Tire recycling equipment. Tire recycling as a business

Every year, thousands of tires go to landfills and landfills, despite the fact that for an enterprising person they are free resource from which crumb rubber can be produced.

If it was needed only once, you can buy it in the right amount from manufacturers.

But where can you get crumb rubber if you need it on an ongoing basis and in large quantities?

It is worth thinking about buying your own.

However full installation is not affordable for everyone, and not everyone will be profitable such an investment. The way out is to create equipment with your own hands, and use it to produce crumb rubber from tires at home.

If you need very little raw materials, you can do without equipment at all.

This will only require scissors and cutter.

The metal cord is first removed from the tire, then it is divided into ribbons and crushed into smaller fractions to the required size.

At this point, the process is considered complete.

Material for the design of paths, flower beds or a separate playground is ready to use.

But to get more raw materials or have an income from tire recycling at home, you need the right equipment.

Tire crusher construction

Three main methods of crumb production are used:

1. Tire crushing after cooling with liquid nitrogen to -190 degrees.
2. Obtaining crumbs on industrial equipment of a full cycle with the removal and subsequent grinding of rubber.
3. Recycling using universal crushers, which you can do yourself at home.

The first two methods require large investments. Third option available to everyone who has the ability and desire to make a crusher at home.

Required units can be make it yourself in the workshop or on the production site- where there are metal-cutting machines (turning, milling) and a welding machine for the manufacture of component parts.

If you cannot do it yourself machining blanks and you will have to order them according to your drawings, all the same, the cost of tire recycling machines will be several times cheaper than similar purchased units.

The main component of the tire recycling line is a shredder (rubber grinder). Let us consider in more detail the purpose of the nodes of this machine.

Unit device

The machine consists of the following main units:

• electric motor 5 kW - 2 pcs;
• housing with disc shafts;
• lattice;
• worm gearbox - 2 pcs;
• shredder frame;
• loading bunker;
• guide tray;
• control cabinet.

Details of the installation are mounted on a powerful frame welded from channels.

Box with cutting discs

The main unit of the crusher for rubber is the body with milling rolls.

Wherein cutting knives made of high-strength steel and heat-treated, which significantly reduces their wear. They are practically do not require sharpening during operation.

The calculation of the openings of the box, shafts and cutting elements must be accurate, so it must be done by a specialist in this field (designer).

Grid for crumb calibration

In order to obtain a calibrated fraction of tire raw materials, shredders are equipped with a special grate, which is installed under the rolls.

Worm gear

The rotation of the shafts with disk cutters is carried out separately, directly from the worm gearboxes connected to the electric motors through couplings.

The gear ratio is selected from 25 to 35 in such a way that so that the cutting is free of sticking and at a sufficient speed.

Machine frame

The frame is welded from profile elements, ensures the reliability and stability of the unit during operation, as well as loading and unloading operations.

loading hopper

The tire recycling plant is equipped with a tire loading hopper and a tray for removing finished crumb rubber.

Due to its design, the bunker eliminates the formation of blockages from raw materials and guarantees the directed movement of the mass towards the rotating rolls.

Tire cutter

Tire cutting and cord removal plant consists of a supporting frame and a rack.

On the carcass is a tire clamping mechanism that rotates with the tire during cutting. The engine speed is reduced due to the different diameter of the pulleys. There is a built-in wedge-shaped cutter on the stand, which is adjusted to a certain size by moving the quill.

How to grind tires?

The technological chain is several preparatory steps before producing the required fraction.

This procedure includes:

1. Inspection and removal of foreign objects from the cavity of the tire.
2. Cord cutting.
3. Tire cutting on tapes measuring 50-80 mm.
4. Grinding raw materials through a shredder.
5. Separation and separating metal from textile parts.
6. Calibration crumbs into fractions using a vibrating sieve.

Equipment performance

The operation of these two main units in the processing of tires done in semi-automatic mode.

For the normal operation of this line, a room of about 150-200 square meters is required. meters. This is due to the fact that you need a place for the location of not only equipment, but also for storing worn tires, finished tire products and metal waste.

The output of rubber crumb on this equipment per hour will be approximately 200-800 kg and up to 100 kg of scrap metal, 2-3 unskilled workers will be needed to service the machines.

In addition to tires, this equipment can process other rubber (conveyor belt, cameras, gas masks). The output is a crumb with sizes from 0.7 to 4 mm, while it is 65-85% of the total mass of raw materials.

Tire recycling is a topical issue of environmental protection. Today, 59.6 million people travel on Russian roads. Vehicle. If we take into account that the average tire wear period is 6-7 years, then 34 million of them are replaced annually with new ones. 300-350 thousand tires per region. In Moscow and St. Petersburg many times more.

