20130702_Proiect tehnologie pulverizare cauciuc prezentare EN-1.pdf

CONTROLLED FINE MILLING OF ELASTOMERS BY ULTRA HIGH PRESSURE (UHP) WATER BY ULTRA-HIGH PRESSURE (UHP) WATER

JET TECHNOLOGY

Competitive edge for traditional grinding chains

Backround M i l li d f diffi l i Material recycling today faces difficulties: granulate purity after separation (textile, nylon metal, halobutyl contamination)

granulate chemical activity (limited usage as „filler”) granulate chemical activity (limited usage as „filler ) Granulate size. (hard to achieve smaller than 1000μ)

Used

TyresM di

GranulatesPowders

TPEs

Safety Surfaces

High Profile Tread Tyres

MoldedProducts

SOURCING AND SORTING

DISTRIBUTIONTRADING

MARKETING SALES

PRODUCTSMANU-

FACTURING

Medium Treads

Carcasses forRetread

POWDER &GRANULATE PRODUCTION

Special Construction

Products

ELT*) Scrap for Shredding

Steel

Textile

MulchProducts

*) ELT = End of Life Tyres

What is JetMilled powder

Obtained from end of life truck tires through using ultra

hi h high pressure water

Chemically active, with extreme high surface/mass ratioy , g

Containing high concentration of isoprene

100% metal free

THE PRODUCT: A TYPICAL APPEARANCEConventional crumb UHP rubber powder

Metal particle contaminations,typically plane, chemically inactive surfaces

Pure material with large specific surface

SEM photos by kind courtesy of theTechnical University of Budapest

yp y p , y

THE PRODUCT: SUPERIOR MATERIAL PROPERTIES

Conventional crumb● Result is a mixture of different rubber

UHP rubber powder● Selective milling: separated rubber f ff

qualities and metal particles● Metal separation requires extra equipment

d N l

g pstripping + intact steel cord

● Guaranteed metal-free separation ( d ” d )and energy. Non-magnetic particles remain

in crumb● Mechanical grinding usually results surface

(one-step „grinding” and separation)

● No surface oxidation (coking)g g y foxidation (friction heat „coking”)

● Typically plane particle surface

f ( g)

● Large specific surface of product ti lparticles

Why this product is novel?

Result of high chemical activity

High chemical activityg yWith high isoprene content

First timeability for direct revulcanization,

Extreme product purity(thread/side wall/halobutyl)

y ,thus can be utilizedin manufacturing of new rubber products, substitutingNR th ti

Unique morphology:V fi i i

NR or syntheticcomponents

Very fine grain size, High surface/volume ratio

Why this product is novel? 100% metal free fine crumb (200-1000 microns) According to the free roots on the nano structures caused by the ultra high pressure water, incomparable active

chemical bonding activity is obtained. Component which can substitute Natural Rubber and Synthetic Rubber Component which can substitute Natural Rubber and Synthetic Rubber

Rubber industry Petrochemical industry

Tyre componentor retreading

Technical rubber component

Special Rubber component

industry

Rubber Bitumencomponent

Coating component

Construction rubber

ThermoplasticDuroplasticcomponents

The technology achievements:

W h b d l f h Won the bronze medal of the European Environmental Press in 2008 (P ll h L )(Pollutech Lyon)

The rubber bitumen developed based on our product is d d b MOL N R (H i Oil d patented, an owned by MOL NyRt. (Hungarian Oil and

Gas company)Pil l i i i 2011Pilot plant in operation since 2011

UHP WATERJET TECHNOLOGY: A BRIEF REVIEW

Unique process for selective production of fine rubber powder from truck tires

One-step process at ambient temperature

Clean technology – clean product

Closed-chain process, no harmful output

Beneficial product propertiesf p p p

No surface oxidation of particles

Chemically active surface morphology with nanostructuresy f p gy

Extra large specific surface

UNMATCHED TIRE PROCESSING TECHNOLOGY

Resulting cost effective, highly selective separation

PLANT TECHNOLOGY

Water treatment unit and tire tread milling machine

PLANT TECHNOLOGY

Product drying and handling line

PERFECT EXTRACTION

Extracted truck tire treads: E t it f t i lExtracted truck tire treads: Extreme purity of material separation

PROVEN MATERIAL SUPERIORITYOutstanding revulcanization: properties remains within 5% of the original even at 20% added UHP powder to the base mixture

Base elastomer: General rubber mix of high NR-contentBuilt-in material: 300 UHP rubber powder of truck tire treadTesting equipment: Ektron EKT-100HTesting equipment: Ektron EKT 100H

THE PRODUCT: NEW HORIZONS

Boundless application fields:Cl h bb d f hi h ifi fClean, amorphous rubber powder of high specific surface with active centers

Wid i d t i l tili ti ibiliti ith t ti tiWide industrial utilization possibilities without activating or devulcanizing of the surface (no need for additional mechanical chemical or other treatment)mechanical, chemical, or other treatment)

Ideal “intelligent” filling or row-material substituting, in different systems Exceptional reactive compoundingdifferent systems. Exceptional reactive compounding properties

R tiBase polymermatrix

Reactivefiller

NEW HORIZONS: WIDE-RANGE APPLICABILITYIntelligent component for various polymer systems

– proven by laboratory and industrial application tests

Rubber industr Rubber industry Reactive filling („dry regenerate”) for various rubber-base systems Homogenous vulcanized polymer matrix from most pre-vulcanizing mixtures

Plastics industry Effective reactive compounding propertiesWide-range polymer compatibility for different TPEs even over 50% UHP rubber-powder load Advantageous interfacial bonding properties with PP, LDPE/HDPE, PUR, PVC

Coatings and dye industry Reservoirs and wire coatings Reservoirs and wire coatings Dye and paint components Insulators for construction industry

R bb bi Rubber bitumen Active component for rubber asphalt road surface Non-settling chemically stable rubber-bitumen produced by mechano-chemical dispergation with

d h d dimproved wearing properties, weather resistance and noise reduction

What is the cost of this product?

To produce 1kg JetMilled product requires 3,5 kwh

energy.

The cost of a plant that produce 1500 tons powder a The cost of a plant that produce 1500 tons powder a

year cost 1,3M Euro

4 people can operate the plant in one shift.

The plant can fit in 600 sqm.p q

The compound price can range from0.9-1.1 euro/kg

Pl t i i l bl t t h i ti it Plant size is scalable to match existing capacity.

Executiv summary

T h l l ti t diti l i di itiTechnology complementing traditional grinding capacities

P i fi i h d d t fi l ti bPremium finished product, fine, clean, active crumb

I t t d d ti i did t t b id f Investment and production is candidate to subsidy from

E i t P t ti F d Environement Protection Funds

R t i t t ithi 4 Return on investment within 4 years