Tire Recycling in the EU
Transcript of Tire Recycling in the EU
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Tyre Recycling in theEuropean Union
Dr. Valerie L. Shulman
Secretary General, ETRA
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ETRA : The European Tyre Recycling Association
• Founded in 1994, with 19 members in 5 EU States
• ETRA has ±250 members in 43 countries, including each EU State;
• The mission : to develop tyre recycling as an environmentally andcommercially sustainable European industry
• Objectives: to develop and advance policies that support the industry;
to expand and develop markets;
to development and implement professional standards;
to prepare and promote guidelines for materials, products,
applications;
to provide communication links
• Membership is open to the public and private sectors
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Post-consumer tyres ~ 3,250,000 tonnes of post-consumer tyres are permanently
removed each year from cars and trucks in the 27 EU States -
and defined as waste
It is estimated that an additional ~60,000 to 70,000 tonnes of
post-consumer tyres are permanently removed each year from
agricultural and other off-road vehicles in the 27 EU States -
but not defined as waste
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Compared with other waste streams
Product Consumption Sub-setPaper ±79,000,000Plastics ±37,000,000
Packaging
Glass ±15,000,000
Aluminium ±8,860,000
Automotive/construction±5,316,000
Packaging
Rubber ±5,000,000Tyres
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The raw materials
Rubber compounds - throughoutthe tyre : treads, sidewalls, etc.
Plies and belts : layers of brasscoated steel with rubber
Bead wire : Cords of high tensilesteel that give form to the tyre
Casing : Made of metal, rayon,nylon. Polyester cords
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Composition by weight of tyres
Material Car/utility% Truck/lorry%Rubber/elastomersa ±48 ±45
Carbon black or silicab ±22 ±22
Metal ±15 ±25
Textile ±5 -
Zinc oxide ±1 ±2
Sulphur ±1 ±1
Additives ±8 ±5
A Truck tyres contain proportionately more natural rubber in comparison to synthetic rubber than do car tyres
b Different varieties of carbon black are used for different purposes and may appear in other categories of material
The rubber compounds, metals and textiles are recovered through material recycling
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Recycling makes sense
• It requires 121,000BTUs to produce 1 kg of new rubber materials
• It requires only 2,200BTUs to produce 1 kg of clean granulate or
powder.
Put another way, the Co2 equivalent for 1kg of rubber is :
4,351 for Natural rubber
3,409 for SBR
0,097 for recycled rubber
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Considering energy use
The production of 1 tonne of rubber requires the following :
– Natural rubber requires the same amount of energy as driving
from Brussels to Singapore (about 10,560km)
– Synthetic rubber (SBR) requires the equivalent of driving from
Rome to Sidney Australia (15,000km)
– Recycled rubber is a much shorter trip - it uses the equivalent of
a 400 km ride from Paris (France) to Geneva (Switzerland)
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Means of tyre valorisation
Re-use and or export
Retreading
Material recycling including :
Civil engineering and construction applications
Environmental rehabilitation projects Consumer and industrial products
Energy recovery for : Co-incineration
Cement kilns
Each form of valorisation requires a consistent flow of input
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The attainment level : 2005-6
In 2005-6, ±2 669 219 tonnes of post-consumer tyres were treated in anenvironmentally sound manner within the 25 States of the EU.
± 222 975 tonnes : export (± 7%)
± 333 250 tonnes : retreading (± 10,5%)
±1 012 920 tonnes : material recycling (± 31,8%)
±1 100 075 tonnes : energy recovery (±34,5%)
Together, ±83,8% of post-consumer tyres were diverted from landfills.
