RECLAIM RUBBER
(RUBBER RECLAIMATION UNIT)
[CODE NO.4250]
Reclaimed or Re-generated rubber is the product resulting from the treatment of ground vulcanized scrap rubber tires, tubes and miscellaneous waste rubber articles by the application of heat and chemical agents, followed by intense mechanical working. The regenerated rubber has almost the original plasticity of virgin rubber, permitting the same to be compounded, processed and re-vulcanized or reused.
In reclaiming of scrap vulcanized rubber, the scrap is normally ground and is then treated with the application of heat, chemical peptizers and is then intensely worked upon mechanically to partially de-vulcanize (break the bonds between rubber polymer chains) the rubber component. This partially de-vulcanized product is commonly called reclaimed or re-generated rubber and can be compounded, processed and re-vulcanized much like virgin rubber. The availability and processing characteristics of suitable scrap sources has dictated the types of reclaim produced. Reclaimed rubber has become widely accepted as a raw material which possesses processing and economic characteristics that are of great value in the compounding of natural and synthetic rubber compounds.
Re-generated or Reclaimed rubber is produced by partial de-vulcanization of rubber granulate obtained from end-of-life tyres and other rubber products. The regenerated rubber has almost the original plasticity of virgin rubber, permitting the same to be compounded, processed and re-vulcanized or reused.
Regeneration can occur either by breaking the existing cross links in the vulcanized rubber (partial de-vulcanization) or by promoting scission of the main chain of the polymer (breakage of C-C bonds) or a combination of both processes.
Partial De-vulcanization means selective cleavage or breakage of Disulphide (S-S) chemical bonds (see: Figure below) leading to the separation of natural rubber polymer chains using heat, mechanical shear force and assisted by peptizers (like process oil & pine tar oil) and reclaiming agent (like Disulphides). The de-vulcanization is partial i.e. some and not all Disulphide (SS) chemical bonds are broken. The main mechanism of de-vulcanization is by means of thermal – oxidative degradation and high shear force acting on the material.
Figure: Vulcanized Natural Rubber (with Sulphur)
By the application of heat and chemical agents followed by intense mechanical working to ground vulcanised scrap or worn out rubber tires, tubes and waste rubber articles, a substantial regeneration on devulcanisation of the rubber compound to its original plastic state is effected, thus permitting the product to be compounded, processed and revulcanised. Reclaiming is essentially depolymerisation and misnomerically called "devulcanisation" although combined sulphur is not removed. By this depolymerisation, the reclaimed rubber shows decreased resistance to deformation at ordinary temperature; thus losing its elastic nature and become less resistant to compression, stretching or swelling. Reclaimed rubber was born because a secondary source of rubber was urgently needed. Entire rubber industry was growing so fast in the early days and there was no enough crude rubber to substantiate the demand. Reclaim rubber soon become indispensable. Apart from this, tire pose a disposal problem and therefore utilized as basic raw material in the form of ground vulcanised waste (crumb rubber) or converted to reusable state-reclaimed rubber.
Because of short break-down and mixing time, the power consumption during break-down and mixing, low temperature required in calendering and extrusion, non-critical calendering temperature penetration to fabric, tack improvement, minimising sulphur bloom, forming of uncurved stock, low swelling and shrinkage on extrusion and calendering, low thermoplasticity, high rate of cure and cheaper rubber/filler are important considerations in the mind of the compounder in deciding upon regular use of reclaim for low cost, energy, conservation and efficient processing steps even with new generation polymers to achieve desired optimum properties. Reclaimed rubber is primarily used in the manufacture of cycle tyres, Rickshaw tyres, Battery Boxes, Automobile tyres and other moulded rubber goods.
