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CIP Eco-innovation Pilot and market replication projects
Call 2008
Call Identifier: CIP-EIP-Eco-Innovation-2008
D8.4. Layman’s report Contract ECO/08/239112
Due date of deliverable: Month 30 Actual submission date: Month 30
Start date of project: July 2009 Duration: 30 months
Lead contractor for this deliverable: IBV Project website: www.eco-rubber.eu
Dissemination Level PU Public √ PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services)
Innovative used tyres recycling and rubber sintering process for eco-friendly
urban equipment fabrication
www.eco-rubber.eu
Duration: 30 months
Budget: € 1 022 304 (EU contribution: 51,75 %)
ECO/08/239112/SI2.535300
Coordinator
INDEX
INDEX ................................................................................................................................................3
THE PROBLEM AND BACKGROUND INFORMATION .....................................................................4
PROJECT OVERVIEW AND OBTAINED RESULTS ..........................................................................4
THE MARKET AND EUROPEAN ADDED VALUE .............................................................................8
REFERENCES ...................................................................................................................................9
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 4 of 10
THE PROBLEM AND BACKGROUND INFORMATION
The 27 countries of the EU had to dispose 2.6 million tonnes
of tyres in 2010 alone. Although since 1996 the trends of the
different recycling and recovery options have significantly
evolved; only 40% of those were recycled while 38% were
used as fuel – substituting one problem for another in the form
of emissions.
Referring to material recycling, the main applications of powders (recycled crumb rubber) are as a
filler or additive and usually in low volumes to modify the properties of the material or to reduce the
manufacturing cost.
In addition, rubber is the basic constituent of
many products used in transportation, industrial,
consumer, hygienic and medical sectors. The
rapid rise in oil prices along with continuing
supply tightness has driven Natural rubber (NR)
prices higher, following the same trend as
Synthetic rubber (SR) feedstock prices. Crumb
recycled rubber could be a valuable
alternative to the use of Natural or Synthetic
rubber for obtaining a wide range of
commercial and industrial products.
Furthermore, the particular qualities characterising end-of-life tyres, such as flexibility, strength, low
weight, high drainage capacity, shock absorption and insulation means they are extremely well suited
for using them, after the grinding-sintering process developed in ECO-RUBBER, to fabricate URBAN
furniture products competing with other materials used until now.
PROJECT OVERVIEW AND OBTAINED RESULTS
The main goal of this project is to adapt the current industrial rubber recycling process to
supply innovative recycled rubber urban furniture products manufactured by an innovative sintering process as an alternative to virgin rubber, wood or concrete products. After the
CRIOSINTER FP6 CRAFT project, it was proved that obtaining products with enough functional
properties comparable to that of traditional products is possible using a recycled rubber sintering
process.
0
500
1000
1500
2000
2500
3000
3500
Natural rubber SBR rubber Recycled rubber (Ref. 6080)
Recycled Rubber (Ref. 3080)
€/t
on
Cost comparative analysis
CA
SE
ST
UD
Y: A
BO
LL
AR
D
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 5 of 10
To reach this main objective different partial goals were achieved:
1. An adapted and improved grinding process in order to obtain the targeted particle
morphology and zero contaminants (ferrous, metal and textile decontamination) and to
improve the morphologies synergy blends to obtain recycled rubber with enhanced
properties
Regarding the grinding process, in order to obtain the required quality of the final material, a
reduction of the amount of contaminants in raw materials was necessary, and thus, an adaptation of the
present grinding lines was performed.
The planed layout was assembled in the RECIPNEU facilities and consists of a pulveriser that
mechanically grinds the largest granules obtained in the previous cryogenic process. To obtain rubber
powder with a more uniform and well defined size distribution, a new sieving system intended for
rubber powders was installed. All fine rubber particles smaller than 0.6 mm are processed in this
sieving system. Regarding the ferrous decontamination of the rubber powders, it is done by using a
high magnetic power automatic system. Concerning textile decontamination equipment, after previous
research work carried out on the combination of different equipments (densimetric column, granulator,
pulveriser, electrostatic column, densimetric table), in order to minimize the textile contamination
level a system for the decontamination of the fibre with the following operations was installed: a
densimetric column (where a large quantity of big fibres is removed), followed by a pulveriser (where
granulates undergo size reduction and release more fibres), then a detextiler (where balls of
microfibres are formed and then separated by vibration), and finally an electrostatic column (for
electrostatic removal of residual textile fibres).
