Utilization and restoration of tires is an additional reserve for the production of rubber products. Tire Recycling Equipment Selection Tire Business
Mankind has long been thinking about how to recycle worn-out car tires, which are becoming more and more every year. But even today from total number only about 20% of all tires in the world are recycled, although there are ways to recycle tires today. And on some of them you can even make money, simultaneously improving the ecological situation.
The fact is that worn-out tires are a rather valuable polymer raw material: 1 ton of tires contains about 700 kilograms of rubber, which can be reused for the production of fuel, rubber products and construction materials. At the same time, if you burn 1 ton of used tires, then 270 kg of soot and 450 kg of toxic gases are released into the atmosphere.
Make tire recycling cost effective industrial scale pretty hard. However, according to manufacturers of waste disposal equipment, owning a mini tire recycling plant is quite a profitable business.
Industrial complex is a prefabricated unit with a total area of 17.5 sq. m and a height of 10 meters, which can process up to 5 tons of raw materials per day. In addition, the production site includes a raw material warehouse (worn-out tires and plastics), a raw material preparation site (tire cutting into pieces), finished product warehouses: a liquid fuel warehouse, a carbon black warehouse, a scrap metal (metal cord) storage area.
Tire Recycling Business: Recycling Process
Tires that have served their purpose are collected and transported by road to the raw materials warehouse. Next, the tire is inspected for the presence of metal discs, rings in it and is sent for cutting. After cutting, the crushed raw material is fed into the receiving hopper of the reactor.
The raw material in the reactor undergoes decomposition at a temperature of approximately 450°C, during which intermediate products are obtained: gas, liquid fuel fraction, carbon-containing residue and metal cord. The gas is partially returned to the reactor furnace to maintain the process. The rest of the gas is emitted through a pipe (comparable in appearance and amount of gas at the outlet to truck exhaust). The carbon-containing residue after quenching and cooling is subjected to magnetic separation (or sifted through a sieve) in order to separate the metal cord wire. Liquid fuel, steel cord and carbon-containing residue are sent to the warehouse for further shipment to the consumer.
Tire Recycling Business: Equipment Description
The productivity of the installation (per day) is: for liquid fuel - 2 tons / day; for carbon-containing solid residue - 1.5 tons/day; for metal cord - 0.5 tons / day; for gas - 1 ton/day.
Consumption of raw materials - 5 tons / day. This means that the yield of liquid fuel is 40% of the weight of the loaded rubber.
The plant operates continuously using the gas produced during the recycling of tires. Installed in an open area.
Overall dimensions: height - 10 m; width - 3.5 m; length - 5 m.
Electricity consumption - 14.5 kW / h (installation - 7 kW / h and scissors - 7.5 kW / h).
Serves 2 people.
Tire Recycling Business: Startup Capital
The installation cost is approximately 1,100,000 rubles. (without delivery). In addition, tanks will be needed to store fuel oil obtained during processing. In order to get more profit during a price decline, it is recommended to accumulate fuel in tanks and sell the accumulated products during a period of increased prices. 60-ton used tanks can be purchased at a price of 20 - 25 thousand rubles per 1 unit. Six tanks will be enough.
Plus warehouse equipment, tools, overalls - at least another 100 thousand rubles. Thus, the cost of equipment, taking into account the lease of territory and premises, delivery, installation and various approvals, will amount to at least 1.5 million rubles.
Current expenses
Four workers are required to work in two shifts. Everyone's salary
about 10 thousand rubles a month. You will also need an office for accounting and at least two more employees, one of whom will organize the supply of raw materials, and the second - the sale of finished products. In total - at least 70,000 rubles per month for salaries of employees, plus taxes and office space rent.
Electricity consumption is 14.5 kW / h, that is, 10440 kW / month.
Monthly expenses for the implementation of the current activities of the enterprise will amount to about 100 thousand rubles.
Tire Recycling Business: Revenue
The advantage of the project is that the raw materials are actually free. Moreover, in some cases, you can already earn money on its collection.
For example, industrial enterprises pay for the disposal of tires, because. tires are not accepted to city dumps. AT different cities the cost is different. This is stipulated in the contract with the company. In Chelyabinsk, for example, enterprises pay 2000 rubles for the disposal of 1 ton of tires, in Krasnodar - 3500 rubles.
Scrap metal is accepted by recycling companies at a price of about 4,000 rubles per ton. The cost of low-quality carbon is about 3,000 rubles per ton. Carbon is used to make various coatings.
Total
Thus, the total income from the installation per month is 375,000 rubles (2x3000 (fuel oil) + 1.5x3000(carbon) + 0.5x4000(scrap metal) = 12500 rubles/day). Monthly costs: 100,000 (salary for workers and office) + 14,616 (electricity) = 114,616 rubles. Thus, the payback period of the plant is about 6 months from the start of production.
The Tire Recycling Business: Pitfalls
Firstly, there are no vacant plots - all the land has already been allocated for building residential buildings. Secondly, the distance from residential buildings should be at least 300 meters - it is not easy to find such a site. It's even harder to get tested. Plus public opinion- people do not want a new enterprise to be built “under their windows”, especially for waste processing.
It is much easier to organize such production on the territory of existing enterprises and organizations. It's no secret that many production sites are now idle. And their territory has all the necessary environmental opinions and agreement. It remains only to agree with the enterprise itself - to agree difficult moments with the landlord is much easier than with environmentalists, firefighters and other authorities.
Another important point. To prevent environmental pollution by such production, most likely, it will be necessary to purchase a special purification plant, which will cost the entrepreneur several times more than the production itself.
