CRUMB RUBBER FROM SCRAP TYRES (PRODUCTION RATE – 24 TONS PER DAY)
[EIRI/EDPR/4564] J.C.: 2781XL
INTRODUCTION
Crumb rubber is the name given to any material derived by reducing scrap tires or other rubber into uniform granules with the inherent reinforcing materials such as steel and fiber removed along with any other type of inert contaminants such as dust, glass, or rock.
Crumb rubber is manufactured from two primary feedstocks: tire buffings, a byproduct of tire retreading and scrap tire rubber. Scrap tire rubber comes from three types of tires: passenger car tires, which represent about 84 percent of units or approximately 65 percent of the total weight of U.S. scrap tires; truck tires, which constitute 15 percent of units, or 20 percent of the total weight of U.S. scrap tires; and off-the-road tires, which account for 1 percent of units, or 15 percent of the total weight of U.S. scrap tires. End product yields for each of these tire types are affected by the tire’ s construction, strength and weight. On average, 10 to 12 pounds of crumb rubber can be derived from one passenger tire.
Overall, a typical scrap tire contains (by weight):
70 percent recoverable rubber
15 percent steel
3 percent fiber
12 percent extraneous material (e.g., inert fillers)
Crumb rubber is not a finished rubber product, but it is only a refined form of raw rubber. For the production of crumb rubber, unlike in the case of sheet or crepe rubber improved processing methods.
Since crumb is technically graded, the world market shows a preference and attaches a premium to crumb over the conventional sucked sheet are crepe. It has been visualized that crumb rubber is a good substitute for synthetic rubber using to its uniform quality and guaranteed properties with regard to dirt content, plasticity etc. There is a ready market for crumb rubber by the manufacturers of rubber products of particularly the Tyre manufacturing units in view of its superiority over the conventional grade of sheet rubber.
By the application of heat and chemical agents followed by intense mechanical working to ground vulcanized scrap or worn-out rubber tires, tubes and waste rubber articles a substantial regeneration on devulcanization of the rubber compound to its original plastic state is affected, thus permitting the product to be compounded, processed and devulcanized. There are several types of rubber powder made in different ways. They may be lightly vulcanized and may contain appreciable quantities of anti-agglomerating agents to prevent massing on storage. The trend now-a-days is towards automation in production of rubber goods during handling, mixing and processing.
COST ESTIMATION
Plant Capacity 24 MT/Day
Land & Building (4035 sq.mt.) Rs. 4.64 Cr
Plant & Machinery Rs. 3.11 Cr
Working Capital for 0.5 Months Rs. 47 Lac
Total Capital Investment Rs. 8.62 Cr
Rate of Return 37%
Break Even Point 49%
CONTENTS
INTRODUCTION
CRUMB RUBBER
UTILIZING CRUMB RUBBER FROM SCRAP TYRES
CRUMB RUBBER RECYCLING & GRADING
USES/APPLICATIONS
PROPERTIES
CRUMB RUBBER STANDARD & GLOSSARY OF TERMS
MARKET OVERVIEW
STANDARD OPERATING PROCEDURE
MOEF PERMISSION FOR THE IMPORT OF USED TYRES IN INDIA
MOULDING TECHNOLOGY
SPRAY TECHNOLOGY
BOND AGENT SELECTION AND MIX DESIGN
SPRAYING DEVICES AND PROCESSES
SPECIFICATION OF CRUMB RUBBER
MANUFACTURERS/SUPPLIERS
MANUFACTURING TECHNOLOGY
MANUFACTURING PROCESS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT & MACHINERIES
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
SEWAGE AND WASTE WATER EFFLUENT
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
ANTICIPATED ENVIRONMENTAL IMPACTS
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
PRELIMINARY LAYOUT
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