Product Requirements
High superficial area of the
particles (rough surface)
Narrow size distribution of
rubber particles
Very low metal
contamination
Very low textile fiber
contamination
Adaptation in the line to achieve the Requirement
Mechanical grinding (pulverizer) Accurate sieving system Magnetic drum
Densimetric and electrostatic separation
QUALITY CONTROL TESTS
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 6 of 10
2. An optimized formulation including up to 89% of crumb recycled rubber.
The addition of additives to the base crumbing material with a minimum percentage of contaminants
(steel and textile fibre), a crumb rubber homogeneous distribution and rough morphology together
with the correct particle size selection, improves the final mechanical properties of the product.
Among the different additives evaluated, the ones that provide the largest increase in tensile strength
and elongation, almost doubling the value achieved with samples without additives, were selected
getting two different formulations; one with 89% and the other with 60% of crumb recycled rubber.
3. An optimized sintering process including dosing chamber and pre-heated phases.
In reference to the mixing process, it was necessary to use the most advantageous mixing and dosing
equipment. After analyzing all different machinery available, the production plant was finally
integrated by solid dosing equipment for crumb recycled rubber, liquid dosing equipment for additives
and a mixer with infrared heating system. This machinery was assembled together in the following
layout:
A headframe pre-dosifier is used to place a load over the conveyor belt, which is connected to
an automatic timer for the optimum dosing of the rubber grain.
Then, this grain is transported to an elevating bucket system where it is conveyed up to the
suspended mixer where it is mixed and heated together with the selected additives. .
In reference to the sintering process, the current hot compression line was adjusted introducing and
modifying different equipment such as mixers, pneumatic feedings and a heating chamber.
4. An Ecolabel stamp for the developed products in order to eliminate user attitude barriers to
the use of urban furniture made of recycled rubber
A specific stamp to be placed on the bollards and increase the visibility of its sustainability has been
designed. In addition, a brochure explaining its benefits has been produced based on an LCA study.
Finally, a proposal for an EU-ECOLABEL group has been sent.
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 7 of 10
5. To aid the introduction of simulation programs into the design process of recycled products
that enables to predict and assess the final product performance
The methodology to perform a Finite Element Analysis has been defined.
6. The selected urban innovation which is safe, comfortable and environmentally-friendly
The results of impact tests where HIC index was determined show that a sintered bollard made of 89%
recycled rubber material, is 4 times safer (HIC index equal to 305 ) than a metallic one (HIC 1211)
and that a bollard made of 60% of recycled rubber is 3 times safer than a metallic one (HCI from 361
to 1211). In addition, these recycled rubber bollards are more flexible, so they produce less friction on
vehicles and minimize scratching.
In addition, the bollard is environmentally-friendly as can be observed in the LCA results.
Identify critical area
•Lower density
•Lower temperature
Stress- strain diagrams
•General scenario
•Worst scenario
•Obtain the breaking strength (Mpa)
Simulate
•Add recycled rubber material properties
Assess mechanical resistance
•Compare high density-high temperature areas with breaking point .
•Compare low density-low temperature with breaking point.
•Assess if either area overcomes its corresponding breaking point.
Life cycle assessment (LCA)
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.018
Recycled Rubber -Recipneu
Natural Rubber SBR
Eutr
op
hiz
atio
n &
Aci
dif
icat
ion
p
ote
nti
al
Glo
bal
war
min
g
Raw materials (1 kg)
0
20
40
60
80
100
120
Recycled Rubber -Recipneu
Natural Rubber SBR
Ene
rgy
reso
urc
es
de
ple
tio
n (
MJ-
eq
) Raw materials (1 kg)
0
20
40
60
80
100
120
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
SBR 89% Recycled Rubber 60% Recycled Rubber Eutr
op
hiz
atio
n &
Aci
dif
icat
ion
p
ote
nti
al
Glo
bal
war
min
g
Bollard
Acidification-general-kg SO2 eq Eutrophication-general- kg PO43-eq
Global warming (GWP 100)- kg CO2 eq
0
500
1000
1500
2000
2500
SBR 89% Recycled Rubber 60% Recycled Rubber
Ene
rgy
reso
urc
es
de
ple
tio
n (
MJ-
eq
) Bollard
Energy resourdes depletion (total)-MJ eq
Energy resourdes depletion (fossil fuel)-MJ eq
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 8 of 10
THE MARKET AND EUROPEAN ADDED VALUE
According to the United Nations
Environment Programme (UNEP) elaborated
by the UN, for the period from now until
2030 it is estimated that 60% of the global
population will live in urban areas, which is
double the amount of inhabitants than in
1950 and 22% more than in 2003..