Meanwhile, statistics claim that only a fifth of car tires are recycled. The rest is either burned for recycling or decomposed in landfills. And rubber, as you know, decomposes for about 150 years.

AT European countries landfills for the disposal of car tires have been banned for more than 10 years.

In this regard, the recycling of automobile tires in Russia has an important environmental significance. Today, there are only 150 mini-factories for the processing of tires in the country. This business has great economic prospects. From used tires with a reasonable approach to their processing, you can get a sought-after secondary product:

Business Benefits

The benefits of a tire recycling business include the following.

1 . As can be seen from the above figures - a large amount of raw materials. Moreover, worn tires will get you for free. Motor transport enterprises are interested in the fastest release from scrap. You can also earn some money at the reception of old rubber (up to 5-6 thousand rubles are paid for the disposal of a ton of tires). The number of cars in the country is growing annually by almost 5%. Therefore, you will not experience a shortage of raw materials.

2 . Premises for doing business need relatively small. For example, for small production, 50 sq. meters. If you have the financial means to deploy a larger business, you need to rent or purchase premises from 300 sq. meters. Keep in mind that for a smaller space, you will have to pay less rent and utilities.

3 . Your products will be in good demand. For example, crumbs are required for the manufacture of coatings for sports and playgrounds, for the construction of which budgetary allocations are allocated. Old tires contain valuable materials: rubber, metal and textiles. Their initial properties during operation basically do not change.

Playground covered with rubber crumb

4 . Only 20% of old tires are recycled. The business is quite new, tough competition does not threaten you. The sooner you enter the market, the more chances you have for further business development. Hurry up to enter the market while the competition is low.

5 . The business is quite simple in terms of technology, does not require additional costs for various operations for the introduction of chemical additives into manufactured products. Good profitability of the project. You will pay back the investment in 1.5 years.

6 . Your company will work in the field of ecology. You will be working in a rewarding environment. Municipal and regional authorities are ready to support you if your work brings results.

Tire recycling options

Tire recycling business can be carried out in several ways.

1. Crushing, the end product of which will be small rubber crumb. Depending on the size and form of manufacture, it is used as an additive in a variety of mixtures, including for the production of new tires, rubber tiles, sports and playground surfaces. At the same time, secondary metal and textile threads are additionally obtained.
2. Obtaining fuel oil, gasoline, kerosene, gas, carbon black, metal cord by heating to high temperature without access to air (pyrolysis). Technology can hardly be called rational, it is very costly and unprofitable.
3. Disposal of used tires by burning. In this case, the released thermal energy can be used for the recycling process. However, this method is accompanied by the release of environment large amounts of soot, sulfur and other toxins.

Crumb rubber production

Processing tires into crumbs using its technology is very simple. The technological process consists of the following stages:

First stage. Tire preparation for cutting. Carry out an inspection of worn tires in order to remove metal small parts and other foreign elements unsuitable for processing: stones, splinters, bead wire.

Second phase. Cutting tires into small pieces or strips (depending on the type of equipment).

From under the hydraulic shears, where the tires are cut into pieces, the rubber goes to the crusher, and then to the granulator

Third stage. Grinding into crumbs, removal of metal cord and textile elements.

Fourth stage. Sorting rubber crumb into the required fractions.

Fifth stage. Packing the received products and sending it to consumers.

How to start a business

Production for the processing of automobile tires will require the resolution of organizational issues.

Keep in mind that you must have a tire recycling license in order to open a business.

The license applicant must have:

• building or premises on the right of ownership or lease, remote from the residential area not less than 300 meters;
• specialized equipment necessary for recycling old tires;
• if it will be engaged in transportation - a transport equipped accordingly and equipped with special signs.

Employees must be trained and receive certificates for the right to work in the field of waste management.

Conclusion on the conformity of all of the above regulatory requirements must provide the sanitary and epidemiological supervision body - a division of today's Rospotrebnadzor. The license is issued by the bodies of the Ministry of Natural Resources.

Based on these requirements, you need to register as a sole trader or legal entity in the tax office.

Pick up the premises and register your rights to it. A room of 50 square meters will be enough to install the equipment. meters. But you need a place for storing raw materials and finished products, rest and meals for staff. A garage business is not the best way out.

Uninterrupted power supply, water supply, sewerage, ventilation system are necessary for production.

Means of production

The purchase of equipment should be given the main attention. This is both the largest expense item and the main link on which the success of the entire production process will depend.

