Questions You Should Know about tire recycling machinery

What is tire recycling?

Tire recycling facilitates the recovery of valuable materials from end-of-life tires in an environmentally friendly manner, addressing both the significant waste issue and offering profit potential through resale to rubber goods manufacturers or by creating value-added products on your own.

Scrap tires can be processed into rubber in various sizes, from chips to crumb rubber and fine powder, meeting high demand across several industries. Successful tire recycling requires consideration of various factors such as minimum production capacity, value-adding technology, long-term contracts, and seasonality.

For more details, including material prices and financial insights, connect with our team of experts! We can assist you in identifying all aspects necessary for launching a successful tire recycling operation.

What is tire pyrolysis?

Pyrolysis is a long-established concept; however, tire pyrolysis has emerged as a rapidly growing market in recent years. Its potential to significantly contribute to a circular economy has attracted substantial investment and propelled technological advancements.

As with any developing market, while there are numerous success stories, there are also many misconceptions, unclear specifications, operational challenges, and inconsistent product acceptance. At Weibold, we continuously monitor industry experiences to identify best practices as the market evolves.

What are the output materials in tire recycling and pyrolysis?

Below, we detail the primary products derived from tire recycling and pyrolysis, along with their consumer goods applications.

1. Tire recycling output materials

   Standard rubber processing technologies produce three primary categories of recovered materials:

   • Tire rubber
   • Liberated steel wire
   • Synthetic textile

   Among these, tire rubber holds the most value, while steel wire and textile are considered by-products with limited profitability. Here’s a detailed breakdown:

   1. Tire rubber

      Key market factors include size and purity, particularly concerning the removal of steel and fiber.

      • Tire chips (≤50mm)

        Produced from rough tire shreds, these can either serve as tire-derived fuel (TDF) or be further processed into crumb rubber.

      • Wire-free rubber chips (38-16 mm)

        Known as rubber mulch, these chips are primarily applied in landscaping and playgrounds, where steel removal adds value.

      • Crumb rubber (16-3 mm and smaller)

        This granulate is devoid of fiber and steel, suitable for molded products, including playground mats and rubberized asphalt.

      • Fine rubber powder (0.85-0.15 mm)

        This high-purity material finds use in sealings, coatings, insulation systems, and more.

   2. Tire-derived steel

      Typically, 20% of a tire comprises high-quality steel wire— a valuable commodity. Advanced separation technology allows for reselling this to smelters.

      Although tire-derived steel is often sold at low prices, researchers indicate a substantial volume can contribute beneficially to concrete properties.

   3. Synthetic tire-derived textile

      Tires typically contain up to 15% fiber, which can serve as a supplement for tire-derived fuel, fiberglass, and absorbent cleanup needs. Currently, the market for these materials is evolving.

      Though not widely adopted, there’s potential for synthetic fibers used in tire reinforcement to control concrete curing early on and prevent explosive spalling during fires.

2. Tire pyrolysis products

   The main outputs from tire pyrolysis include:

   • Fuel oil
   • Recovered carbon black (rCB)
   • Steel wire
   • Synthetic gas

   The steel wire and synthetic gas are by-products, with the former being easier to sell. Conversely, synthetic gas quality proves inconsistent and less marketable.

   Fuel oil and recovered carbon black are commercially promising products, warranting further exploration:

   1. Fuel oil

      Approximately 35-45% of output weight in tire pyrolysis is oil. Applications encompass maritime fuel and stationary engine fuel, though stringent regulations may necessitate further purification.

      Effective utilization often requires compliance with local environmental standards, particularly regarding sulfur content.

      Weibold's team is available to assist with the technical requirements necessary to establish a successful pyrolysis operation, ensuring compliance with industry standards.

   2. Recovered carbon black

      Accounting for 30-45% of pyrolysis output, rCB is increasingly utilized in energy recovery applications and manufacturing for paints and rubber products. Marketing this material may necessitate post-pyrolysis treatment for optimal value.

What are tire recycling and pyrolysis technologies?

Below, we discuss various production methods and the commonly utilized equipment in the tire recycling and pyrolysis sectors.

1. Tire recycling

   Meeting the diverse requirements for recycled rubber necessitates processing systems capable of creating products with specific characteristics suitable for myriad applications.

