THE ECONOMICS OF RECYCLING RUBBER

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Bruno Osborne
5 years ago
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1 THE ECONOMICS OF RECYCLING RUBBER Bob Kind Polymer Recyclers Ltd Rubber in Engineering Meeting - 10 th December 2010 Key Drivers Rubber prices follow oil prices but can be influenced more dramatically by demand and availability. The cost of rubber disposal is rising, soon landfill may not be an option By getting more out of the rubber we ve got we reduce pressure on global resources Recycling now seen as mainstream 1

The ReTern Concept Growth through innovation We identify and process consistent sources of high quality production waste and end of life rubber matched to meet customer needs.

2 The ReTern Concept Growth through innovation We identify and process consistent sources of high quality production waste and end of life rubber matched to meet customer needs. ReTern Rubbers Vulcanised Rubber Sources Natural rubber from EOL whole truck tyres and tread buffings Synthetic rubber from EOL passenger car tyres Butyl from EOL cure bladders EPDM from ELV s HNBR from in process grindings 2

3 The ReTern Concept The Input Materials Vulcanised rubber powders or granules Polymer matrix Process Chemicals The ReTern Concept The formulation Vulcanised rubber crumb % Polymer matrix 5 20 % Chemical package 2 5% 3

4 Routes to manufacture Batch process internal mixer Continuous extruder [single or twin] with mixing capability Mixing in a conventional mixer 4

5 Economics of the process Cost of raw material in some cases a negative value less than fee to landfill Size reduction, wire and fibre removal High shear mixing of the process including :- labour, power, raw materials Transport Overheads and profit 5

6 RETERN NR1 FORMULATION 2009 SMR 5L-natural rubber Truck tyre crumb Chemical pack TOTALS Compound SG 1.14 % Recycled content Material cost 387 Profit & overhead 30% 212 TOTAL COST /TONNE 849 VOLUME COST p/litre TYPICAL TRUCK TYRE RETREAD FORMULATION 2009 SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD TOTALS Compound SG 1.13 % Recycled content 0.00 Material cost 1068 TOTAL COST /TONNE 1318 VOLUME COST p/litre

7 TYPICAL TRUCK TYRE FORMULATION SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD ReTern NR TOTALS Compound SG 1.13 % Recycled content Material cost 1013 TOTAL COST /TONNE % ADDITION OF RECYCLED MASTERBATCH Saving 3.4% VOLUME COST p/litre TYPICAL TRUCK TYRE FORMULATION SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD Truck tyre crumb TOTALS Compound SG 1.13 % Recycled content Material cost 988 TOTAL COST /TONNE % TRUCK TYRE CRUMB Saving 6% VOLUME COST p/litre

8 TYPICAL TRUCK TYRE FORMULATION + 25% COMBINED RECYCLED SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD Truck tyre crumb ReTern NR Compound SG % Recycled content Material cost 964 TOTAL COST /TONNE 1214 Saving 8.0% VOLUME COST p/litre Formulation ref >>> Ingredients vvv phr phr phr phr BASE SVR10 -natural rubber BR1220- polybutadiene N339 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur Truck tyre crumb ReTern NR SECOND STAGE MBTS TMTD TOTAL % RECYCLED

9 Rheometer 160 o C Tmin -Viscosity Tmin+1 Scorch dec mins T max T90 % Optimum cure - dec mins Physical properties on moulded sheet cured o C Hardness - Macro I.R.H.D. Tensile Strength (Mpa) Elongation at Break %

Trouser tear strength - N/mm 34.0000 32.0000 30.0000 28.0000 26.0000 24.0000 22.0000 20.0000 Abrasion resistance DIN 53516 - %loss by volume 8.00% 6.00% 4.00% 2.00% 0.

10 Trouser tear strength - N/mm Abrasion resistance DIN %loss by volume 8.00% 6.00% 4.00% 2.00% 0.00% Practical considerations ReTern NR1 can be added to truck tyre tread formulations. Mixing and extrusion properties are maintained Physical properties are affected but may still be acceptable When raw material prices rise the use of ReTern becomes more cost effective. 10

11 RETERN NR1 FORMULATION + 20% CHEMICAL PRICE INCREASE SMR 5L-natural rubber Truck tyre crumb Chemical pack TOTALS Compound SG 1.14 % Recycled content Material cost 410 Profit & overhead 30% 220 TOTAL COST /TONNE 880 VOLUME COST p/litre TYPICAL TRUCK TYRE FORMULATION + PRICE INCREASE 20% SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD TOTALS Compound SG 1.13 % Recycled content 0.00 Material cost 1281 TOTAL COST /TONNE 1531 VOLUME COST p/litre

12 TYPICAL TRUCK TYRE FORMULATION + PRICE INCREASE 20% SMR 5L-natural rubber BR1220- polybutadiene N330 HAF Naphthenic oil TMQ- antioxidant Wax blend Zinc oxide Stearic acid Sulphur MBTS TMTD ReTern NR TOTALS Compound SG 1.13 % Recycled content Material cost 1180 Saving 6.6 % TOTAL COST /TONNE 1430 VOLUME COST p/litre Conclusion In practice higher proportions of masterbatch can be used and processability maintained The use of a masterbatch plus tyre crumb can optimise processability and price. 12

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