At a minimum, the list of equipment looks like this:

1. hydraulic shears;
2. tape cutter;
3. shredder;
4. magnetic separator;
5. air separator;
6. conveyor;
7. vibrating sieve.

Tape cutter

You can buy equipment in parts, you can in the complex. For example, it seems to be a very profitable and reasonable business idea to purchase a mini tire recycling plant.

mini plant

For example, the Alpha-tire-recycling/atr 300 automatic tire recycling line can process up to 4,000 tons of tires per year, while producing up to 3,000 tons of crumb rubber. It can successfully and profitably work in settlements with a population of more than 150,000 people.

The cost of purchasing and installing the line is 10.1 million rubles.

The final product will be:

• rubber crumb 3 fractions: up to 1 mm, 2-3 mm, 4-5 mm;
• metal cord;
• textile cord.

How the ATR-300 line works

On the initial stage the tires are cut into pieces and fed along the conveyor to the initial grinding shredder. Then the whole process proceeds without human intervention. From the primary processing shredder, the tire pieces enter the block, where they are crushed into smaller ones with the metal cord being removed from them at the same time. The scheme for further processing of tires provides for the passage of the resulting rubber chips through a set of impact crushers through pneumatic transport.

Location of ATR-300 Tire Recycling Line

The result is the receipt of all three components of processed products with lower energy consumption and lower cost than on semi-automatic lines. In addition, the compactness of the line, due to the absence of belt conveyors, makes it possible to conveniently place machines and more efficiently perform their maintenance. The automated process ensures environmentally friendly production, no harmful emissions and emissions during crushing are observed.

Tire Recycling Line ATR-300

The number of personnel serving the line with a monthly capacity of 150 tons should include 10 employees with a payroll fund of about 350 thousand rubles.

The business plan for tire recycling should be calculated taking into account the receipt of minimum volumes of finished products.

Number of recycled tires per month: 150 tons.

Crumbs received: 110 t.

Steel cord received: 20 t.

Textiles received: 20 t.

Monthly income

Sale of crumbs (110 tons at an average price of 16 rubles / kg) = 1.76 million rubles.

Sale of steel cord (20 tons at a price of 5.0 thousand rubles / ton) = 100 thousand rubles.

Sale of textiles (20 tons on average at a price of 2.0 thousand rubles / ton) = 40.0 thousand rubles.

Acceptance of used rubber for processing (100 tons at the lowest price of 1,300 rubles / ton) = 130.0 thousand rubles.

Total: minimum income per month = 2.03 million rubles.

Expenses

Staff salary (per month) with insurance payments = 350 thousand rubles.

Purchase of bags for packaging (with a capacity of up to 30 kg) at the rate of 8 rubles / bag = 40.0 thousand rubles. per month.

Payment for electricity (120 kW / t x 4.5 rubles / kW) = 80.0 thousand rubles.

Maintenance of the line, replacement of knives, household expenses = 130.0 thousand rubles.

Rental fee (300 sq. m. x 150 rubles) = 45.0 thousand rubles.

Total expenses: 645 thousand rubles.

Monthly minimum profit: income (2.03 million rubles) - expenses (0.645 million rubles) \u003d 1.385 million rubles.

This indicator can be increased by increasing the volume of processing, prices for sold crumbs, receiving raw materials and other components.

Franchise

One option is to buy a franchise.

A franchise is the right to open a business for a certain fee under the auspices of a brand or simply a more experienced franchisor, using its technologies, work system, and equipment.

What does a tire recycling franchise give? By signing an agreement with the franchisor, you get:

1. A set of equipment for processing tires into crumb rubber.
2. Equipment for the production of rubber tiles is also possible.
3. Inventory, tools and spare parts necessary for work.
4. Carrying out by the franchisor the installation of equipment and commissioning.
5. Assistance in the repair of equipment.
6. Training.
7. Customer base of raw material suppliers.
8. Quality control of manufactured products.

The franchise fee can be from 3 million rubles. In addition, you will have to pay a certain percentage of your income to the franchisor.

Supply of raw materials

Despite the fact that there are many raw materials for recycling car tires, it is necessary to think over their uninterrupted delivery to the place of production. Your main suppliers are companies that have a significant fleet of vehicles, as well as tire fitting companies, landfills.

It is better to conclude contracts with them for the recycling of old tires on an ongoing basis. You can organize collection points for used tires. Acceptance is made for a fee, the amount of which varies from one thousand to five thousand rubles per ton.

Sales of products

Rubber crumb is a demanded material. It is used as:

• bases for the production of coatings in stadiums;
• material for the construction of children's playgrounds and sports grounds;
• sports equipment fillers;
• the main material in the manufacture of paving slabs. Its share in the tile is 80%.
• filler when creating bituminous roofing, forming
• fiber-reinforced concrete for pouring foundations, production of road surfaces;
• regenerating agent when retreading old tires.