   Shredding, grinding, and milling technologies form the backbone of these processes, where the quality of equipment significantly influences the range of recycled materials.

   Selection of technology directly impacts rubber granulate quality:

   • Size
   • Shape
   • Surface
   • Purity
   • Output volume
   • Final product cost

   Customer acceptance often hinges on these quality aspects, while output quantity and cost determine the overall success of a tire recycling enterprise.

   Successfully converting used tires into rubber granulates and powders has historically involved two principal technologies:

   1. Normal temperature (ambient) process

      This encompasses all mechanical shredding conducted at room temperature, primarily through knife shredding, leading to smaller sizes before classification through sieving technology. Roller mills have recently gained traction amongst recyclers for producing rubber powders.

   2. Cold temperature (cryogenic) process

      Utilizing liquid nitrogen, this approach cools rubber to approximately minus 90 degrees Celsius until it becomes brittle. The frozen rubber can then be efficiently fragmented using hammer mills or other high-impact machinery.

      This technique currently accounts for about 1% of rubber granulates and powders produced, but it offers unique advantages for specific applications.

2. Tire pyrolysis

   Numerous technological concepts for tire pyrolysis exist today, with many in developmental stages. The core of any pyrolysis facility is a reactor that decomposes rubber chips in an oxygen-free environment.

   Tire pyrolysis plants are capital intensive

   Establishing a viable pyrolysis operation demands consideration of local market demands, regulatory frameworks, and potential investments in additional processing stages. This starts with ensuring compliance with emission controls, quality feedstock requirements, and product specifications.

   Weibold advocates for a strategic approach to establishing tire pyrolysis projects that emphasizes:

   • Understanding market demands and cultivating strong customer relationships prior to selecting technologies.
   • Creating a base-line operation to secure initial cash flow whilst enhancing capabilities over time.
   • Emphasizing quality control in feedstock parameters for consistency and cost-effectiveness.
   • Partnering with reputable technology suppliers recognized for delivering economically viable projects.

   For existing operations, we recommend diligent customer tracking and analyzing specific needs before evaluating new technologies or investments.

How to choose tire recycling equipment?

Launching your first tire recycling business or upgrading existing facilities necessitates selecting reliable, high-performance machinery. Below, we outline critical equipment parameters to help with your decision-making:

Input and output capacities

Ensuring your equipment aligns with anticipated supply and processing timetables is essential for maximizing efficiency and minimizing operational costs. Lower production rates can adversely affect profit margins unless they facilitate enhanced output quality or safety measures. High-capacity lines allow for unexpected maintenance needs.

By-product separation

Numerous equipment modules play a role in separating or purifying materials, as scrap tires comprise rubber as well as by-products like steel wire and textiles. These components can diminish the overall quality and value of your rubber output, so prioritizing effective separation technologies will boost profitability.

Power requirements

Energy efficiency remains a cornerstone of any tire recycling enterprise. Utilizing inefficient machinery can lead to inflated operational costs, negatively affecting your financial performance. Energy considerations vary depending on local electricity costs.

Operating requirements (personnel)

Assess how much labor will be necessary for the successful operation of your recycling equipment. Lower labor costs may influence the feasibility of a labor-intensive model, while high labor expenses may necessitate a shift toward automated solutions.

Time of operation

Confirm the expected lifespan of the machinery by consulting manufacturers to facilitate financial forecasting for replacement schedules. Engaging tire recycling companies currently using the equipment allows for validating theoretical longevity claims.

Replacement parts and maintenance kits

Advance knowledge of maintenance cycles is critical for planning production downtimes. Comparing maintenance costs from different equipment manufacturers, alongside discussions with current users, aids in anticipating potential financial impacts.

Safety considerations

Safety protocols are paramount when handling heavy equipment, particularly for potentially hazardous materials. Ensure that safety features are well-documented and accessible for cross-comparison among different models.

Customer support by manufacturer

Establishing a comprehensive relationship with your machinery supplier is essential for ongoing operational success. Seek reviews and testimonials regarding customer service quality from previous clients to gauge satisfaction levels.

Warranty

Typically, warranties cover the initial year of operation, as equipment reliability heavily depends on recycling processes employed. Ensure you understand reimbursement protocols and what technical support entails in case complications arise.

