Tire Recycling in the EU

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17-19 February 2008 RecShow 08 Jordan 1

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






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






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






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






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






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






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)






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






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.






Elements of the recycling process

•Collecting (manual)

• Sorting

• Pre-treating• Debeading

• Cutting

• Processing (mechanical)• Shredding

• Granulating

» Sieving

» Packaging

» Storing» Delivering






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






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






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






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






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






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






2. Pre-treatment : Manual processes

Removal of debris

Rinsing - remove dirt, etc.

Cutting in halves/quarters

Debeading

Preparation for recycling






Not all tyres are ready for treatment






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






Tyre processing

• Shredding

• Chipping

• Granulating

• Fine granulating

• Powders

•

Material upgrading






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






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






Granulation plant in operation






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.






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






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






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






Characteristics of whole tyres

Characteristics

• Lightweight,

• Low compacted density,

•High void ratio,

• Good compressibility,

• Water permeability,

• Thermal insulation

• Non-biodegradable






Slope stabilisation

Erosion control

Construction bale

Coastal and fluvial protection

Examples of whole tyre uses






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






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






Loose unbound chips :

Compacted unbound chips

Bound chips

Compacted shred

Landfill cell

(geotextile)

Loose shred

Building insulation

Examples of shred and chips

Drainage systems






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.






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






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






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






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






We’ll continue to work on it






We’ll continue to work on it

Thank you for your attention

Th 15 h A l E C f






The 15th Annual European Conference

on tyre recycling

Towards a Recycling society :

the challenge

2 - 5 April 2008 The Crowne Plaza Europa, Brussels

Tire Recycling in the EU

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