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Physics and Chemistry to
integrate Economics and
Ecology : Recycling and
Reuse of Waste
Rajeev Pandia
Contents (Rubber)
Global Challenges of End Of Life Tires
Approaches for addressing the challenge
Reclaim rubber as environmentally friendly
preferred option
• Process of Manufacture : Physics & Chemistry
• Applications
• Properties
Scrap Tire Challenge
981 million tires scrapped every year, equivalent to 13.5 million tons of scrap tires annually
The enormous amount of scrap tires will create a major environmental problem, unless the recycling solutions are optimised
• In addition, huge waste also from non-tire rubber products
• With growth in developing countries, the challenge will grow further
Waste Hierarchy
Waste Hierarchy
Reclaim and Recycling
Material recovery:
Crumb rubber
Incineration:
-Cement kilns
-Energy Recovery/Pyrolysis
Landfill : Now banned in the EU
Reduction:Traffic /Technology
Disadvantages of some approaches
Landfills
• Fire hazards and environmental pollution
• Inefficient use of space
• Slow decomposition of rubber
• Ban in EU• Breeding ground
for insects
Energy recovery (Cement kilns)
• Only 16% of energy used in manufacturing tires is recovered
• Environmental pollution, Carbon footprint
Retreading
• Manual labor intensive
• Needs careful sorting and inspection
• Economics and other limitations
Reclaim Rubber :
Environmentally favored option▫ Reclaim rubber is partially de-vulcanized rubber treated using
a combination of chemical , mechanical and thermal processes whereby the material is converted to its plastic stage. This is accompanied by a reduction in molecular weight, helping process ability.
Reclaim rubber imparts process advantages
• Lower mixing time and temperature
• Improved tack
• Potential of replacement of resins and process aides
Major sources of Manufacturing
Reclaim Rubber
• End of life whole tires
- Nylon Bias ply tires- Passenger car tires, cycle tires and tread peelings
• Butyl Inner Tubes
• Latex Waste
• Other auto and non auto rubber products based on EPDM, NBR and other rubbers
Types of Reclaim Rubber
From tread peelings
• Source: Tread Peelings (High Tensile Reclaim)• Applications: Tires, Tread Rubber, TSR Goods,
Conveyor belts, Automobile Components
Butyl Reclaim
• Source: IIR and CIIR Automobile Tubes• Applications: Inner tubes, Automobile Innerliner, Hot
Melt Adhesives, Roofing, Automobile Components
Whole Tire Reclaim
• Source: End of life tires• Applications: Tires, Tread Rubber, Conveyor belts, Hot
Melt Adhesives, Automobile components, Footwear
Uses of Reclaim Rubber and
AdvantagesA price stable alternative rubber hydrocarbon
A process aid ensuring shorter mixing times, enabling higher productivity
An agent for savings in energy and compound cost
Automobile tire and tubes
Belts and other civil construction applications
Automobiles and industrial hoses
Adhesives and Sealants
1. It works as a polymer2. It brings a major cost advantage to the tire industry3. Responsibility of the rubber industry for saving virgin resources
Energy and Greenhouse emissions
Material Energy (MJ/kg) Greenhouse (kgCO2/kg)
Natural Rubber 8 0.4
Synthetic Rubber 110 5
Carbon black 125 5.7
All other additives 100 8.2
Fabric 45 2.1
Steel tire cord 36 3.2
Manufacture (per kg tire) 11.7 1.9
Reclaim 2.1 0.1
Potential of Resource Conservation
Polymer Replacement Ratio
At 5% At 10%
Area ( Sq Mtr) 2, 348,984 4,697,971
Energy (GJ) 42, 318, 637 84, 637, 388
Oil (Gallons) 30,800,000 61,600,000
Area : Due to landfill reductionEnergy: Savings in GJ energy/kg of rubberOil: Gallons saved in production of a tire when substituting virgin polymers
At the current level of 4% substitution, there is an annual saving close to USD 500 mn. for the rubber industry
Opportunities for Reclaim Rubber in
the Tire Sector
Reclaim rubber in the Tire Sector
Area Potential Usage (in %age to virgin rubbers)
Potential savings in process cost
PCR 5% ~2%
Solid Tires 10-15% ~4-6%
Retread Rubber (Hot) 20-30% ~4-6%
Inner Tubes 20-40% ~5-7%
Flaps 20-40% ~8-10%
Replacement of reclaim rubber can lead to savings of up to US $ 800-1200 per ton of Virgin Polymers substituted.
Opportunities for Reclaim Rubber in the
Non-Tire SectorReclaim rubber in the Non-tire Sector
Area Potential Usage (in %age to virgin rubbers)
Potential savings in Process Cost
Conveyor Belt 20-25 ~5%
Automobile Profile 20-30 ~10-12%
Hoses 10-15 ~4-6%
Mats and Flooring 40-50 ~12-15%
Roofing applications 40-50 ~10-12%
Hot Melt adhesives 10-15 ~5%
Civil engineering 30-40 10-12%
Contents (PET)Applications of PET
Volumes of Post-Consumer PET waste
Levels of recovery
Processing of PET Waste: Physics & Chemistry
Applications of Recycled PET
PET Recycling Process
Sorting Crushing Baling Flaking Washing Melting Extrusion
Conversion to final product
Conclusions Used Rubber and Plastic products pose major
environmental challenges
Examples of Reclaim Rubber and RPET products indicate multiple options studied
Evolution of technology has provided optimal solutions integrating Economics and Ecology
Recycled rubber and plastics will continue to see strong growth and newer applications