Technological Complex For Automobile Tires Recycling

(Basic version)

1. General characteristics

The materials produced from scrap tires (rubber powder, viscose and metallic cord) are the products of high demand and cost, that is why tire recycling process is determined by profitability of the technology and quality of recycled products.

Presently, all over the world and in Russia there is a big selection of complexes offered for tires recycling to produce crumbled powder of various qualities, manufacturing cost, efficiency and sophistication level of production. However a careful analysis indicates that basic parameters of all known solutions, in their aggregate, are very power intensive and non- efficient with low quality and high cost of the product. In other words all tire recycling procedures with the application of traditional equipment is still unprofitable, since the key principal of the technological processes is based upon mechanical grinding of crumbs into powder, while most of the milling mechanisms require much power. Besides, they are very complicated and costly.

Hereby we offer highly efficient universal equipment of a new generation. The equipment is economical, compact, simple and reliable in operation, universal and easy-to-readjust, has a high specific output with lower power intensity. The equipment is capable of producing high quality materials and its technical parameters exceed all traditional models.  The equipment provides great potentialities for upgrading existing crushing-grinding technologies mostly for recycling sticky-plastic and elastic- sticky materials, such as fibrous, polymeric and rubber materials.

Besides, as a result of many-year investigations there were  simple and highly efficient vortex aerodynamic separators, normalizers and classifiers built to separate and classify the materials within a wide range of sizes (from granular-and-loose up to micron powders) and capabilities, including powders of sticky-elastic and sticky-plastic materials, such as soybean flour, polymeric and rubber materials.

Basing upon the scientific and technical approach, the line of profound recycling of scrap tires was built to process the tires into dispersed powder of high quality rubber with the separation of  textile and metallic cord as well as the line to produce coarsely dispersed powder (crumbs) for road construction purposes. There can be technological systems of any output and configuration built on the basis of the line.

The offered complex consumes only 300 kwt per one ton of raw materials,
its weight does not exceed 10 tons,
while the rubber powder can be milled down to less than 100 мкм.

2. Description of scrap tire recycling complex

Engineering and technological basis for scrap automobile tire recycling process is accurate and efficient implementation of all required operation: crushing, grinding, separation of reinforcing elements and classification of rubber powder to produce high quality material with minimum power consumption. In accordance with the proposed technology the scrap automobile tires are processed in the utilizer to become 3–6 мм crumbs, containing metal-cloth cord. After that the crumbs are delivered to the disc defibrator and blade dismembrator to be crushed into less than 1 мм crumbs with simultaneous separation of cord components, which in  magnet and vortex separators are separated to become an independent end product. The rubber crumbs are further ground in rotor-screening mills to become powder of predetermined size and to be separated in a vortex aerodynamic classifier.  During the recycling   the materials are transferred by pneumatic transport devices. The schematic of the complex is provided in Appendix №1.

The complex comprises two production lines.

LINE 1 (Mini–factory of initial crushing of   tires)  of 10 t/h output, including:

• Platform for collecting tires and supplying them to the Utilizer  receiving device,
• Milling-utilizer of initial crushing of automobile tires to be processed into 6 мм crumbs, of 10 t/h with 15 кВт.ч./т specific power consumption.
• Transportation system to take the crumbs away.
• System for taking away and initially processing side rings.

The line provides:

• Transportation and sizing of automobile tires
• Initial crushing of automobile tires into crumbs
• Transportation of crumbs to be stored

TECHNICAL  CHARACTERISTICS OF LINE 1 for initial crushing of automobile  tires

• Output, t/h … 10
• Nominal power, kwt … 75
• Specific power consumption, kwt.h/t .… 12
• Time per one tire crushing, sec …  10
• Particle size, mm …  6
• Pay-roll operating personnel  …  3
• Wight, t … 5,5
• Overall  dimensions, м  …  3 x 3,5 x 2

LINE 1 can be built in a mobile modification. There are no specific requirements for production facilities.

LINE 2 (Rubber powder and cord components)   1 t/hour output, including:

• Conveyer for transportation of  6 мм crumbs from a warehouse to the  disc defibrator.
• Disc defibrator to crush initial 6 мм crumbs into 1–2 мм crumbs and to separate metallic components with specific power consumption  equal to 38 kwt.h./t.
• Magnetic separator for metallic cord  detachment.
• Rotor  dismembrator for  1–2 мм crumb crushing into coarse powder with less than 1 мм particles with a complete separation of rubber from a cloth cord with 55 кВт.h./t. specific power consumption.
• Vortex aerodynamic separator for cloth cord separation with 5–10 кwt.h./.specific power consumption.
• Rotor-screening mill to produce rubber powder of  required dispersion  (less than 350 мкм)  150 кwt.h./t. specific power consumption.
• Vortex aerodynamic classifier for breaking rubber powder into fractions with 5–10 кwt.h./t. specific power consumption.
• Dust and gas cleaner.
• End product unit (collecting and loading in big bags).

The line provides:

1. Metallic cord separation
2. Crushing of big-size rubber crumbs, cloth cord   separation
3. Rubber crumbs milling
4. Scalper for rubber powder
5. Exhaust flow purification
6. End product packing

TECHNICAL CHARACTERISTICS OF  LINE 2 Rubber powder and cord components production:

• Output (by initial product),  t/h … 1
• Nominal power, кwt … 380
• Specific power consumption, кwt.h./t   … 287
• Particle size of fraction 1, мкм  …  250
• Particle size of fraction II, мкм …  350
• Pay-roll operating personnel (3 teams,  5 persons each) … 15
• Weight, t …  4,5
• Overall  dimensions, m …  5 х 2 х 2

The key advantage of the proposed solutions is high cost-effectiveness  of recycling scrap tires of various sizes into high quality products, simplicity of basic technical means providing high durability of the equipment and high output of top quality dispersed rubber powder as well as producing alloyed metals and viscose cord of great consuming characteristics.
High efficiency of the proposed power saving technology of tire recycling   is based upon engineering implementation of physical model of destruction during milling by using new generation of intensive power-saving methodologies and equipment, including recycling of sticky-plastic materials.

4. Earnings expected from selling end products.

End materials produced as a result of scrap tire recycling are in high demand at the market.
Below you will find the list of products and rough minimum prices:

5. Conclusions

1) The proposed project of tire recycling  is economically attractive  

• For investments, as a promising money allocation,  since the payback timeframe for invested 970 000 USD runs to one year from the date of reaching production capacity.
• For attributing the recycling technology to highly remunerative production methods and creating conditions for building new factories.
• For finding ecologically safe solutions to solve rubber utilization problem.

2) When implementing the project of recycling scrap tires, a wide spectrum of reserves can be used of technical, technological and purely economical character. The following compensation payments can be considered potential possibilities for future:

• Payments from enterprises – manufacturers/consumers of automobile tires as well as other enterprises and establishments interested in utilization of waste materials.
• Tax remissions — especially in the territorial part of budget and funds.
• Grants and subventions of government and intergovernment character.

3) Presently the market of recycled tires is not duly shaped. The materials produced from tires being the product of top quality and high price can be used as a substitute of rubber resin for many technological processes. That is why rubber powder producers face prospects of substantial widening of existing market as well as shaping a market niche for rubber powder and reclaim. 

3) We own technologies and equipment to produce rubber compounds reclaim as well as other highly sophisticated and top quality expensive products from powder vulcanizate  of high cost and demand.

For purchasing purposes apply to:

• Теl.(495) 797-63-60
• Fax (495) 958-09-83
• e-mail: petrov@licenz.ru