Also, according to experts, it is not advisable to build one small processing plant specializing in one type of product. It is necessary to cover the recycling of as many products as possible: glass, plastic, metal, rubber, paper, etc.
The project does not provide for many unforeseen expenses that will most likely arise in the process of preparation and full-fledged production activities. There will be problems with environmentalists, firefighters. For example, to store fuel oil in old tanks, one fire shield is not enough. This requires a range of safety measures, from hoses carrying fuel or gas to instructions for personnel.
And environmentalists, so they are completely jealous of landfills and processing plants. There is always something to complain about, and the cost of fulfilling all the requirements is more than one hundred thousand rubles.
Dmitry Kiro
Magazine "Svoe Delo"
Just imagine, approximately 70 thousand tons of old tires are thrown away in Moscow annually, in St. Petersburg - 30 thousand tons, in Rostov-on-Don and Chelyabinsk - 5-6 thousand tons each. According to experts, only 15-20% of them are recycled, the rest are taken to landfills, lie in garages or are buried in the ground. “Sometimes mountains of old tires are set on fire to make room for the ‘new’ junk,” says environmentalist Zhanna Izmailova. “Meanwhile, from one ton of old tires, 450 kg of toxic gases and 270 kg of soot are produced during the combustion process.” In other words, tire recycling in itself is a matter of environmental importance, however, it also turns out to be a highly profitable business.
Today, there are a number of technologies for the processing and disposal of tires. In particular, the developers believe that this product is a valuable recyclable product, as it has high percent release of required materials. “One tonne of used tires contains 700 kg of rubber plus metal cord,” says Ivan Gerasimov, a recycling specialist from Moscow. “And most importantly, the tire recycling process is well developed, which allows the use of ready-made equipment.” According to him, the choice of the principle of utilization of raw materials depends on consumers who are within easy transport accessibility.
Overview of tire recycling technologies
First of all, we are talking about technologies for the physical grinding of tires into dispersed materials, for example, for the production of concrete as additives or asphalt pavements for roads with a consumption capacity of 14-15 tons per 1 km of road surface. In addition, crushed tire crumb retains the original structure and properties of rubber and other polymers. This means that it can be successfully used for the production of various rubber products, including rail sleeper pads, floor mats, sports rubberized coatings for football fields and tennis courts.
“The mechanical processing of tires differs in terms of grinding temperature and the method of exposure,” says Ivan Gerasimov. - The easiest way to crush a tire is when it is frozen to a brittle state, at minus 60 ° C and below degrees. To do this, you will need a cold generator of an air turbo-refrigeration machine, of course - a refrigerating chamber where this air is supplied, a rotary-vane grinder, magnetic separator and an air separator. You can use the principle of "pseudo-liquefaction" of rubber when high pressures, and can be processed into crumbs at normal temperatures by stepwise grinding, with maximum preservation of rubber properties.
And where there is an acute shortage of high-quality fuel oil for heating, the technology of processing tires into this type of fuel will be in demand. “To be fair, this is not classic fuel oil,” says Zhanna Izmailova. - This is pyrolysis oil, identical in chemical properties fuel oil. But for combustion in boiler rooms and heat generators, it is quite suitable, however, pyrolysis oil can be processed both into fuel oil and into diesel fuel or even gasoline. This type of disposal will require a tire shredder and a pyrolysis reactor, as well as fuel storage tanks.
Issue price
In general, any tire recycling equipment is not cheap, as high metal consumption machines are used. For example, equipment according to the classical technology for obtaining crumb rubber manufactured by Vtorrezina Ecoprom LLC UPP costs about 7 million rubles. On similar equipment, a crumb of 5-40 mesh (up to 0.42 mm) is obtained. In principle, it is possible to install thinner sieves and obtain a fraction of up to 0.1 mm, however, in this case, productivity will have to be sacrificed. “Based on experience, such lines pay off in about half a year or a year,” says Ivan Gerasimov. - A newly-minted entrepreneur will need about 200 m² of premises and plus a site for a tire warehouse, it is possible in the open air. Two or three workers will be required per shift.
It is clear that many novice businessmen will not be able to afford such expenses. In this case, you can start with a contract for processors, in particular, with a tire divider along the treadmill into two halves. Such a machine costs about 500 thousand rubles and allows you to quickly and efficiently produce a semi-finished product for further processing by abrasion. It can even cut truck tires, which allows you to dramatically increase the productivity of subsequent processing into crumbs. Thus, substantial funds are saved when transporting a compact semi-finished product instead of capacious tires, storage space is reduced, and the crumb is clean from dirt. According to experts, such equipment pays off in a matter of months when installed in places where old tires are stored. 
As for the processing of tires into pyrolysis oil, experts unanimously argue about possible problems ecological character. “If we talk about an alternative to recycling tires into crumbs, then it is logical to focus not on recycling into pyrolysis oil, but on tire retreading,” states Zhanna Izmailova. “We environmentalists often urge entrepreneurs to take a closer look at these technologies.” Indeed, for example, D&M equipment worth 2.2 million rubles can make this business not only environmentally friendly, but also profitable. Thus, the restoration of only 16 R-22.5 tires brings the owner about a thousand dollars in net income.
What's on the forums?
Of course, the opinion of experts deserves to be heeded. But, as experience shows, more accurate judgments can be found at various business forums.