Cities have suffered a spectacular growth of
population during the last century, and
particularly since the „50s, when a city was
only considered as an urban agglomeration
with a number of inhabitants higher than ten
million. In 2000, the number of cities in this
category was 19, and it is estimated that in
2015 this number will rise to 23 urban
centres.
Nowadays in the European Union, over 60% of the population lives in urban areas of over 50 000
inhabitants. Nevertheless, this is not a recent phenomenon within Europe, where for centuries, towns,
cities and metropolitan areas have contributed significantly to define European society and
civilization. Furthermore, small and medium-size cities have developed an important role in the
urbanization process.
In this context, the concept of a sustainable construction appears with the aim of promoting
environmentally friendly construction materials, energy efficiency in buildings and construction and
demolition waste management. The ECO-RUBBER products allow manufacturing companies to
introduce into the market products made of recycled materials that will be of sufficient quality, safer
and more comfortable for the final users. Additionally, the project products promote the use of
recycled rubber as an environmentally friendly material allowing that a residue, whose destination was
the landfill or incineration, could be used again as raw material for the production of urban
innovations.
In addition, green public procedures are being promoted around Europe due to the fact that public
authorities spend each year over €1,500 billion on urban procurements (16 % of the GDP). The
introduction of recycled rubber in the urban furniture market will also promote green public
procedures into this kind of goods. This sector, only in Spain, has a production of over €3 billion and
210 companies working on it.
Moreover, total world rubber consumption is estimated to have reached a Moving Annual Total
(MAT) of 25.8 million tonnes by end Q3 2011 (December 2011-International rubber study group).
Global synthetic rubber production was 7.5% higher than at end Q3 2010, in line with the relatively
strong growth seen in SR consumption, while global NR supply was 4.1% higher than at end Q3 2010.
Furthermore, the rapid rise in oil prices along with continuing supply demand has driven natural
rubber prices higher. The use of recycled rubber as a raw material will reduce the dependence of the
virgin rubber, so it will improve the competitiveness of the companies.
Thus, there is a huge market for recycled rubber. It is important to highlight the fact that all the
processes proposed in the ECO-RUBBER project could be replicated for a wide range of high volume
KEY POINTS FOR THE MARKET INTRODUCTION
Green public procurements
People living in
cities
Rubber prices
CIP-EIP-Eco-Innovation-2008. ID: ECO/08/239112
Layman’s report p. 9 of 10
rubber products such as automotive, industrial, consumer and leisure sectors competing with rubber as
a raw material.
REFERENCES
http://www.rubberstudy.com/news-article.aspx?id=5032&b=default.aspx
European Tyre and Rubber Industry. Statistics. Edition 2011. ETRMA Accesed on January
2011. Available on line http://www.etrma.org/
European Union. Regional Policy. State of European Cities Report. 2007 Accesed on July
2008. Available on line at <
http://ec.europa.eu/regional_policy/themes/urban/audit/index_en.htm>
The European Commission. Executive summary of the final report on sustainable
construction. Accesed on August 2008. Available at
<http://ec.europa.eu/enterprise/construction/suscon/finrepsus/sucoex.htm>
ECO SMEs, 2000. Accesed on September 2008. Available at <http://ex-
elca2.bologna.enea.it/cm/navContents?l=&navID=urbanFurniture&subNavID=1&pagID=4&f
lag=FONT>1>
EUROPA. European Commission. Environment. Green Public Procurement. Accesed on
September 2008. Available at
<http://ec.europa.eu/environment/gpp/facts_and_figures_en.htm>
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ECO‐RUBBER “Innovative used
tyres recycling and rubber
sintering process for eco-friendly
urban equipment fabrication” is a CIP Eco-innovation Pilot and
market replication project.
ECO/08/239112/SI2.535300.
The project has a total duration of
30 months (from July 2009 to
December 2011) and a budget of
€ 1 022 304 (EU contribution:
51,75 %)
CONTACT:
www.eco-rubber.eu
AIMPLAS E-mail:[email protected]
Tel: +34 96 136 60 40
IBV
E-mail:[email protected]
Tel: +34 96 387 91 60