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Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
The Green Rubber Opportunity
“A sustainable solution for dealing with waste tyres at mine sites”
Prepared by Green Rubber Pty Ltd for Australia’s Mining Companies
10 October 2014
COMMERCIAL-IN-CONFIDENCE
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
The Green Rubber Opportunity A sustainable solution for dealing with waste tyres at mine sites
Green Rubber The Green Rubber brand is so classified as a name given to recycled rubber that would be extracted exclusively from the Waste OTR tyres to be found buried or stockpiled in the mine sites across Australia. Green Rubber Pty Ltd has developed the “virtuous cycle” of Waste to Valuable Resource (see diagram on Page 4) using a holistic approach that takes into account collection, recycling and giving back to the mining sector products that would substitute for existing products made out of timber and other natural scarce and expensive materials. Over time the carbon reduction of the Green Rubber Project along with cheaper and longer life products makes this project a unique example for greener industries and better management of waste that can be utilized using the right technologies available to Green Rubber Pty Ltd globally. Green Rubber Pty Ltd is currently a registered Member of Tyre Stewardship Australia Pty Ltd and was earlier a party to the Federal Government’s Tyre Industry Working Group activities seeking a national solution to waste tyre problems and to regulate recycling and bans across Australia of burial of waste tyres.
An example of a “Crumb Rubber Hot Mix Asphalt” road after 11 years of service
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
Review of the current disposal of waste tyres in mining sites in Australia
• Waste tyres are currently buried and stockpiled across most sites of Australian
mining operations in Australia and abroad.
• This practice represents an environmental and reputation risk as well as an
operational and direct cost that brings no benefits whatsoever under the
licence to operate and sustainability reporting.
• Proposals for safe disposal are underway with the establishment of Tyre
Stewardship Australia (TSA) and agreements with tyre manufacturers to
recycle waste and collect levies from buyers, including mining tyres.
• The formation of TSA and the participation in it by the Minerals Council of
Australia is a real opportunity for individual mining companies to show
leadership and to reap the benefits of research funding as well as reduction in
operational costs and increase in the sustainability reporting of the waste.
• Green Rubber Pty Ltd (GRPL) has been working closely on the recycling of
end of life OTR tyres for over seven years to see a cost effective and
sustainable solution for the disposal and recycling of the OTR tyres used in
mining operations.
• There are cost effective solutions for the waste tyres to be collected, recycled
and turned into new green products of benefit to the mining companies.
• The “virtuous cycle” of waste to resource, shown overleaf, is a reality and
could be implemented for the mining sites across the operations of each
mining company, depending on the number of tyres in existence being
discarded and buried or stockpiled on each site.
• GRPL is proposing that a scoped logistics and feasibility study for a global
solution to waste tyre problems at mine sites be undertaken which will see a
cultural change in the current burial practices and a sustainable solution to this
waste.
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
THE GREEN RUBBER PROJECT – A VIRTUOUS CYCLE OF WASTE TO VALUABLE RESOURCE AND A SUSTAINBLE SOLUTION
OPERATING ENTITY
OTR WASTE TYRE LOGISTICS GROUP
ASSOCIATED
MINING COMPANY
WASTE TYRE RECOVERY & PRE-CUTTING AT MINE
SITES
TRANSPORT FROM MINES TO
RECYCLING PLANTS
RECYCLING PLANTS
WA, QLD, NSW
MANUFACTURING PLANTS HIGH NET RESOURCE VALUE DOWNSTREAM PRODUCTS FOR THE
MINING INDUSTRY
Reporting on Outcomes under Global Reporting
Initiative G4 Guidelines
POSSIBLE MINING COMPANIES BACKLOADS
INITIATORS & CONSULTANTS GREEN RUBBER
PTY LTD
RECYCLED PLASTICS AND
FILLERS SUPPLY
CRUMB RUBBER AND/OR POWDER
WASTE TYRE SUPPLY
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
Some aspects to be considered to move forward with a solution 1. Eliminating a current mining industry cost associated with
environmental compliance transformed into an opportunity.
OTR tyres at the end of their useful life: • Represent around 65,000 tonnes of waste annually across Australia.
• Handled like most waste at the end of its useful life, a cost of disposal is
involved and the current tyres given their size and difficulty in handling as
well as transport distances are presently costing mining companies
considerable annual expense in collection, burial and “environmental
protection compliance”.
• Furthermore, waste tyres in all states in Australia have come under a
great deal of attention and discussion over several years by all
environmental authorities.
• By their very nature, tyres are difficult to dispose of. They float and they
are highly flammable. See photograph of a waste tyre fire overleaf.
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
A Waste Tyre Fire
• In the Northern hemisphere approx 18% are burnt as a "replacement
fuel" in the manufacture of cement. This is fast becoming the most
popular way of disposing of them but is difficult to justify on cost.
• Tyre burning emits ultra-fine particles that have a toxicity all of their own.
The toxicity is even stronger if this contains metals such as nickel and tin,
which you get when you throw the whole tyre into the furnace. If the
metal content of the particles goes up, then there is going to be an
increasing impact on human health.
• Tyres outside mining sites are banned from burial in State owned
landfills.
• Recycling methods such as pyrolysis and turning waste tyres into tyre
derived fuel have proved to be too costly and have failed to provide
workable solutions.