Opinion of experts

Sourcing tire recycling equipment can be a daunting and resource-intensive endeavor, particularly for newcomers to the industry. Consulting with experts who specialize in tire recycling can expedite this journey and help you make sound decisions.

Weibold collaborates with both nascent and established tire recyclers to clearly analyze equipment pros and cons, leading to substantial cost savings. To request a technical comparison study, reach out to us for support in establishing an impactful tire recycling operation.

Which value-added products can be produced from rubber?

Transitioning scrap tires into materials such as steel-free crumb rubber and fine rubber powder used to generate consumer goods can yield higher profit margins than raw materials alone. Given the market saturation in developed economies, shifting focus to high-value consumer goods is advantageous. Options include investing in presses and molds for producing molded goods or blending recycled rubber powder with polyethylene or polypropylene for thermoplastic elastomers (TPE).

Manufacturing consumer goods typically results in increased margins compared to raw material distribution. The market for molded products continues to grow, with playground mats, flooring tiles, rubber curbs, safety products, and insulation panels being popular examples. Constant innovation is vital as the supply expands and technology evolves, paving the way for new market opportunities.

Rubber wheels for waste bins

Chassis from recycled tire rubber | Photo: courtesy of Gumiimpex

Chassis manufactured from recycled tire rubber are increasingly adopted by waste bin manufacturers throughout Europe, enhancing environmental efforts while achieving cost savings. Yet, developing regions often rely on imports for such products, creating untapped market opportunities.

Security products from recycled rubber

ADS Advance| Photo: courtesy of Rosehill Security

A recent partnership in the UK has enabled Rosehill Security to provide its molded security products, including barriers and defense components derived from recycled tires, to the US market.

Rubberized metro tracks

Rubberized metro tracks in Spain | Photo: SIGNUS

In collaboration with Spanish authorities, Acciona Infrastructure Group is researching how recycled tires can be utilized in municipal railway systems, improving both noise control and environmental impact.

Railroad ties and tie covers from recycled rubber

Giovanni Maria De Lisi, founder of Green Rail | Photo: courtesy of Green Rail

Greenrail has developed innovative, eco-friendly covers for railroad ties, aimed at improving energy efficiency and safety in railway maintenance gatherings.

Weibold&#;s market researches will help you identify new market opportunities

A successful tire recycling enterprise requires excellent returns on investment, continually innovating to explore fresh revenue streams. Weibold’s expertise spans 20 years and includes insights into both the economic and technological dimensions of tire recycling and pyrolysis. Contact us to learn more about our tailored market research services!

Choosing between rCB and fuel oil production

This article highlights the complexities involved in planning and operating a tire pyrolysis venture and the support Weibold provides to facilitate the development of sustainable tire pyrolysis plants.

Though pyrolysis is an age-old concept, pyrolysis from end-of-life tires is a burgeoning field in an evolving market. This technology's attraction is significant as it increases investments and technological advancements in tire recycling.

Despite the promising outlook, significant challenges persist, including regulatory constraints and the achievement of viable production levels. The development of reliable standards will be integral to the growth of this field.

Weibold is committed to assisting pyrolysis operators in navigating this landscape by providing tailored solutions and expert guidance. We can offer feasibility studies, market research, and technology assessments to support your enterprise and improve profitability.

Tire collection regulations in tire recycling and pyrolysis industry

Management of used and end-of-life tires varies depending on economic factors and legislative frameworks in different countries. For instance, within Europe, various models exist, including producer responsibility systems, free market models, and taxation-funded systems. Regulations significantly influence scrap tire management, and it’s crucial to stay informed on relevant guidelines.

Free market system

This system establishes objectives while allowing operators to contract freely, facilitating compliance with legislative requirements. Countries such as Austria, Switzerland, Germany, and the UK utilize this model effectively.

Responsibility of government

Countries like Denmark and Croatia implement a government responsibility model, wherein taxes on tire manufacturers fund scrap tire management. This ensures that end-of-life tires are dealt with responsibly.

Extended producer responsibility

This approach requires the tire manufacturer to oversee the end-of-life process for their products. By mandating producers take responsibility for their product disposal, these regulations help to promote environmentally friendly practices.

Have more questions?

At Weibold, we offer customized studies and expert guidance in tire recycling and pyrolysis to help your business thrive. Reach out for insights on our services.

For additional information, feel free to visit shredder portable.