Rubber tiles are widely used not only for flooring in gyms, playgrounds and school yards, but also suburban areas

Manufacturers of rubber products, companies working for the oil industry may also be among the consumers.

What problems may arise

As in any business, a project can turn out great on paper, but in practice, an entrepreneur expects real failures. To minimize the losses from them, the risks should also be calculated in advance and the solution of problematic issues should be considered.

The main problem is disruptions in the supply of raw materials. For some reason, a queue of cars overloaded with old tires does not line up at the gates of your factory. The solution to the problem must be found in the timely conclusion of long-term contracts with motor transport enterprises. One option is to open a mini-factory directly on the territory of a major carrier. It is worth considering a system of points for collecting used tires.

Acceptance of tires for recycling

Frequent equipment failure. This most often happens with used machines or due to human error. It is necessary to establish strict observance of the terms of maintenance of all units of the line, to regularly instruct workers.

Problems with the sale of products. Its solution must be found in long-term agreements with consumers, participation in various tenders for the supply of crumbs for the manufacture various types urban sites.

The main indicators of the business plan with calculations, market analysis indicate that the production of automobile tire processing is a profitable and fairly quickly payback enterprise, which also brings great benefits to the environment.

In this material:

A business plan for recycling tires into crumbs will help determine the initial investment for renting or buying premises, and purchasing equipment. Market monitoring will minimize risks and downtime, competition in this area is low. The launch of the line quickly pays off, the ability to purchase raw materials at a very low prices(and even earning on it!) makes the business economically profitable.

Crumb rubber production

Recycling car tires with further production of crumb rubber is a profitable business, but this niche is still relatively free. If there are funds to purchase equipment, the mini-factory will not be idle due to lack of raw materials: used tires are not so easy to dispose of, many enterprises and individual entrepreneurs are faced with real problem. Competently organized business will also allow you to earn money on the collection and export of tires.

Business Description

Waste tires are waste of the 4th hazard class. Legislative relaxations have simplified their disposal, which often comes down to either long-term storage or tire burning. In both cases, the environment is damaged, there is a danger of rodent reproduction and the spread of infectious diseases.

Environmental services pay close attention to the storage of used tires. The materials that were used to make them take decades to decompose, and the tire recycling business is a modern solution to the problem. Besides, recycling rubber reduces oil consumption. The problem of tire recycling is acute all over the world, and Russia is no exception. Penalties for improper storage of used tires are high for both enterprises and individual entrepreneurs.

Competition analysis

Paradoxically, in small towns city ​​authorities are faced with the need to organize landfills, look for ways to solve the storage and destruction of tires with minimal damage to nature. An individual entrepreneur who solves an urgent problem by organizing a mini-factory for tire recycling will most likely receive support from the authorities, both legal and material.

Competition in business today is low, small enterprises operating on the basis of factories of the Soviet period are rarely equipped with modern equipment. The problem of recycling is often solved with the help of fire, and you can make money on this garbage that no one needs. The problem is in the mentality (the idea that it is possible and necessary to benefit from the separate collection of garbage that has not fully fit into the minds) and in the start-up capital.

Activity registration

Tire recycling can individual entrepreneur licensed:

• fire service;
• Rospotrebnadzor;
• environmental inspection;
• body for labor protection;
• regional authorities.

In addition, contracts with suppliers and buyers of finished products, employment contracts with staff and medical books with a medical examination will be required.

As a taxation system, the USN is preferable.

Room selection

The choice of a suitable room rests primarily on its location: the territory of the urban industrial zone is suitable for such purposes, far from residential buildings, but within the city. The closer the enterprise is located and the more convenient the entrance to it, the higher the probability of delivering tires to the site by those who are interested in this.

In other cases, you will have to pick up the tires yourself, and these are additional costs for fuel and vehicle maintenance.

It must be said that processing plants may well be located in close proximity to residential areas, but in this case they must comply with all sanitary standards and not cause any trouble to residents. Otherwise, complaints and “showdowns” from the inspection services will follow, which in one way or another will negatively affect business development.

The size of the room depends on the choice of equipment, you will also need a room for staff, a shower room and a bathroom, a warehouse for storing finished products. Tires can be stored outdoors, with or without shelter, provided the area allows.

Buying a property or limiting yourself to rent is a voluntary choice for everyone. Own premises can be converted "for yourself" with the expectation of long-term use, on the other hand, if there is no confidence in the prospective development of the business, you can limit yourself to renting (for example, subsequent purchase).