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Elements of the recycling process
•Collecting (manual)
• Sorting
• Pre-treating• Debeading
• Cutting
• Processing (mechanical)• Shredding
• Granulating
» Sieving
» Packaging
» Storing» Delivering
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The start of tyre recycling : Collecting
• Knowing where the tyres are – At small individual sites :
• Garages, tyre shops, small retailers, vehicle sales
– At large communal depots
•
Tyre distributors• Fleet managers
• Municipal depots
• Vehicle dismantlers
• Knowing how to move the tyres
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Basic collection information
Category
• Off road/agricultural tyres
• Truck tyres
• Bus tyres
• Utility tyres
• Passenger car tyres
• Winter tyres
Approx. Wt./ tyre
170 kg
56 kg
54 kg
8 kg
7 kg
8kg
Tyres
p/tonne
5.88
17.86
18.52
125
142.60
125
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EU Collection systems
Producer responsibility
Free market system
In transition
Adaptation
Norway
SwedenFinland
Lithuania
Latvia
Estonia
Hungary
Czech Republic
Poland
France
Germany
IrelandUK
Spain
Italy
Greece
Austria
Bulgaria
Romania
CyprusMalta
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Formula for tyre Collection
• To move 1 tonne of tyres costs approximately 2 € per km
• Passenger car tyres : 6 - 12 tonnes per delivery
15 tonnes in a walking floor truck
• Truck tyres : approximately 14 - 15 tonnes per delivery
17 - 18 tonnes in a walking floor truck
•
Off-road tyres : 15 tonnes per delivery
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Stacked tyres
Whole tyres are often stackedin a basketweave to save
space - particularly when the
tyres will be retreaded
Tyres for recycling are often
transported in bulk - as
whole, or as tyre cuts
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The next steps
1. Sorting : Manual process
According to category : truck, passenger car, other
Road-worthy : undamaged with minimum 1.66mm tread
Retreadable : repairable casing in good condition
Non-retreadable : raw material for recycling
Many of these tyres are exported to other countries that have
less restrictive road-use standards
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2. Pre-treatment : Manual processes
Removal of debris
Rinsing - remove dirt, etc.
Cutting in halves/quarters
Debeading
Preparation for recycling
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Not all tyres are ready for treatment
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Truck tyre debeading
• Truck tyres are debeaded
• The steel is removed
•
A 60 second spurt at 150kW/h/t is used
• Clean tyre bead steel cansubstitute virgin material -
dependent upon use
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Tyre processing
• Shredding
• Chipping
• Granulating
• Fine granulating
• Powders
•
Material upgrading
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Environmental impacts : per tonneMaterial Feedstock Energy use Emission limits/unit of operation
Debeading Truck tyres 150 kWh/t
60 sec spurt
+0,4 mg/m3
dust
+95 dB (A) noiseShred, chips Dependent upon use : Whole
and/or cut car, utility, truckand other tyres
35-50 kWh/t +0,2 mg/m3
dust+95 dB (A) noise
SOx 0 NOx 0Water - trace
Size reductionGranulate &powder
Dependent upon product:whole, cuts, shred, chips,treads, sidewalls, technicalrubber
120 kWh/t 0,2 mg/m3
dust G; 0,4 mg/m3
dust P+85 dB (A) noise (newer systems encased)+90 dB (A) noise (encased) some older, dualprocess systems
Sox0NOx 0Water – below allowable levels
Fine powder <600 µm
Dependent upon product:granulate as producedabove
110-150 KW/t1.3 tN2 /t
granulate
+0,2 kg/h dust+85 dB noise (encased system)
Sox 0 NOx 0
Water – below allowable levels
Devulcanisation(non-chemical)
Dependent upon product:Shredded/granulated tyres,As produced above
150 – 200 kWh/t +0,2 mg/m3
dust+90 dB noise
SOx
0 NOx
0Water – below allowable levels
Pyrolysis Dependent upon product :As above
370 kWh/t Local legal limi ts for ai r emissions 30– 45 dBWater – below allowable levels
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Shred and chips
•Shredders can be mobile or fixed
Shred can vary in size from±75mm to 300mm in anydimension.
