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