The question of price is relevant, but very individual: renting and buying a building even within the same locality varies greatly, not to mention the spread of prices in a metropolis and a small town. Before making a choice, it is worthwhile to thoroughly study this issue, not limited to official announcements in the media, not shunning word of mouth and reviews from acquaintances or business partners.

Necessary equipment

To start production, you will need to install and adjust an automatic line, the processed products will be:

• rubber crumb of several fractions;
• metal cord;
• textile cord;
• pyrolysis carbon black;
• synthetic fuel (liquid phase) and gas.

Necessary equipment:

1. Tire shredders. Machine tools for removing steel cord and its separation, cutting rubber, grinding it.
2. Separators. Vibrating screens of various types of cleaning.
3. Transporters. Belt, bucket, screw.

A set of machines for grinding tires will cost, on average, 1,250,000 rubles.

The cost of the line depends on the performance and power, as well as on the "brand name" of the manufacturer. The simplest equipment will cost from 2 million rubles. Modern high-performance equipment allows processing up to 1.5 tons of raw materials per hour.

Recruitment

To determine the number of employees, you need to decide what schedule the enterprise will work on: shift production of crumbs around the clock without days off, or work only on a day shift with a five-day work week.

In the first case, you will need workers for 3 shifts (2 people each), a foreman for each shift, a technician for servicing (adjusting, repairing) equipment, a tire receiver (he is also a raw material warehouse manager), a manager who combines the position of a purchase and sales manager crumbs.

Daytime work involves recruiting one shift - 2 workers, 1 foreman, otherwise everything is the same. Immediately or over time, you can open your own tire shop (a source of used tires), but it will justify itself only if the processing plant is located within the city.

Workers and foremen are specially trained to work with the equipment. Such services can be provided by the manufacturer.

Business promotion

Given the specifics of the business, it is worth taking care of advertising for your services in advance. In addition to working directly with stakeholders (enterprises, tire shops, individual entrepreneurs), it is worth paying attention to advertising in the media, opening your own website and posting information on third-party portals. It may seem that an information campaign is an unnecessarily costly side of things, but the faster the general public learns about the work of the workshop, the greater the likelihood of a quick return on investment.

Financial plan and profitability

Based on approximate calculations, then at first the main costs will be (per month):

• rent of premises - 15 thousand rubles;
• payment for electricity, water supply, sewerage - 20 thousand rubles;
• fund wages- 100 thousand rubles;
• advertising campaign - 5 thousand rubles;
• maintenance / repair - 2 thousand rubles.

In addition, you need to add the purchase of machine tools - 10-15 million rubles; taxes and loan payments.

When recycling tires, the crumb yield is about 70% of the mass, the rest is textile and metal cord, they also go into business, the prices for the purchase of recyclables and, especially, scrap metal are quite high.

The cost of a kilogram of rubber crumb, on average, is 20 rubles; textile and metal cord with rubber content up to 5% - 2-3 rubles.

The tire recycling business has its pros and cons, whoever wisely takes the risk and takes the relatively free market space will reap their profits. Provided that the business plan is thought out and calculated to the smallest detail. First of all, the question concerns the supply of raw materials (will not powerful, promising high profitability through turnover, expensive equipment be idle?) And the sales market (rubber crumb is widely used in various sectors of the economy, but you need to be able to interest consumers in the price, quality of goods and services ).

Worn-out car tires are a problem for mankind.

If the situation does not change, their disposal will soon require more funds than production, where the cost of materials reaches 75% of the cost of the product.

Therefore, today the problem is quite acute.

Important recyclables

The use of waste tires and other rubber products is possible in a variety of industries. For example, to generate combustible gas through the thermal splitting of residues of hydrocarbons synthesized from oil. With it, you can not only heat, but also generate electricity, as is done in France and a number of other Western countries.

Tire recycling is also needed to add their particles in the form of a filler to asphalt bitumen, create all kinds of technical mastics, as well as for the thermal decomposition process -. The liquid product of pyrolysis goes as an additive to rubber (plastic), while an adsorbent is obtained from the solid. It's pretty promising direction, because the output is a valuable product.

But pyrolysis has not yet received industrial scale, and the activities of scientists alone without the participation of production workers and businessmen in this area are not enough. The idea of ​​producing regenerate has been recognized in the world as untenable for some time now, and work on this part has been suspended.

A very important task is the transformation of outdated polymer products (containers, packaging, films, automotive tubes and tires) into new ones.

The problem of recycling and recycling used tires in Russia

Worn-out tires are the most massive organic ballast, and they don't decompose well. In the context of the globalization of the economy, the issue of unification of the nomenclature becomes relevant.