A forum member with the nickname streker, commenting on the problem of selling fuel oil obtained by processing tires, wrote: “Fuel oil, also called “furnace”, is mainly used for heating, in particular at thermal power plants. The volumes of its consumption there are great. Squeezing your small percentage of supply into the planned purchase of CHP will be quite problematic. Further, the consumption of fuel oil is seasonal, that is, even after agreeing with the CHPP, we must remember that when there is no heating season, fuel oil will have to be harvested. What are containers for? pump equipment. And at this time we will have to work “for the future” in the hope of recouping our investment by delivering tons of fuel oil when demand arises again. It’s not that there is no demand at all during the off-season, it’s just that prices really fluctuate ... ”. Commentator Senya K-J also threw a pebble into the garden of pyrolysis production: “Do not forget about the terrible smell problem! The neighbors will demolish the whole factory for you. He himself worked next to the pyrolysis shop.
There is also an alternative opinion, however, it concerns mechanical processing. “For 4 years I have been working on a topic very close to recycling car tires, - Av22 nickname shares his experience. - In my production I use the product of this processing - rubber powder. The main problem is the certification of rubber powder. If you manage to do this, then keep in mind that it will be conditional. In my opinion, one of the most successful applications of a tire recycling product is its use in the construction of roadbeds on highways.”
Thus, the business of recycling old tires has its pros and cons, but with a professional approach to business, there are more “firsts”. In particular, success is almost one hundred percent guaranteed if the businessman agrees to sell the same crumb rubber to a large road repair company.
Worn-out car tires are a problem for mankind.
If the situation does not change, their disposal will soon require more funds than production, where the cost of materials reaches 75% of the cost of the product.
Therefore, today the problem is quite acute.
Important recyclables
The use of waste tires and other rubber products is possible in a variety of industries. For example, to generate combustible gas through the thermal splitting of residues of hydrocarbons synthesized from oil. With it, you can not only heat up, but also generate electricity, as they do in France and a number of others. Western countries.
Tire recycling is also needed to add their particles in the form of a filler to asphalt bitumen, create all kinds of technical mastics, as well as for the thermal decomposition process -. The liquid product of pyrolysis goes as an additive to rubber (plastic), while an adsorbent is obtained from the solid. This is a rather promising direction, because the output is valuable product.
But pyrolysis has not yet received industrial scale, and the activities of scientists alone without the participation of production workers and businessmen in this area are not enough. The idea of producing regenerate has been recognized in the world as untenable for some time now, and work on this part has been suspended.
A very important task is the transformation of outdated polymer products (containers, packaging, films, automotive tubes and tires) into new ones.The problem of recycling and recycling used tires in Russia
Worn-out tires are the most massive organic ballast, and they don't decompose well. In the context of the globalization of the economy, the issue of unification of the nomenclature becomes relevant.
Thus, products that are in use in the post-Soviet space do not meet foreign standards. The structure of matter and products is different, and rubber waste Russian origin it is more difficult to bring to mind than, say, European ones. The reason is that domestic tires are additionally reinforced with a radially synthetic cord. This is a mixed type (rubber + metal + textiles) with a large admixture of textiles.
Abroad, more than half of the slopes contain an all-metal type of cord, that is, there is no textile in them or is contained in such an amount that it can be neglected. We have the largest mass of tires that need to be disposed of in freight transport, followed by “passenger cars”; special tires (including aviation ones) are almost never recycled. And abroad - the opposite is true.
Thus, approaches to solving the problem of recycling in the Commonwealth of Independent States and developed countries ah, they can't help but differ. There are the following conclusions:
- It has been verified empirically that the European, American, Japanese-Chinese tools are not suitable for our conditions.
- Due to the presence of textiles in the waste, it is necessary to use methods and techniques that are an order of magnitude more complicated and expensive than required for servicing products with an all-metal cord type.
- With the help of multi-stage processing technology for products with a mixed type of cord, imported tires can be processed.
Existing technologies
Extending the life of automotive "shoes" has 2 goals - to save on organic resources and improve the environment. The meaning of the operation is to build a new layer on the old base. This applies mainly to the tread, because. it is he who experiences the greatest friction. But what to do with tires that cannot be restored? Utilize with maximum effect! For this there are special methods:
- products are mechanically crushed to a coarse mass without the breakdown of molecular relationships;
- the crystal lattice of the rubber substance is partially destroyed with the appearance of regenerate;
- pyrolysis occurs (the final decomposition of the elemental base during the combustion of rubber goods in gas generator complexes).
Hot and cold tire retreading
Foreign experience restoration by the "hot method" applies to auto and aircraft tires. Moreover, the latter, due to a more solid frame, with proper use, are able to live 5-6 lives, as, for example, Goodyear brand products. But the cost of restoring tires is comparable to the cost of a tire from scratch, which makes this method unpopular in the US and Europe. In the Russian Federation, the “hot” method is not in demand today also due to domestic features slope damage that is so impossible to eliminate. This type of recovery technology includes: 
- cleaning the base of the old tread;
- smearing it with glue;
- placement of the raw tread on the prepared surface;
- the operation of vulcanization in a mold with a predetermined duration of heating.
The "cold method" has been successfully used for the last 20 years for tires with a steel cord in the carcass. On the European continent, 46% of trucks drive on secondary tires of this type, and in Norway, Sweden, Finland, in general, 60-70%. In our country, only imported frames are subject to repair by this method on foreign equipment. It is younger and cheaper than the "hot" one, has high quality characteristics, providing individual tires with 3-4 work cycles. This type of recovery technology includes:
- revision of frames, processing of local defects;
- cleaning the base of the old tread on a roughing machine, repairing damage;
- lubrication of the frame and raw rubber with glue;
- combining with them and pressing a pre-heat-treated tread tape with an arbitrary pattern;
- the imposition of a special reinforced shell that fixes the protector on the frame;
- vulcanization in hot air environment not higher than 100° 6 hours;
- verification of the refurbished product.
