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The technical and economic proposal
Advanced technology and plant for recycling wastes of tires production and worn tires
Experts of Scientific-Engineering Center (Ma’alot, Israel) and RRR-company (Moscow, Russia) have developed technology, plant and series special machines for recycling waste tire of vehicles, wastes of tires production and other rubber waste products. The technology and technological scheme of manufacture are protected by patents of the Israel, Lithuanian Republic and USA.
Recycling of worn tires, wastes of tires production and other of rubber products manufacture can be done: using of the ozone-containing gas (ozone technology), with the use of cryogenic technology (cryogenic technology) and combined method (processing gas containing ozone - the first process step and cryogenic treatment - the second process step).
Ozone-containing gas falling onto the surface of the waste (lump) or rubber tires into rubber reacts with an oxidation reaction that leads to destruction of the hydrocarbon bonds. Ozone acts as a knife which cuts the wrapper or the tire pieces to chips of waste and crumb.
In cryogenic processing the rubber is frozen, for example, of liquid nitrogen to a temperature embrittlement rubber. Frozen lumpy waste rubber or chopped pieces of comminuted tires in a known manner, for example, in a roller crusher.
The combined method is most appropriate to use in the processing of waste tires. In the first step the shell tires partially destroy of ozone and then the remains of the rubber on the tire frozen to a temperature embrittlement. Separation of the frozen rubber from the cord is carried out in a special machine equipped with a camera freezing.
Reprocessing the wastes of tires production or other rubber products production expedient and economically it is profitable using the ozone technology. For restoration the properties of rubber the rubber crumb of expose are de-vulcanization to updating. After de-vulcanization, the rubber crumb can be used for manufacture of general mechanical rubber goods, rubber products for various purposes, for example, the goods of household use, the building industry.
Economically feasible plant productivity (plant, factory) is 300 kg/h to 800 kg/h.
1. The basic distinctive features of the advanced technology and the plant
1.1. Recycling waste tires:
1.1.1 The tire intact is compressed or is stretched by a mechanical pressure and then a rubber covering tire partially is destructed by means of ozone-containing gas (combined method);
1.1.3 In lunging after the destruction of the ozone shell rubber tires are the remains of which are frozen to temperature embrittlement in the chamber intensive cooling;
1.1.4 Separation of rubber cord is carried out at the temperature of minus 75 - 85°C and atmospheric pressure;
1.1.5 The intact tire is compressed or stretched by mechanical stress and completely destroy the rubber covering tire ozone-containing gas. The resulting rubber crumb and chips are separated from the cord (ozone technology);
Recycling the wastes of tire
production and other rubber waste products:
1.2.2. The destruction of lumpy waste is performed at ambient temperature and at atmospheric pressure;
1.2.3. Destruction of lumpy waste produced in the apparatus batch-type or continuously;
1.3. Ozone technology and install environmentally friendly and safe. The exhaust ozone is removed in the destructor ozone, where he was again converted into oxygen;
1.4. De-vulcanization of crumb rubber and chips (pieces of tire tread portion) produce thermo-mechanical without additional grinding.
2. The basic advantages of technology and plant:
2.1. The main advantages of advanced technologies and equipment are specialized machines and equipment, as well as the flow charts of specific industries and plants for the processing of waste tires and other rubber waste;
2.2. Special machines and apparatuses of advantages technologies:
- The apparatus for destruction of a tire rubber cover contained by means of the ozone gas and the separation system of a rubber crumb and chips;
- The apparatus for rubber intensive freezing;
- The machine for indecomposable tire freezing and separation of a frozen rubber from a cord,
- The plant for de-vulcanization of a rubber crumb and chips;
2.3. Apparatus for the continuous recycling of tire production and other waste rubber products;
2.4. According to the known data in the advanced technology of electric energy consumption per ton of recycled tires (waste) is 220 - 250 kWh (maximum) with the de-vulcanization process resulting crumb rubber and chips.
For comparison, for example, cryogenic processing flow of electricity is 560 - 680 kWh (minimum). In mechanical tire recycling energy consumption is more than 940 -1100 kWh per ton of processed tires;
2.5. The process de-vulcanization of a rubber crumb and chips generates a rubber composition which completely corresponds to initial structure of a tire before processing;
2.6. The technology and plant generate a clean rubber crumb without synthetic fibers and steel wires;
2.7. The number of technological operations processing less than with other species, thus reducing the production area and the number of attendants in 1.5 - 2.0 times;
2.8. Processes of a shredding and a milling, operations of sorting and crumb clearing have not in the technology.
3. Use fields:
3.1. The advanced technology and the equipment are used for newly created enterprises or partially replace existing technological lines;
3.2. The technology and equipment can be applied an the tire industry enterprises or an the factories rubber products for reprocessing of the reject and waste;
3.3. The technology and the equipment can be used at the enterprises of the construction industry. The rubber crumb, steel and synthetic cord is used at road-building, of ferroconcrete production, in construction and insulation materials;
3.4. The advanced technology can be used for modernization and replacement of the existing enterprises of mechanical processing of tires and other rubber waste.
4. Economic efficiency of use technology and plant
4.1. Economic efficiency of technology designer and the equipment manufacturer is defined as follows:
4.1.1. Cost of set technological and accessory equipment at the prices on 1.08.15 for plant by productivity 360 – 500 kg/h of processed tires makes $790,000 – 850,000 (without of the equipment cost for liquid nitrogen storage or a refrigeration machine for combined technology);
4.1.2. In case of manufacturing of specialized machines and apparatuses, delivery of all complete set of the additional equipment, installation, starting-up and adjustment works the enterprise-developer profit will make approximately $500,000 only from sale of one plant;
4.1.3. The period of the pay-back of the half-industrial plant will make approximately 2.7-3.2 years;
4.2. Economic efficiency for the company which purchases advanced technology and the equipment includes following data:
4.2.1. The cost price of one ton of recycling waste tires at plant productivity 360 – 500 kg/h makes $170 – 190;
4.2.2. Cost of reprocessing one ton of waste and scrap does not exceed $ 90 - 110;
4.2.4. Sale price of a rubber crumb makes $380 – 600 for ton, and price of de-vulcanization rubber: $950 – 1,200;
4.2.5. The period of the pay-back of the plant by productivity 360 – 500 kg/h will make 2.7 – 3.0 years in case of realization a rubber crumb, a steel ware and synthetic fibers;
4.2.6. The period of the pay-back of the same plant will make 2.2 – 2.4 years in case of realization the de-vulcanization rubber;
4.2.7. The income of the enterprise can be increased, if payment from getting of waste tires on recycling will be made.
5. The Scientific-Engineering Center in cooperation with the manufacturer of specialized equipment can prepare and carry out:
1) can work out the technical and economic assessment for plant construction;
2) develop of the technological scheme for production;
3) to develop the technical documentation on special types of machines and apparatuses;
4) to organize the equipment manufacturing for recycling waste tires of vehicles;
5) control during installation and commissioning.
6. There are various ways of cooperation:
1) the development of new machines and apparatuses for all known technologies for recycling of waste tires,
2) recycling and marriage in the manufacture of tires and other rubber products;
3) technology and machinery for de-vulcanization of crumb rubber and chips;
Phones: +7-910-4046904; +7-905-782-2040 (Moscow); +972-50-8509416 (Israel);