirstprocessedintochipsof2(50mm)insizeinapreliminaryshredder(A).Thetirechipsthenenteragranulator(B).Inthis
processingstepthechipsarereducedtoasizeofsmallerthan3/8(10mm),whileliberatingmostofthesteelandfiberfromtherubber
granules.Afterexitingthegranulator,steelisremovedmagneticallyandthefiberfractionisremovedbyacombinationofshakingscreensand
windsifters(C).
Whilethereissomedemandfor3/8rubbergranules,mostapplicationscallforfinermeshmaterial,mostlyintherangeof10to30mesh.For
thisreason,mostambientgrindingplantshaveanumberofconsecutivegrindingsteps(D).Themachinesmostcommonlyusedforfine
grindinginambientplantsare:
Secondarygranulators
Highspeedrotarymills
Extrudersorscrewpresses
Crackermills
Ambientgrindingcanbeoperatedsafelyandeconomicallyifthebulkoftherubberoutputneedstoberelativelycoarsematerial,i.e.,downto
approximately20meshmaterial.
Products:RubberCrumbofdifferentsizes.Itsafurtherrefinedprocessandthiscrumbismorevaluableanduseful.

Cryogeniccrushing
wholetiresortirechipsarecooleddowntoatemperatureofbelow80C(112F).Belowthisglasstransitiontemperature,rubberbecomes
nearlyasbrittleandglassandsizereductioncanbeaccomplishedbycrushingandbreaking.

Thistypeofsizereductionrequireslessenergyandfewerpiecesofmachinerywhencomparedtoambientsizereduction.

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Anotheradvantageofthecryogenicprocessisthatsteelandfiberliberation,ismucheasier,leadingtoacleanerendproduct.Thedrawback,of
course,isthecostforliquidnitrogen(LN2).

Products:Rubbercrumb.Itsonlyeconomicalifclean,finemeshrubberpowderisrequired.

SRC:http://www.entireengineering.de/str/en.html
Pyrolysis
Thepyrolysisprocessisthethermaldegradationofwasteintheabsenceofoxygenatelevatedtemperaturesandpressures.Theprocessis
carriedoutattemperaturestypicallyupwardsof430C.Inpractice,itisnotpossibletoachieveacompletelyoxygenfreeenviromentandsoa
smallamountofoxidationoccurs.Theproductsofpyrolysis(fromorganicwaste)aregases,smallquantitiesofliquid,andasolidresidue
containingcarbonandash.Thegasesproducedintheprocesscanthenbeusedtoprovidetheheatingenergyforcontinuingtheprocess.
Thetyrepyrolysisprocessessentiallyreturnsthehighheatingvalueoftherubberandoilsthatwereinitiallyusedinthemanufactureofthe
tyres.Bycarefullycontrollingthetemperature,pressureandoxygenlevelmorepyrolysisoilandcharcoalisencouraged.Thispyrolysisoilcan
thenbeusedasareplacementdieselfuel.
Sincethetyresusedinthepyrolysisprocesswereoriginallyproducedfromrubbersandoilsextractedfromfossiloilthenthisfuelcannotbe
describedasrenewablenorcanitprovidesavingoncarbonemissionsorothergreenhousegases.Itdoeshoweverprovideanalternativeto
landfillingaswellasprovidingotherusefullproductssuchasrawtyrepyrolysiscarbon,commonlyknownascarbonblackwhichcanbe
combustedorusedasafiller.
Products:
PyrolysisolfCanbeusedabiodiseal
CarbonBlackCanbeusedinindustriesortogenerateelectricity.
CanbeusedasanalternativetoLandFilling(whichisbannedinUKnow)

Molectraprocess:
http://www.abc.net.au/newinventors/txt/s1300273.htm#otherinfo2
Howdoesitwork?
TheMolectraprocessintegratesmechanical,chemicalandmicrowavetreatmentstocleanlyandefficientlybreakthetyredownintoitsbase
materialsoil,carbon,rubbergranules,steelandplasticfibres,whichcanthenbemadeintovaluableproductsandresources.

TheProcess:

1.Thefirststepoftheprocessmechanicallyremovesthetwosteelbeadwiresintactfromtherimofthetyre.Thishighqualitywirecanbecut

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12/28/2016 5TypesOfTireRecycling::RecycleRubberTireProcess

intosmallpelletssuitableforsandblastingshots.Thetyresareslicedinto412segmentsdependingontyrediameter,eliminatingtheneedfor
energyintensiveshreddingequipment.

2.Nextthetyresegmentsarechemicallytreatedfor4hoursinablendofsofteningagentsincludingtheoilthatisextractedfromthetyresinthe
laststageoftheprocess.Thisdramaticallysoftenstherubbercomponentofthetyresegments.Anotherimportantbenefitofthischemical
treatmentisthatitcleanstherubberparticlesbyremovingdirtandothercontaminantspriortoremovingtheoil.Thisstepactuallyfacilitatesthe
separationofthecomponentsunlikeothermethods,whichmagnetisetherubbermakingitdifficulttoseparateitfromthemetalandfibreswhich
holdittogether.

3.Thereinforcingsteelwiresandfibrecordsembeddedinthetyresegmentsarethenmechanicallyseparatedfromtherubberandfromeach
other,usingaseriesofpurposedesignedrollers.Sincethesteelandfibrearen'tactuallycutlikeintraditionalshreddingtechniques,theyremain
inlongpiecesandareeasilyseparated.

4.Thesoftenedrubber,whichhasbeenpartiallygranulatedintheseparationprocess,isthenfurthergranulatedintovariousmeshsizesranging
fromthesizeofapeppercorndowntoaveryfinepowder.

5.Atthispoint,achoiceismadetoeitherheatthesoftenedrubberonlowheattoextractthesofteningchemicals,andproducea100%pure
rubber,ortoheatthesoftenedrubberathighheattoproducecarbonandoil.TheheatingoccursintheMolectraVac,anindustrialvacuum
microwave.

Onlowheat,thisprocesscanrecover7.6kgofpurecrumbrubberfromatyreweighing10kilogramsthatcanbeusedtomanufacturearangeof
rubberproducts(seeefutherdetails).

Alternatively,thecrumbrubberismicrowavedfor20minsto1300degreesCelsiustoproduce3.9litresofoil,and3.8kgofcarbonpertyre.

Thiscarboncanbeeitheractivatedcarbon,commonlyusedforpurifyingindustrialwater,orcarbonblack,whichhasahugenumberofindustrial
applications,includingbeingusedtogenerateelectricity.

TheMolectraprocesscanrecycleanysizeandtypeofrubbertyre.
Furtherinformation
Relevancy:Annuallythereareanestimated1.2billionoldtyresthatarediscardedaroundtheworld,continuallyaddingtothegrowingstockpiles.
Australiacontributesaround18milliontothisnumbereachyear.TheUnitedStatesgeneratesbyfarthemostastaggering270millionevery
year.Someexpertsestimatethattherearecloseto3billionwastetyresstockpiledthroughouttheUnitedStatesalone.

Products:

Molectrausestyrestoproducethefollowingrubberbasedproductsforresidentialandcommercialapplications:

RubberMatting,SiliconeTiles,RebondedPavers,RebondedBlock,RebondedPipe,SoilAerator,andHyrdoChips.

OtherproductsandusesderivedfromMolectra'sTyreRecycling:

CrumbRubber,Steel,Fibre,RawOil,Carbon,HeavyHydrocarbons,LightHydrocarbons,Limonene,CarbonBlack,ActivatedCarbon,Casting
Carbon,FurnaceOil,Dieseladditive,Automativelube,Electricity,andGasOil.
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