SMARTSMARTSustainable Moulding of Articles from Recycled Tyres

Project Overview, objectives and expected Project Overview, objectives and expected resultsresults

KICK-OFF MEETINGRome, 21st of March 2012

Full Title: Sustainable Moulding of Articles from Recycled Tyres

Funding Scheme: FP7–SME-2011 - Research for SMEs associations

Grant Agreement n°: 286465

Starting Date: 01/03/2012

Project Duration: 36 Months

Project budget: 2.568.148 €

Requested funding: 1.972.100 €

Consortium: 9 Partners: 3 SMEs AGs (Associations), 3 SMEs and 3 RTDPs (Performers)

SMART Project IDSMART Project ID

Ekoguma did not accede the contract

The project is eligible, hence the contract with the EC is in force but the EC officer asked to proceed with an amendment substituting the Association with another one. (IN THE PRESENTATION THE TABLES FROM THE CONTRACT STILL INCLUDE EKOGUMA BUT SHOULD BE CONSIDERED AS “NEW PARTNER”)

Information about Orius were sent to the EC officer to get approval of their participation. If approved the formalities will be carried out.

SMART partners and contract status SMART partners and contract status

Added value of a recycled product derived from tyre shredding process is low due to the

poor mechanical performances.

Limited possible applications : cheap "filler" material (expanding array in civil engineering or

asphalt) or is compression-molded with polyurethane binders into tiles that can be secured

to an asphalt base as a cushioning surface for athletic fields, jogging tracks, play areas safety

surfaces.

No possible use in structural rubber applications, where certain physical features and

mechanical performances are needed (hoses, machine accessories, rollers or anti-vibrating

pads etc). These markets are only available for virgin rubber.

The profit of recycling is limited by the manufacturing costs: polyurethane resin binders,

constitute by themselves 50% of the material-related costs of tyre recyclers.

Project backgroundProject background

To optimise the tyre pulverisation process for producing a fine rubber powder (crumb)

which will substitute polyurethane resins presently used as binding chemical elements

To define a direct compression moulding process, using the rubber crumb powder as filler

and to optimise the parameters relevant to the final moulds implementation (crumb mesh

size, temperature and pressure of operation, etc.)

Define and realise three innovative mould products, in the application fields of transports,

sport facilities and industry (to be chosen among Consortium, e.g. sheets and rail profile for

noise and vibrations reduction in rail, mats, ramp and kerbs for safer roads furniture and

sports facilities applications, rubber technical articles for industry).

To validate the technology and carry out the assessment from the technical-economical and

environmental point of view also through Life Cycle Analysis (LCA) of the technology

compared to alternative routes, including energy recovery

Project objectivesProject objectives

Recycling costs vs traditional moulding: the reduction of costs is expected to be 50% when

compared to traditional tyre recycling through moulding process. Presently for rubber

sheets with a thickness of 20 mm:

energy cost is about 3 €cent/kg,

cost of binder is 20 €cent/kg

cost of the crumbed rubber is of the order of 20 €cent/kg)

Product mechanical performances: rubber parts that will present the compressive strength

resistance needed for many applications in the industrial, sport and transport sectors, where

presently only virgin rubber can be used, at a price which is 60% lower.

Decrease to zero the polyurethane binder or other chemical agent component of the

recycled rubber mixtures

The product will be fully further recyclable, being no additive in it.

Project quantitative targetsProject quantitative targets

SMART RESULTSSMART RESULTS

N RESULTSMEs AG. mainly

involved in exploitation

SMEs mainly involved in exploitation

RTD involved

1

PULVERISATION PROCESS CHARACTERISATION +

OPTIMISED MOULDING PROCESS AND MACHINE

ETRA, EKOGUMA, IASLIM

TEBAMIX, ADRIA, GRP

UNITV, LABOR

2FINAL PRODUCT PROTOTYPE AND

LIFE CYCLE ANALYSIS (TRANSPORT APPLICATION)

ETRA ADRIA, GRP UNITV, TI

3FINAL PRODUCT PROTOTYPE AND

LIFE CYCLE ANALYSIS (SPORT APPLICATION)

ETRA, IASLIM GRP UNITV, TI

4FINAL PRODUCT PROTOTYPE AND

LIFE CYCLE ANALYSIS (INDUSTRY APPLICATION)

ETRA, EKOGUMA, TEBAMIX, ADRIA UNITV, TI

Research for SMEs

TRANSACTION (INVOICES)MONEY FOR RESULTS

FUNDING

OWNERSHIP

PROJECT MECHANISMPROJECT MECHANISM

RESULT 1 OWNERSHIP AND REMUNERATIONRESULT 1 OWNERSHIP AND REMUNERATION

RESULT 2 OWNERSHIP AND REMUNERATIONRESULT 2 OWNERSHIP AND REMUNERATION

RESULT 3 OWNERSHIP AND REMUNERATIONRESULT 3 OWNERSHIP AND REMUNERATION

RESULT 4 OWNERSHIP AND REMUNERATIONRESULT 4 OWNERSHIP AND REMUNERATION

SMART technical approach SMART technical approach

We will discuss about the WPs involving the work for the first year – WP1- WP2 – WP3

+ WP8-WP9

SMART Work PlanSMART Work Plan

SMART Deliverables for the first yearSMART Deliverables for the first year

SMART milestones for the first yearSMART milestones for the first year

SMART effort expected for the first yearSMART effort expected for the first year

1. The Negotiation Phase started in May, 2011 and a meeting with the Officer was successfully held in Brussels at the beginning of the same month.

2. A revision process of the DoW was provided on the basis of the reccommendations received from the REA in the Negotiation Mandate and Evaluation Summary Report.

3. There was a change in teh consortium: the SMEs beneficiary Elastrade was substituted with the SME Adria

4. The negotiation procedure took longer than expected due to problems in the validation of some partners who were not recognised as SME and therefore there was the need to modify the budget and the DoW. The Negotiation process was finalised in November 2011.

5. The Grant Agreement was signed by the REA in February 2012 and 1° of March 2012 was fixed as official starting date for SMART project.

6. Forms A (accession to Contract) were received from each partner with exception of Ekoguma and sent to the REA, who acknowledged the receipt and the entry into force of the contract.

7. REA asked to replace Ekoguma with another association, we are in the process to do this and to make an amendment to the contract that could be valid retroactively from the first day of the project

What was going on…

D9.1 - Consortium Agreement for Month 2 (end of April 2012) D1.1 – SMART Process requirements and specifications for Month 3 (end of May 2012)

D1.2 – SMART machine requirements and specifications for Month 3 (end of May 2012)

D8.5 –Web portal for Month 3 (end of May 2012)

… Let’s get down to work! …

What will happen …

Thank you!Thank you!

Ettore Musacchi

ETRA