Thus, products that are in use in the post-Soviet space do not meet foreign standards. The structure of matter and products is different, and rubber waste of Russian origin is more difficult to bring to mind than, say, European ones. The reason is that domestic tires are additionally reinforced with a radially synthetic cord. This is a mixed type (rubber + metal + textiles) with a large admixture of textiles.

Abroad, more than half of the slopes contain an all-metal type of cord, that is, there is no textile in them or is contained in such an amount that it can be neglected. We have the largest mass of tires that need to be disposed of in freight transport, followed by “passenger cars”; special tires (including aviation ones) are almost never recycled. And abroad - the opposite is true.

Thus, approaches to solving the problem of recycling in the Commonwealth independent states and developed countries cannot but differ. There are the following conclusions:

1. It has been verified empirically that the European, American, Japanese-Chinese tools are not suitable for our conditions.
2. Due to the presence of textiles in the waste, it is necessary to use methods and techniques that are an order of magnitude more complicated and expensive than required for servicing products with an all-metal cord type.
3. With the help of multi-stage processing technology for products with a mixed type of cord, imported tires can be processed.

Existing technologies

Extending the life of automotive "shoes" has 2 goals - to save on organic resources and improve the environment. The meaning of the operation is to build a new layer on the old base. This applies mainly to the tread, because. it is he who experiences the most friction. But what to do with tires that cannot be restored? Utilize with maximum effect! For this there are special methods:

• products are mechanically crushed to a coarse mass without the breakdown of molecular relationships;
• the crystal lattice of the rubber substance is partially destroyed with the appearance of regenerate;
• pyrolysis occurs (the final decomposition of the elemental base during the combustion of rubber goods in gas generator complexes).

Hot and cold tire retreading

Foreign experience in the restoration of the "hot method" concerns auto and aircraft tires. Moreover, the latter, due to a more solid frame, with proper use, are able to live 5-6 lives, as, for example, Goodyear brand products. But the cost of restoring tires is comparable to the cost of a tire from scratch, which makes this method unpopular in the US and Europe. In the Russian Federation, the “hot” method is not in demand today also because of the domestic features of damage to skates, which are so impossible to eliminate. This type of recovery technology includes:

• cleaning the base of the old tread;
• smearing it with glue;
• placement of the raw tread on the prepared surface;
• the operation of vulcanization in a mold with a predetermined duration of heating.

The "cold method" has been successfully used for the last 20 years for tires with a steel cord in the carcass. On the European continent, 46% of trucks drive on secondary tires of this type, and in Norway, Sweden, Finland, in general, 60-70%. In our country, only imported frames are subject to repair by this method on foreign equipment. It is younger and cheaper than the "hot" one, has high quality characteristics, providing individual tires with 3-4 work cycles. This type of recovery technology includes:

• revision of frames, processing of local defects;
• cleaning the base of the old tread on a roughing machine, repairing damage;
• lubrication of the frame and raw rubber with glue;
• combining with them and pressing a pre-heat-treated tread tape with an arbitrary pattern;
• the imposition of a special reinforced shell that fixes the protector on the frame;
• vulcanization in hot air environment not higher than 100° 6 hours;
• verification of the refurbished product.

Recycling tires unsuitable for their intended use

There are several such ways.

burial

Today, about 80 million tons of used tires have accumulated on Earth. There is an opinion that every year this figure will increase by 10 million tons. Europe suffers from this disaster more than others, where 3 billion pieces are stored. used tires.

Of the total volume of car ramps that have become unusable, only about a quarter are used in the future as recyclable materials. The rest of the environmentally harmful material due to unprofitable processing technologies is stored in special landfills and spontaneous dumps, representing great danger. It is these problem areas that act as a source of toxic fires, which are difficult to extinguish due to the persistent flammability of synthetic rubber.

The expediency of civilized recycling of tires is explained by the lack of space for their burial, especially in East Asia. And in the EU states, such a burial is not allowed by law (the tire decomposes in the ground for about 150 years).

Grinding of worn tires to obtain crumb rubber

One of the most common methods of disposal is the processing of rubber goods into crumbs. It is simple and rational due to the observance of the basic technological parameters of rubber while maintaining molecular bonds. Although it has one drawback - unprofitability.

Grinding technologies

The following grinding technologies are divided:

• shock wave (explosive circulation) with 2 stages of processing,
• mechanical with 4 steps.

The first one is unique because is based on the unconventional principle of crushing with the circulation of explosion products, which is recognized as the most effective and inexpensive destructive means. Equipment, factory products are represented by the Russian brand explotex.

