RECLAIM RUBBER (RUBBER RECLAIMATION UNIT)
[EIRI/EDPR/1347] J.C. 110
INTRODUCTION
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 loosing 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 15 MT/Day
Land & Building (5000 sq.mt.) Rs. 5.62 Cr
Plant & Machinery Rs. 2.10 Cr
Working Capital for 3 Months Rs. 4.89 Cr
Total Capital Investment Rs. 13.08 Cr
Rate of Return 55%
Break Even Point 36%
CONTENTS
INTRODUCTION
WHAT HAPPENS DURING RECLAIMING
USES APPLICATION AND ADVANTAGES
RAW MATERIALS
RUBBER WASTE (USED TYRE AND TUBE SCRAP):-
BIS SPECIFICATIONS
MARKET SURVEY FOR RECLAIM RUBBER
SO WHAT EXACTLY IS RECLAIM?
EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE
SOME FORMULATIONS FOR RUBBER RECLAIMED
RECLAIMED RUBBER
GENERAL
FINISHED RECLAIMED RUBBER:-
MANUFACTURING PROCESS OF RECLAIMED RUBBER
METHOD OF RECLAIMING RUBBER
FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER
TESTING & EVALUATION OF RECLAIMED RUBBER
THE PRINCIPAL TESTS APPLICABLE TO RECLAIMED RUBBER ARE:-
OTHER METHODS
METHOD FOR RECLAIMING RUBBER
APPARATUS
EXAMPLE OF APPARATUS
TEMPERATURE
REVULCANISATION
PROCESS OF RECLAIMING RUBBER AND ITS REFINING
DESCRIPTION OF REFINING EMBODIMENTS
COMPARATIVE RECLAIMING DATA
METHOD OF PRODUCING RECLAIMED JOINT SHEET
METHOD FOR RECLAIMING CURED RUBBER SCRAPS
PLANT LAYOUT
COMPLETE PLANT AND MACHINERY SUPPLIER FOR RECLAIM RUBBER
DETAILS OF RECLAIM RUBBER MACHINERY
RUBBER GRINDER MILL
RUBBER REFINER MILL
PRE - REFINER MILL
DE-BEADER MACHINE
STRAINER
AUTOCLAVES
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR RECLAIM RUBBER
PLANT AND MACHINERY SUPPLIERS
RUBBER MANUFACTURING MACHINERY
RUBBER MIXING MILL
VIBRATING SCREENS
AUTOCLAVE, OVENS,
CONVEYOR BELT
CHOPPER MACHINE
MERIT INDUSTRIES LIMITED
TINYTECH PLANTS
PORTABLE GENERATOR
CHEMICAL STORAGE TANKS
RECLAIMED RUBBER
SUPPLIERS OF RAW MATERIALS
RUBBER MANUFACTURING CHEMICALS
COAL TAR PITCH
SODIUM HYDROXIDE
BENZENE
CARBON BLACK
ZINC OXIDE
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)