Recycling tires unsuitable for their intended use
There are several such ways.
burial
Today, about 80 million tons of used tires have accumulated on Earth. There is an opinion that every year this figure will increase by 10 million tons. Europe suffers from this disaster more than others, where 3 billion pieces are stored. used tires.Of the total volume of car ramps that have become unusable, only about a quarter are used in the future as recyclable materials. The rest of the mass of environmentally harmful material due to unprofitable processing technologies is stored in special landfills and spontaneous dumps, which pose a great danger. It is these problem areas that act as a source of toxic fires, which are difficult to extinguish due to the persistent flammability of synthetic rubber.
The expediency of civilized recycling of tires is explained by the lack of space for their burial, especially in East Asia. And in the EU states, such a burial is not allowed by law (the tire decomposes in the ground for about 150 years).
Grinding of worn tires to obtain crumb rubber
One of the most common methods of disposal is the processing of rubber goods into crumbs. It is simple and rational due to the observance of the basic technological parameters of rubber while maintaining molecular bonds. Although it has one drawback - unprofitability.
Grinding technologies
The following grinding technologies are divided: 
- shock wave (explosive circulation) with 2 stages of processing,
- mechanical with 4 steps.
The first one is unique because is based on the unconventional principle of crushing with the circulation of explosion products, which is recognized as the most effective and inexpensive destructive means. Equipment, factory products are represented by the Russian brand explotex.
The second is considered less progressive, but no less high quality. At the initial stage, "chips" with a particle size of 10 to 50 mm are obtained. Then, for the purpose of separation, they are transformed into 3-10 mm granules. The crumb is freed from cord, fiber, foreign elements on sieves, in drums and separators.
Methods for modifying crumb rubber
Distinctive feature crushing waste is that the result is smooth, like broken glass, particles. To improve the functional characteristics of the produced substance, the surface of the particles is modified, making it softer and looser. This is a complex physical and chemical process using powder, beam, laser, steam technologies.
Areas of use for crushed rubber
Every year, at least 34 million tires are turned into shreds, which are used to build coatings and surfaces, add to mortar, and make tires, mats, and soles. And this costly method has successfully taken root in the laying of roads.
Recycling of used tires
In Russia, only 7% of used tires are recycled, while the world average, we recall, is 23-30% (which is perhaps not so much for the 21st century). Question further fate of worn tires became especially acute with the advent of steel cord frames. And with the fall iron curtain“In addition, a flood of low-quality German products poured into our country.
In the Russian Federation, about 1 million tons of rubber materials annually become unusable and remain unclaimed, and 9/10 of this amount are automobile ramps.
The share of the capital and St. Petersburg with the region accounts for almost 200 thousand tons.
The main reason that an industrialized state like Russia has a percentage of tire recycling comparable to the recycling rate in African countries is the Soviet mental legacy. We are traditionally not accustomed to investing in economical secondary production, and there are no prerequisites for stimulating it at the government level, with rare exceptions. 
Passed law on waste as a whole had a positive impact on the implementation of civilized programs for the disposal of rubber goods. But what exactly can the Russian champions of the “waste-to-profit” principle write down as a “rubber” asset? Let's list.
An enterprise with a stably functioning reactor has been created in Kaliningrad, where high-quality fuel oil is generated as a heat engineering fuel through pyrolysis, as well as a substitute for activated carbon.
In the first 15 years of independence, with a complete rejection of burning tires, the volume of crushed tires "used" tires increased from 5 to 10%, and now it reaches 30%.
Tushino Machine Works has mastered the production of crumbs with two lines with an installed annual capacity of 5,000 tires, and has also increased the production of panels for railway crossings, which are especially relevant at the moment.
Ecological production facilities with imported manufacturing equipment were put into operation in Tver, Kursk, Vyazma, Samara.
In Primorye, CJSC "Templar Center" is engaged in the manufacture of roofing materials from crumbs. Moreover, it revives a complete closed cycle for the production of regenerate by the thermomechanical method.
Notably, this leap was made possible by the use of mechanical way grinding at normal temperatures. Alternative (cryogenic) technologies are not widespread all over the world due to the high cost of low-temperature crumbs, and efforts to use the power of an explosion or "ozone knife" are experimental in nature. An interesting project for high-speed processing without preliminary cutting and crushing was proposed by Orenburg developers, but the future will show how viable it will be.
Reforms in the field of environmental protection, which began to be implemented in last years are gradually tightened.
What should natural resource users expect? A complete ban on the disposal of waste tires and car tires is introduced.
This position of legislators should stimulate the development of the industry recycling waste, the opening of new industries for their modification.
Deserves close attention. low cost, easy way Recycling tires requires the use of special equipment.
Let us consider in more detail the popular types of machine tools and the production lines formed from them, the characteristics of these units and how much they cost.
The technology for the production of crumb rubber from used machine tires is a process of successive grinding of raw materials into small pieces, followed by grinding them into a fine fraction.
Manufacturers offer a wide range of machines for the production of crumb rubber, prices depend on the performance of the equipment.
Single shaft shredders
The principle of operation of a single-shaft plant is based on the grinding of raw materials successively lowering and rising low-speed cutting shaft.