The second is considered less progressive, but no less high quality. At the initial stage, "chips" with a particle size of 10 to 50 mm are obtained. Then, for the purpose of separation, they are transformed into 3-10 mm granules. The crumb is freed from cord, fiber, foreign elements on sieves, in drums and separators.

Methods for modifying crumb rubber

Distinctive feature crushing waste is that the result is smooth, as if broken glass, particles. To improve the functional characteristics of the produced substance, the surface of the particles is modified, making it softer and looser. This is a complex physical and chemical process using powder, beam, laser, steam technologies.

Areas of use for crushed rubber

Every year, at least 34 million tires are turned into shreds, which are used to build coatings and surfaces, add to mortar, and make tires, mats, and soles. And this costly method has successfully taken root in the laying of roads.

Recycling of used tires

In Russia, only 7% of used tires are recycled, while the global average, we recall, is 23-30% (which is perhaps not so much for the 21st century). Question further fate of worn tires became especially acute with the advent of steel cord frames. And with the fall of the "Iron Curtain", in addition, a stream of low-grade German products poured into our country. In the Russian Federation, about 1 million tons of rubber materials annually become unusable and remain unclaimed, and 9/10 of this amount are automobile ramps.
The share of the capital and St. Petersburg with the region accounts for almost 200 thousand tons.

The main reason that an industrialized state like Russia has a percentage of tire recycling comparable to the recycling rate in African countries is the Soviet mental legacy. We are traditionally not accustomed to investing in economical secondary production, and there are no prerequisites for stimulating it at the government level, with rare exceptions.

The adopted law on waste generally had a positive impact on the implementation of civilized programs for the disposal of rubber goods. But what exactly can the Russian champions of the “waste-to-profit” principle write down as a “rubber” asset? Let's list.

An enterprise with a stable functioning reactor has been created in Kaliningrad, where high-quality fuel oil is generated through pyrolysis as a heat engineering fuel, as well as a substitute for activated carbon.

In the first 15 years of independence, with a complete rejection of burning tires, the volume of crushed "used" tires increased from 5 to 10%, and now it reaches 30%.

Tushino Machine Works has mastered the production of crumbs with two lines with an installed annual capacity of 5 thousand tires, and has also increased the production of tires that are especially relevant in this moment and panels for railway crossings.

Ecological production facilities with imported manufacturing equipment were put into operation in Tver, Kursk, Vyazma, Samara.

In Primorye, CJSC "Templar Center" is engaged in the manufacture of roofing materials from crumbs. Moreover, it revives a complete closed cycle for the production of regenerate by the thermomechanical method.

It is noteworthy that this leap was made possible due to the use of a mechanical method of grinding at normal temperatures. Alternative (cryogenic) technologies are not widespread all over the world due to the high cost of low-temperature crumbs, and efforts to use the power of an explosion or "ozone knife" are experimental in nature. An interesting project for high-speed processing without preliminary cutting and crushing was proposed by the Orenburg developers, but the future will show how viable it will be.

This equipment is used for mechanical processing of old tires into crumb rubber under normal temperature. Metal cord and textile cord stand out.

This tire recycling plant includes all the necessary equipment to make crumb rubber out of tires.

Tire situation

There is a continuous accumulation of old worn-out tires. Only about 20% of their total number is recycled. Worn-out tires are the largest production of polymer-containing waste products that are not subject to natural decomposition. Therefore, the recycling and recycling of end-of-life tires is of the utmost economic and environmental importance. Besides is a profitable business.

Old tires are a valuable polymer raw material: 1 ton of tires contains about 700 kg of rubber, which can be reused for the production of fuel, rubber products and building materials, and for many other purposes.

The problem of recycling tires is very acute, and recyclers of old tires are often asked to accept tires for recycling.

Main benefits for you from this tire recycling line:

1. Availability of raw materials. Tires and old tires will get you cheap or free.
2. Simplicity. Recycling equipment uses the force of friction. No chemical reactions.
3. Demand for products. You can make products from crumbs yourself or sell them.
4. Payback. The line pays off in half a year - a year.
5. Compactness. Requires only 200 m² + storage space.
6. Reliability. The equipment is simple, only mechanics, there is nothing to break.
7. Durability. The equipment requires a minimum of maintenance, it will work for you for years.
8. Environmental friendliness. Only the final product stands out - crumbs, iron, textiles. Gases, noises, chemistry are not present.
9. Few staff. Requires only 2-5 workers, no qualification needed.