Smaller shred, of <±100mm, canbe used loose or compacted, inapplications with or withoutbinders
Chips, from ±15 - ±75mm, canbe used in applications with or without binders
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Granulation plant in operation
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Cost-use-triangle
The Po st-consumer tyre usage hierarchy Capital investment Principal Consumers Examples of use
Whole < 100,000€ 100% public sector artificial reefs, erosion control
Cut noise barriers, stabilisation
Shred and chips < 1,000,000€ ±80% public sector lightweight fill for construction,
±20% private sector roads, insulation, landfill construction
> 1,000,000€ ±80% private sector consumer/industrial applications,
Granulate and powders ±20% public sector products, sports surfaces, some public
civil engineering applications
Multi-treatment materials <10,000,000€ ±95% private sector consumer/industrial products,
±5% public sector coatings, some road construction
Preliminary specifications of many of these applications and products are provided in the CEN Workshop Agreement on Post-consumer tyres.
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The range of materials : outputs
Since 1995, the range of post-consumer tyre materials produced and usedhas expanded - principally at the extremes
Larger materials, i.e., whole treated and untreated tyres, bales, shred, chips
are increasingly selected by civil engineers
Smaller materials, i.e., granulate, powders, fine powders and specialised
products (reclaim, devulcanisates, thermoplastic elastomers, etc.) are being
selected by manufacturers of consumer and technical products
Recycling residues are increasingly used for specific innovative applications
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Post-consumer tyre materials Granulate
54%
Shred/chips15%
Whole tyres
12% Misc. 2%
Specialty 7%
Powders 10%
The changing balance of material production and use
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Whole tyres can be recycledwithout physical or chemicaltransformation
Principal methods of treatmentinclude cutting into halves or quarters,
untreated or, treated byremoving the beads or sidewalls, or by compression
Whole tyres
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Characteristics of whole tyres
Characteristics
• Lightweight,
• Low compacted density,
•High void ratio,
• Good compressibility,
• Water permeability,
• Thermal insulation
• Non-biodegradable
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Slope stabilisation
Erosion control
Construction bale
Coastal and fluvial protection
Examples of whole tyre uses
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Shred and Chips
Shred and chips are the result of mechanical processes by which tyresare fragmented into irregular pieces
Shred can vary in size from ±75mm to300mm in any dimension.
Smaller shred, of <±100mm, can beused loose or compacted, inapplications with or without binders
Chips, from ±15 - ±75mm, can be usedin applications with or without binders
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Characteristics of shred and chips
Characteristics
• Lightweight,
• Low compacted density,
• High void ratio,
• Good compressibility,
• Water permeability 10-1 to
10-3 m/s
•Thermal insulation
• Low earth pressure
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Loose unbound chips :
Compacted unbound chips
Bound chips
Compacted shred
Landfill cell
(geotextile)
Loose shred
Building insulation
Examples of shred and chips
Drainage systems
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Granulate
Granulate is the result of processing rubber to reduce it insize into finely dispersed particlesfrom ±1mm to ±10mm
There are two principal methods of production : ambient and cryogenic
Ambient size reduction is the mostcommon, particularly for larger
truck tyres.
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Characteristics of granulate
CharacteristicsVariations are based upon
the treatment technology
Ambient : irregular shape;
some thermal degradation
due to treatment; reducedcross-linking
Cryogenic : regular shape
and particle size; smooth,
glossy surface; no surface
decomposition or thermalstress
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Road furniture Running tracks
Sports stadia
Children’s play grounds Indoor or outdoor
tiles/pavers
Artificial turf
Examples of granulate uses
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Sports arenas
Road furniture
Artificial turf
Insulation
P d d fi d
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Powders and fine powders
Fine granulate is the result of ambient or cryogenic process-ing to obtain finely dispersedparticles of less than ±2mm.
Powders and fine powders arethe result of processing andpost-treating the material to
obtain finely dispersed particlesof ±500µm - <1.mm
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Characteristics of powders Characteristics
Powders are processed to
modify one or more charac-
teristic to restore some
properties of virgin rubber.
Powders include reclaim,surface modified or re-
activated material, elasto-
meric alloys, among others.
They are most often used as
ingredients in compounds
that are mixed or blended with
virgin material
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We’ll continue to work on it
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We’ll continue to work on it
Thank you for your attention
Th 15 h A l E C f
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The 15th Annual European Conference
on tyre recycling
Towards a Recycling society :
the challenge
2 - 5 April 2008 The Crowne Plaza Europa, Brussels