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
A change in tyre waste legislation and compliance is inevitable globally Unsustainable practices for the disposal of tyres are forcing review and restructure of regulations for compliance at all levels where the waste is produced.
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
2. Virtuous cycle of waste to valuable resource - A waste OTR tyre is too
valuable as a resource to be kept out of sight, burnt or buried.
• By their very nature wastes are end of life products, to be discarded as having
no further economic value. However this is not the case with tyres as they
contain useful, valuable and recyclable materials such as rubber and steel.
• GRPL has produced an Australia-wide Green Rubber Project, providing
proven solutions to the logistics, environmental and financial feasibility of fully
integrated facilities for recovery, downsizing, transport and recycling of mining
industry “off the road” (OTR) tyres.
• This proposal is for mining companies to take the lead by adapting the existing
research into a solution for their sites and provide an opportunity to turn an
end-of-life product into a valuable and beneficial resource.
Examples of Global State of the Art Mobile Equipment These units are mobile and can be easily moved around a mine site
OTR Tyre Debeader for up to 55/80/R63 tyres Bagel Cutter for halving 55/80/R63 tyres
Rotary Shears Super Chopper
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
Using recycled rubber to manufacture new products
A feasibility study is required to review earlier work by GRPL to determine the viability of collecting the end of life tyres available on mine sites and converting them into recycled new products with some returning to the mining industry.
Replacing old timber railway sleepers with a recycled rubber product
Moulded and/or extruded products
Waterproof sheets
Posts for Underground Mine Supports being Tested
Misc Extruded Products
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
3. The Green Rubber Opportunity to deal with OTR tyre waste sustainably ie:
economic benefits, environmentally safe and best practices for a socially
desirable disposal and leadership engagement with a Green industry
The Green Rubber Project will bring financial benefits to the mining companies not just in substitution of the raw material but also in the safety and longer life-cycle performance of the Green Rubber products and the virtuous cycle of reducing and working towards a zero waste in this area for the mining companies and the producers of OTR tyres across the world. • Establishing a new practice of well organized collection and downsizing of the
tyres on mine sites and in stages also collecting tyres from existing stockpiles
will deliver direct cost and organizational benefits. The new practice will
comply with mine site occupational health and safety requirements and
individual mine site access requirements, all prior to commencement and
thereafter.
• The carbon footprint of the Green Rubber Project is less than 1% of the initial
embodied energy of the new tyres, which is a compelling case for the need to
ensure that the mining companies work closely with the tyre producers, the
recycling industry and Green Rubber Pty Ltd to arrive at an environmentally
and socially acceptable solution for the disposal of the waste and its
conversion into Green Rubber.
• The opportunity for mining companies to participate in the usage of
downstream products on mine sites can be utilized in Reporting under the
Global Reporting Initiative G4 Guidelines with clear environmental and
community benefits declared to improve the image of the mining companies.
• Tyre Stewardship Australia has implemented a new Levy to be charged on all
tyres around Australia to pay for research and ongoing costs of
implementation.
• The formation of Tyre Stewardship Australia and the participation in it by the
Minerals Council of Australia is a real opportunity for individual mining
companies to show leadership and to reap the benefits of research funding as
well as reduction in operational costs and increase in sustainability of
operations.
• The Green Rubber Project provides training and employment opportunities in
the “green industries” adding value to the corporate and social responsibility
agenda for the mining companies and the mining industry in general.
Green Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty LtdGreen Rubber Pty Ltd Project Managers and Consultants To the Mining & Waste Industries
ACN 129 366 383
Africa Zanella, Director – Mob: 0424 202 949 Email: africa.zanella@gmail.com Phillip Isaacs OAM, Director – Mob: 0408 283 902 Email: phillip.isaacs@greenrubber.com.au Dr Simon Michaux, Consultant – Mob: 0419 716 165 Email: simonpetermichaux@gmail.com
Address: 1167 Barrenjoey RdPalm Beach NSW 2108
Proposed Steps going forward: Step 1 Determination of the current and projected situation regarding waste OTR
tyres including annual throughput, tyre types, site locations, stockpile data and accessibility, OH&S and environmental conditions that apply at the mine sites and indicative costs of collection, burial and maintenance applying at these mine sites.
Step 2 Review and adapt the completed Green Rubber Project Stage 1 Report to
determine applicability of data and strategies to current situation determined in Step 1. Note that the Stage 1 Report covers extensive research and study of an industry-wide approach to end of life tyre strategies, including equipment for downsizing and recycling as well as new technologies for the development of new recycled green products under negotiations with our partners, the University of NSW School of Mining Engineering and the Bureau of Mines Pittsburgh Research Centre.
Step 3 Determination of the most appropriate scale of a first Project and its mine
site location(s). This would involve consideration of the extent of new equipment and facilities and the suitability of existing recycling and downstream products manufacturing facilities to speed up the Project.
Step 4 Preparation of a detailed design and feasibility study for the agreed site(s)
of the Project and agreement on costs and also starting dates.
The GRPL Management Team Africa Zanella M.Comm GAICD - Director GRPL and waste and sustainability expert Phillip Isaacs OAM BE FIEAust FRSA AOM(USA) - Director GRPL and engineering and environmental expert Dr Simon Michaux B.AppSc. PhD, Principal consultant, scientist and mining engineering expert Best wishes Africa Zanella
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