Line Description

tire recycling tire recycling equipment in crumbs, the main anditrating complex with a slight modification

This mini plant recycles old wheels into crumbs, textiles and metal cord is removed. Equipment for the processing of tires into crumb rubber uses mechanical grinding on roller grinders. The line processes tires up to 1200 mm in diameter, these are all passenger and most truck tyres. It is possible to increase the diameter up to 1700 mm

The incoming product is old tires, as well as rubber products (conveyor belt, gas masks, etc.). Outgoing product:

1. Rubber crumb size fractions
2. Shredded textiles in the form of cotton wool
3. Crushed high alloy steel

On average, depending on the quality of the tires, 60-80% of the crumbs are obtained, the rest is metal and some textiles.

The characteristics of the crumb are highly dependent on the feedstock. Sample data:

1. Rubber crumb purity 99.8%
2. Metal inclusions less than 0.1%
3. Inclusions textile fiber within 0.2%
4. High purity separation by fractions
5. Black color
6. No thermal oxidation effect

Chip Size: Tire Recycling Equipment produces crumbs up to 0.8mm in size. Standard productivity is calculated based on 1 mm chips. It can be made smaller or larger by changing the screens and the distance between the rolls, but this affects productivity (the smaller it is, the longer the production time). Below 0.8 mm it becomes unprofitable, to obtain rubber dust up to 0.1, you can purchase a grinder.

The output of the crumb by fractions depends on the quality of the tires (hardness and wear) and the size of the crumb. The sieves determine the maximum size. That is, if the sieve is 1 mm, then the crumb will be the bulk of 0.8-1, the rest is less. Usually put 1-3 mm.
If further distribution into fractions is needed, then it is possible to purchase a vibrating separator.

The line consists of two sections: a preparation section and abrasion section. The line includes the following equipment:
1. seat ring cutter
2. wheel cutter for tape
3. tape cutter into blanks
4. main grinding unit
5. coarse vibrating sieve
6. magnetic separator (2 pcs)
7. air separator
8. conveyors (3 pcs)
9. electric board
10. fine vibrating sieve
11. seat ring squeezer

Attrition rollers for rubber crumb processing line
(main unit of the line)


wheel preparation machines: seat ring cutter, belt cutter, chunk cutter, seat ring squeezer

Mini Tire Recycling Plant, main technical parameters:
Performance- from 200 to 1000 kg of crumbs per hour (depending on the model of equipment, raw materials and the required crumb size). This is 1200-1500 tons per year (300 days, 22 hours a day).
The crumb size is adjusted by changing the sieves. Two factions at the same time.
Matalocord per shift (10 hours) - up to 200 kg.
Textilecord per shift - up to 1000 kg. (depending on raw materials)

Process technology:
1. The seat ring is removed from the tire.
2. Metal is squeezed out of the cut ring (to separate the remaining rubber)
3. The tire is cut in a spiral into a tape 3-5 cm wide.
4. Cut out the second seat ring
5. Reducing the thickness of the rubber band
6. The tape is cut into blanks
7. Production of powder and crumbs from blanks (grinding on rolls)
8. Separation of crumbs into fractions
9. Removing the textile cord
10. Grinding of pure rubber and rubber with a textile cord.
11. Warehousing of finished products

Necessary amount of workers- 2-5 people.
Wheel preparation area up to 24-inch pieces - 2-3 people.
Eraser area - 1-2 people
Engineer master (control in general) - desirable, but not required. Skilled workers are not required.
These numbers are standard, depending on the performance and process, it can be either more or less. The minimum number of workers is 2 people. When fully loaded up to 6 people.

Timing and delivery:
Production time: 45 days
Delivery: 30-60 days (depending on the city of delivery)
Transportation: the line fits in one 40ft high and one 20ft container

loading equipment for recycling old tires
Installation and commissioning:
The equipment is installed indoors
Foundation - required for main grinder (for rollers)
Area - 200 m² (+ warehouse for raw materials and finished products) Installation time - 2 weeks
The manufacturer's specialist for commissioning and training of personnel is desirable, but not required, all necessary instructions are issued. The buyer pays for the round-trip ticket, expenses and travel engineer.

Technical specifications

(minimum performance configuration is indicated)


Side view of the main grinding unit
1 - Coarse vibrating screen drive
2 - Receiving raw chute
3 - Feed conveyor
4 - Magnetic separator
5 - Air separator mounting frame
6 - Fine vibrating sieve
7 - fine vibrating screen drive
8 - Fine fraction conveyor
9 - Coarse vibrating sieve
10 - Main eraser
11 - Eraser fine tuning mechanism

The use of crumbs

Rubber crumb obtained by recycling old tires has numerous and promising areas for further use. With the effective organization of marketing support for production, this definitely guarantees its fast and sustainable implementation both in domestic and foreign markets.