The operation of a rubber shredder is as follows:
- Tires are fed into the chamber of the raw material loading shredder, where, under the action of a hydraulic press, they are fed to rotating knives.
- The press moves from top to bottom, returning to its original position after reaching the maximum degree of pressure on the shaft.
- The crushed raw materials are pressed through special sieves placed under the shaft.
Fastening double-sided knives to screws allows them to be reused after one of the edges is worn out. This design feature allows increase standard service life tire crushers.
Among the advantages of single-shaft rubber shredders, the following can be distinguished:
- simple design;
- ease of operation;
- the possibility of individual use and inclusion in the production line;
- processing of thick raw materials.
An example of such equipment is a single-shaft machine for processing rubber and tires into chips from Netmus; the price of the presented equipment varies in the range 120,000 - 2,800,000 rubles.
Twin shaft rubber shredders
Two-shaft tire shredders are designed for cutting raw materials into pieces no larger than 5x5 cm. The shredder blades can process tires from both passenger cars and heavy vehicles.
Principle of operation machine as follows:
- A tire is fed into the raw material receiving chamber. The size of the window allows you to load the entire product, the only requirement is the preliminary extraction of the cord.
- The shafts of the tire shredder into crumbs rotate in opposite sides. Hooks placed on the rotors grab the raw material and tear it apart.
- The crushed raw material is sifted through a sieve, which is a rotating drum. Particles that exceed the size of the sifter cell are thrown into the loading chamber for re-processing.
- The finished material after sorting into fractions falls on the conveyor belt and is fed to packaging.
Benefits of using twin-shaft machine for the production of crumb rubber:
- the possibility of processing large-sized raw materials;
- no need to regrind the blades of the knives when reinstalling them.
The performance of the rubber processing machine directly depends on given dimensions end products. So, in the manufacture of tapes and pieces measuring 5x5 cm, the output of 1 machine will be 2 tons / hour and more, with more thorough grinding - up to 2 tons / hour.
No special skills are required from the personnel serving the machines.
The number of auxiliary workers to work in 1 shift is 1-2 people: 1 person for loading raw materials, 1 person for receiving finished products.
Double shaft tire crusher supplies Russian company TechnoService LLC.
Tire Shredding Plant
Let's consider tire shredding installations on the example of UPSHK equipment from the Tekhnoresursy company.
The installation is a rotating crown with 25 knives mounted on it, brought to a tire clamped in a special cartridge.
Manufacturing process as follows:
- Feeding the tire to the clamping drum.
- Installing and fixing the tire in the drum manually, or using the lifting mechanism of the installation.
- Turn on the drive and start rotating the drum. The unit control system provides 3 rotor speeds. It is advisable to choose them depending on the outer diameter of the tire.
- Approximation of the cutting crown rotating in reverse side in relation to the drum. The speed of movement of the crown is set by the attendants and depends on the desired size of the fraction of the finished product - the slower the movement, the finer the rubber crumb.
Rubber is removed from the tire, starting with the outer layer, and before reaching the layers of the cord.
Textile cord can be crushed together with rubber, metal cord is the boundary beyond which the use of the machine is prohibited.
Benefits of using the machine:
- successfully replaces the whole tire shredding line;
- competitive price;
- ease of transportation;
- fast installation;
- instant connection to the power supply system;
- the possibility of processing tires of various sizes;
- short payback period.
Maintenance of the installation is carried out by one worker. The production technology itself is very simple and does not require additional training.
For a month, one installation is capable of producing 34 tons of clean rubber crumb.
Prices for such equipment for processing rubber into crumbs start from 770 000 rub.
lines
Integrated approach to problem solving tire recycling is provided by lines for grinding used tires into crumbs.
The complete set of equipment offered by various manufacturers differs little from each other:
- bead ring removal device;
- guillotine for grinding tires into a tape;
- machine for squeezing steel cord;
- rollers for the manufacture of crumb rubber;
- magnetic and air separators;
- vibrating sieve.
Technology tire processing is as follows:
- Separation of tires by weight and diameter, cleaning from large contaminants.
- Installing the tire in a vise to separate the bead ring from the rubber.
- Cutting the resulting rubber into ribbons about 4 cm wide.
- Dividing strips into small pieces.
- Grinding blanks into crumbs with subsequent supply of products to the conveyor.
- Product cleaning in the separation chamber. With the help of the magnetic fields created by the installation, metal cord particles are separated from total weight crumbs. In the air cleaning chamber, due to the formed vortex flows, the final separation of impurities from rubber particles occurs.
- Sorting of the obtained products into size fractions.
The finished crumb is packed and can be sent for sale. Larger particles are returned to the conveyor and subjected to repeated grinding.
The line capacity is from 500 kg of raw materials per hour.
To maintain the line, 2-3 people will be required for 1 work shift, while special education No equipment skills required.
In the market of production equipment, tire processing lines are represented by manufacturers different countries. Consider the distinctive features of individual brands of equipment.
Tire processing line from the Novokuznetsk company ALPHA SPK "ATR-250" declared by the manufacturer as fully automatic. Human participation is required only if it is necessary to grind especially large tires. Equipment price starts from 5,000,000 rubles. You can study the supplier's offer in more detail on the website.
Factories
Mini-factories for the production of crumbs from rubber tires - best option for those who want to organize the processing of raw materials on a large scale.
Such production will have not only a personal, economic, effect, but also a social one.
New jobs will be created, social tension will decrease.
Benefits of using mini-factories for the production of crumb rubber:
- low energy consumption, and hence the cost of produced crumbs;
- compactness;
- ease of maintenance;
- excellent quality of grinding raw materials, allowing you to set up production in one cycle;
- environmental friendliness.