COST ESTIMATION
Plant Capacity 24 Ton/Day
Land & Building (2 Acres) Rs. 4.08 Cr
Plant & Machinery Rs. 5.50 Cr
Working Capital for 1 Month Rs. 1.60 Cr
Total Capital Investment Rs. 11.65 Cr
Rate of Return 36%
Break Even Point 55%
INTRODUCTION
FIGURE: VULCANIZED NATURAL RUBBER (WITH SULPHUR)
WHAT HAPPENS DURING RECLAIMING
USES APPLICATION AND ADVANTAGES
ADVANTAGES OF RECLAIM RUBBER
RAW MATERIALS
RUBBER WASTE (USED TYRE AND TUBE SCRAP):-
B.I.S. SPECIFICATIONS
1. SCOPE:
2. REQUIREMENTS:
RECLAIMED RUBBER
3. PACKING:
4. MARKETING:
5. SAMPLING:
MARKET OVERVIEW FOR RECLAIM RUBBER
SO WHAT EXACTLY IS RECLAIM?
DIFFERENT MANUFACTURING PROCESS OF RECLAIM RUBBER
DIGESTER PROCESS
PAN PROCESS
HIGH PRESSURE STEAM PROCESS
BANBURY PROCESS
RECLAIMATOR PROCESS
CRUMB RUBBER AND RECLAIM RUBBER PROCESS
TIRE BEAD SEPARATOR
TIRE SHREDDER
CRACKER MILL
MAGNETIC METAL & NYLON FIBER SEPARATOR
FIBER SEPARATOR
RUBBER CRACKER MILL WITH MAGNETIC METAL SEPARATOR, BELT CONVEYER AND VIBRATING SIEVE
SEQUENCES IN CRUMB RUBBER AND RECLAIM RUBBER FROM WHOLE SCRAP TYRE
DEVULCANIZER (AUTOCLAVE)
KNEADING MIXING MILL
TWO ROLL MIXING MILL
STRAINER EXTRUDER
STRAINER EXTRUDER HEAD
REFINING MILL
EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE
TYPICAL COMPOUNDING RECIPES FOR INCORPORATING RECLAIMED RUBBER
MANUFACTURING PROCESS IN DETAILS OF RECLAIMED RUBBER
METHOD OF RECLAIMING RUBBER
FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER
TESTING & EVALUATION OF RECLAIMED RUBBER
A) CHEMICALS
B) PHYSICALS
RECLAIM RUBBER PRODUCTION FOR CROSS PLY TYRES
PROCESS FLOW DIAGRAM OF CRUMB AND RECLAIM RUBBER FROM TYRES /TUBES
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
DETAILS OF RECLAIM RUBBER MACHINERY
RUBBER GRINDER MILL
RUBBER REFINER MILL
PRE - REFINER MILL
DE-BEADER MACHINE
STRAINER
AUTOCLAVES
PRESSURE RATING:
TYPES OF DOOR:
TEMPERATURE INDICATION:
FORCED AIR CIRCULATION:
STANDARD ACCESSORIES:
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR RECLAIM RUBBER
SUPPLIERS OF RUBBER PROCESSING MACHINERY
SUPPLIERS OF RUBBER MIXING MILL
SUPPLIERS OF VIBRATING SCREENS
SUPPLIERS OF AUTOCLAVE, OVENS
SUPPLIERS OF CONVEYOR BELT
SUPPLIERS OF CHOPPER MACHINE
SUPPLIERS OF MERIT INDUSTRIES LIMITED
SUPPLIERS OF BOILERS
SUPPLIERS OF PORTABLE GENERATOR
SUPPLIERS OF CHEMICAL STORAGE TANKS
SUPPLIERS OF RECLAIMED RUBBER
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF RUBBER MANUFACTURING CHEMICALS
SUPPLIERS OF COAL TAR PITCH
SUPPLIERS OF SODIUM HYDROXIDE
SUPPLIERS OF BENZENE
SUPPLIERS OF CARBON BLACK
SUPPLIERS OF ZINC OXIDE
SUPPLIERS OF CHINA CLAY
BUYERS OF RECLAIM RUBBER
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)