Compact rubber grinding plants "ATR-300" from the company ALFA SPK capable of producing up to 350 kg of tire crumbs. Equipment grinds rubber tires mechanical crusher.
The crumb produced by this technology is different high quality, which means it is of great value to end users of the product.
The miniplant is equipped with the following equipment:
- tire crusher;
- double-sided bead ring puller;
- knives for cutting tires into noodles;
- conveyer belt;
- impact crusher;
- magnetic separator;
- vibrating screens.
Miniplant works like this:
- Visual inspection of raw materials for the presence of impurities that can disable the equipment.
- Grinding large pieces of raw materials with a hand tool. Small tires are fed into the loading chamber as a whole.
- Shredding rubber shredder equipment into smaller fractions. At this stage, the raw material is cleaned from metal impurities.
- Feeding raw materials into a compartment with a rotating knife element for grinding raw materials to the right sizes. Cleaning of metal cord particles is an additional option launched by the system at this stage of rubber processing.
- Receipt of raw materials into the separation compartment, where the final cleaning of crumb rubber from impurities takes place.
- Passing finished products through vibrating screen cells for sorting by fractions.
The price of such a mini-factory - RUB 9,800,000. The productivity of the mini-plant for the production of crumbs of three fractions is up to 350 kg per 1 working hour. 3-4 people are enough to service the equipment. On the need for special training for service personnel the equipment manufacturer does not explicitly state. All questions of interest can be asked on the site.
Pay attention to tire recycling plants from EcoStep.
In the line of equipment there are models designed for both beginner entrepreneurs and more experienced tire processors.
The advantage of the equipment declared by the manufacturer is European quality and reliability.
Tire recycling plants model KPSh from the company Doza-gran recycle tires into 3 fractions, including rubber dust.
On the company's website, you can calculate the required equipment performance depending on your needs and end goals.
Cost of equipment - from 8,300,000 rubles.
Another manufacturer of tire processing equipment is Europlit.
The equipment of the NEO line presented by it allows you to independently adjust the desired parameters of the final product.
Comparative characteristics and prices
| Equipment brand | Characteristic | Price | Link to the website of the manufacturer (supplier) | |
| Mini plant "ATR-300" | Energy consumption, kW/h | 80-120 | 9.8 million rubles | alfaspk.ru |
| 500 | ||||
| Output, kg/hour. | 350 | |||
| Formation of by-products (additional income) | Yes | |||
| 120 | ||||
| Shop LxWxH, m | 20x4.5x4.2 | |||
| Number of workers, pers. | 3-4 | |||
| Plant Bio-KPSh | Volume of processed raw materials, t/year | 720-3000 | From 8.3 million rubles | dozagran.com |
| Production output, t/year. | 650-2700 | |||
| Power consumption, kW/h | 180-430 | |||
| Line NEO-300 | Output, kg/hour. | 300 | On request | epilit.ru |
| Power consumption, kW/h | 55 | |||
| Number of workers, pers. | 3 | |||
| Shop LxWxH, m | 33x6x3 | |||
| Obtaining by-products (additional income) | Yes | |||
| Line NEO-500 | Output, kg/hour. | 500 | At buyer's request | |
| Power consumption, kW/h | 90 | |||
| Number of workers, pers. | 3 | |||
| Shop LxWxH, m | 41x6x4 | |||
| Additional products | Yes | |||
| Line NEO-1000 | Output, kg/hour. | 1000 | Reported upon buyer's request | |
| Electricity consumption, kW/h | 180 | |||
| Number of workers, pers. | 5 | |||
| Shop LxWxH, m | 43.75x8x4 | |||
| Additional products | Yes | |||
| ECO STEP 500 | Energy consumption, kW/h | 100 | eco-step.ru | |
| Output, kg/hour. | 350 | |||
| The volume of processed raw materials, kg / hour. | 500 | |||
| Number of workers, pers. | 4 | |||
| Maximum diameter of recycled tires, cm. | 150 | |||
| Shop LxWxH, m | 30x10x5 | |||
| ECO STEP 700 | Power consumption, kW/h | 100 | Provided upon buyer's request | eco-step.ru |
| Output, kg/hour. | 350 | |||
| The volume of processed raw materials, kg / hour. | 500 | |||
| Number of workers, pers. | 4 | |||
| Maximum diameter of recycled tires, cm. | 150 | |||
| Shop LxWxH, m | 30x10x5 | |||
| Line LT400 | The volume of processed raw materials, kg / hour. | 250 | 52 thousand dollars | best-china.ru |
| Line LT450 | The volume of processed raw materials, kg / hour. | 500 | 59 thousand dollars | |
| Line LT560 | The volume of processed raw materials, kg / hour. | 1000 | 74 thousand dollars | |
| Line LPSH-300 | The volume of processed raw materials, kg / hour. | 500 | www.uas.ru | |
| Release of a crumb, kg/hour. | 300 | |||
| Maximum inner diameter of tires, cm. | 150 | |||
| Power consumption, kW | From 100 | |||
| Number of workers, pers. | 2-3 | |||
| Opportunity to earn additional income | Yes | |||
| Room size, m 2 | 200 | |||
| LPSH-200 | Room size, m 2 | 40 | RUB 1.853 million | www.uas.ru |
| up to 200 | ||||
| LPSH-400 | Room size, m 2 | From 120 | 5.781 million rubles | |
| The volume of processed raw materials, kg / hour | Up to 400 | |||
| LPSh-600 | Room size, m 2 | From 150 | RUB 6.135 million | |
| The volume of processed raw materials, kg / hour | Up to 600 | |||
| LPSh-800 | Room size, m 2 | From 200 | RUB 8.800 million | |
| The volume of processed raw materials, kg / hour | 800-1000 | |||
| LPSh-1500 | Room size, m 2 | From 250 | RUB 11.105 million | |
| The volume of processed raw materials, kg / hour | up to 1500 | |||
| KGSh-1500 | Room size, m 2 | From 200 | RUB 14.156 million | |
| The volume of processed raw materials, kg / hour | up to 1500 | |||
| "ATR-250" | Power consumption, kW/h | 80-100 | 5.6 million rubles | alfaspk.ru |
| Room size, m 2 | 80 | |||
| The volume of processed raw materials, kg / hour | Up to 300 | |||
| Crumb volume, kg/h | Up to 250 | |||
| Number of workers, pers. | 3-4 | |||
| UPShK-1200 | Power consumption, kW/h | 5 | 0.77 million rubles | stanki-ru.ru |
| Installation size, LxWxH, m | 1.8x1.2x2 | |||
| The volume of processed raw materials, kg / hour | 35-52,5 | |||
| Number of workers, pers. | 1 | |||
| UPShK-2000 | Power consumption, kW/h | 8 | 0.87 million rubles | |
| Installation size, LxWxH, m | 2.5x1.7x3.2 | |||
| The volume of processed raw materials, kg / hour | 87,5 | |||
| Number of workers, pers. | 1 | |||
| UPShK-2200 | Power consumption, kW/h | 8 | 1.12 million rubles | |
| Installation size, LxWxH, m | 2.8x1.8x3.4 | |||
| The volume of processed raw materials, kg / hour | 100 | |||
| Number of workers, pers. | 1 | |||
| UPShK-2700 | Power consumption, kW/h | 11 | 2.25 million rubles | |
| Installation size, LxWxH, m | 3.0x2.0x3.4 | |||
| The volume of processed raw materials, kg / hour | 112,5 | |||
| Number of workers, pers. | 1 | |||
| Single shaft machine Model 800 | 400-600 | 1.285 million rubles | darex.pro | |
| Receiving chamber size, see | 147.5x80 | |||
| Total number of knives | 49 | |||
| Power consumption, kW | 22-37 | |||
| Up to 4 | ||||
| Single shaft machine Model 1000 | Equipment productivity, kg/h | 600-800 | 1.41 million rubles | |
| Receiving chamber size, see | 147.5x100 | |||
| Total number of knives | 68 | |||
| Power consumption, kW | 37-45 | |||
| Finished product size, see | Up to 4 | |||
| Single shaft machine Model 1300 | Equipment productivity, kg/h | 700-900 | RUB 1.845 million | |
| Receiving chamber size, see | 147.5x130 | |||
| Total number of knives | 91 | |||
| Power consumption, kW | 45-55 | |||
| Finished product size, see | Up to 4 | |||
| Single shaft machine Model 1800 | Equipment productivity, kg/h | 1400-1800 | 2.75 million rubles | |
| Receiving chamber size, see | 147.5x180 | |||
| Total number of knives | 130 | |||
| Power consumption, kW | 75-90 | |||
| Finished product size, see | Up to 4 | |||
| Tire Crusher #1 | Equipment productivity, kg/h | 2000 | Provided upon buyer's request | texservis.com |
| Finished product size, see | Noodles -5, chips - 5x5 | |||
| Receiving chamber size, see | 120 | |||
| Total number of knives | 22 | |||
| Machine dimensions (LxWxH) see. | 630.3x280x366.7 | |||
| Tire Crusher #2 | Equipment productivity, kg/h | Before 2000 | Provided upon buyer's request | |
| Fraction of finished products, see | Noodles -4, chips - 4x4 | |||
| Receiving chamber size, see | 75x22x6 | |||
| Power consumption, kW | 58 | |||
| Machine dimensions (LxWxH) see. | 282x230x258 | |||
| Single Shaft Shredder 3E WT 2260 | Total number of knives | 34 | 0.998 million rubles | pragmat.ru |
| Rated power, kW | 18,5 | |||
| Productivity, kg/h | 200-300 | |||
| Machine dimensions (LxWxH), m | 1.774x1.359x1575 | |||
| Two-roll crusher DDR-300 | Power consumption, kW | 60 | Provided upon buyer's request | tet-ua.com |
| Productivity, kg/h | 300 | |||
| Receiving window size, see | 60x70 | |||
| Maximum tire diameter, cm. | 600 | |||
| Two-roll crusher DDR-500 | Power consumption, kW | 60 | Provided upon buyer's request | |
| Productivity, kg/h | 500 | |||
| Raw material receiving chamber limit, see | 75x80 | |||
| Maximum tire diameter, cm. | 750 | |||
| Two-roll crusher DDR-750 | Power consumption, kW | 90 | Provided upon buyer's request | |
| Productivity, kg/h | 750 | |||
| The size of the window for laying tires, see. | 82x100 | |||
| Maximum tire diameter, cm. | 870 | |||
| Two-roll crusher DDR-1000 | Power consumption, kW | 90 | Provided upon buyer's request | |
| Productivity, kg/h | 1000 | |||
| Receiving chamber size, see | 85x130 | |||
| Maximum tire diameter, cm. | 1200 | |||
findings
Tire recycling equipment is real find for those who want to establish a recycling business.
Affordable price, simple installation and maintenance, a wide scope of use of the resulting products - the reasons to consider this type of production as a priority for start-up entrepreneurs, as well as master additional view activities of established businessmen.
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Removal, processing and disposal of waste from 1 to 5 hazard class
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The need to recycle used tires arose due to the rapid growth in the number of cars in most developed countries. The number of used tires is growing every year, so the problem of their disposal has become an acute problem for the authorities of the states. Tire recycling equipment is not cheap.
Special factories and enterprises for their processing are being built. They decide the environmental and economic problem associated with the disposal of obsolete car tires. This waste tire business is already growing by leaps and bounds today. First of all, this is facilitated by a large amount of inexpensive raw materials.
A tire processing plant is being built near the place of sale of the product obtained after processing, namely: rubber crumb, saw, steel cord, fuel oil. A tire recycling plant is a cost-effective solution to the problem. It is located at the place of accumulation of raw materials or near the plant, the production in need of recyclables. The main thing is that the tire recycling plant should be located at a distance of more than 300 meters from the located residential buildings.
The plant is equipped with special equipment for the production of crumb rubber. To open a business in this area, investments are needed, however, due to the small number of competitors and the demand for this raw material, all investments pay off in the near future.
Waste Tire Recycling Equipment
Equipment for rubber processing is a plant - a reactor. It is installed in a specially designated open area.
Medium tire shredding equipment has the following capacity:
- 2 tons of liquid fuel
- 1.5 tons of solid residue containing carbon
- 0.5 tons of steel cord
- 1 ton of gas
The volume of tires to be shredded is 5 tons per day. Processed products serve as raw materials for many types of production. The reactor itself operates using gas, which itself is capable of producing during the processing of used tires. The installation is low maintenance, it only needs two people for one shift. To work on such an installation, employees of the enterprise must pass special training and study the features of the process.
Tire recycling products include:
- Rubber granulate and crumbs. Rubber crumb comes in various fractions: 0.1 - 0.45 mm.
- Regenerate. Finely ground crumbs with improved quality. Dimensions: 0.6 - 10 mm.
- Chips. Size 2 - 5 cm. Represented by pieces of tires along with steel cord.
- Resinoplast. Used in the manufacture of soft roofs.
- Rezinopol. Represented by a floor polymeric covering.
- Bireplast. It is represented by a multi-layer waterproofing roll roofing material.
- Reisol. Represented by rubber with a waterproof adhesive layer of rubber.
- Fiber concrete. A mixture of crumb rubber and two types of cord: textile and metal.
Rubber processing technologies
Rubber recycling can be done in several ways. The choice of method ultimately determines appearance and demand for the resulting product. The paragraph will not deal with landfilling. Despite the fact that this option is the simplest, at the same time, the crumb plant causes the least harm to the environment.
There are four main recycling methods:
- Crumb production - equipment for the recycling of tires into crumbs is considered the most rational, it can process several tons of tires per year and brings a stable income to the owner. But the technology is not perfect, it has a significant number of disadvantages, such as the need to select raw materials with the same composition in order to standardize the properties of the final product.
- Pyrolysis is the decomposition of tires under the influence of high temperature. This method is extremely inconvenient because during this process a huge amount of toxins released into the atmosphere is released. Another obvious disadvantage of this method of disposal is economic unprofitability. Decomposition equipment is expensive and pays for itself in a significant amount of time.
- Incineration is the complete destruction of tires. The only benefit from such an action is the production of energy, however, such products do not act very well as fuel. This is due to the fact that during combustion a large amount of soot is formed, which over time makes the equipment (furnaces) unusable. Since rubber contains sulfur, when using this disposal method, the substance enters the atmosphere and, when interacting with water, sulfuric acid is formed.
- Recovery is a process similar to recycling. This is the most promising and rational way. So, in the manufacture of one new tire, approximately 30 liters of crude oil are consumed, and only 5 are needed for restoration.
In recent years, business in this area is gaining momentum, it is especially popular in European countries, because it is there that society takes environmental protection most seriously.
Another clear advantage that this business is famous for is the purchase of inexpensive equipment for processing tires into crumbs. You can organize a recycling plant with your own hands in any room, even in your own garage.
Tire crumb line
Tire recycling line produces crumb rubber for business, it is considered environmentally friendly due to the absence of emissions into the atmosphere or into the ground.
The line and all equipment must be made in accordance with the requirements of the Russian Federation, which were put forward for equipment of this type:
- The level of noise emitted.
- By the amount of harmful emissions.
- According to life safety.
- Accordingly, the safety of waste processing.
The whole line for processing tires into crumbs consists of sectors:
- Preparatory, which includes 2 machines: 1 - for removing bead wire, 2 - shears for cutting tires.
- Crusher, consisting of 1 - crushing chamber and 2 - return sifter.
- Crushing rollers, representing two drums that rotate at different speeds towards each other.
- Granulator that feeds the mixture from the feed funnel to the crushing zone.
- Vibrating table of magnetic picker for uniform distribution mixtures under the influence of vibration.
- Knife granulator, consisting of a body with knives, a shaft with knives, a mesh with a hole diameter of 4 mm.
- Vibrating table in the form of an inclined rectangular structure.
- Magnet for picking up fine wire residues.
- Textile separators for a high level of crumb removal from textiles present.
- Automatic packers filling bags with crumbs.
This is how the process of recycling tires into crumbs, which serves as a secondary raw material for further production, looks like. It is not difficult to organize this recycling business. This is due to the relative cheapness of equipment and fast payback periods. The main mission of this business is to protect the environment.