Friday, October 23, 2015

Recycling Plant (CRUMB RUBBER) - (CRMB)

Manufacturing of Crumb Rubber Powder Production
    Modern Industrial world external use of Crumb Rubber based on disposal method of waste tyres as Raw material for production to clean environment. Crumb Rubber is non biodegradable, carried out recycled rubber from tyre scraps. There are two major technologies used in commercial market for producing crumb rubber – ambient mechanical grinding (Economy) and Cryogenic grinding. of the two processes, cryogenic process is more expensive but it produces smoother and smaller crumbs. In this project we are using Ambient mechanical grinding process.
Ambient grinding is a multi-step technology and uses whole or pre-treated tires in the form of shred or chips, or sidewalls or treads. The rubbers, metals and textiles are sequentially separated out. Tires are passed through a shredder, which breaks the tires into chips. Ambient system is generally used for the initial size reduction phases. The outputs from ambient system can be used directly or as feedstock for further processing.
Ambient can be repeated to produce finer particles. The chips are feed into a granulator that breaks them into small pieces while removing steel and fiber in the process. Any remaining steel is removed magnetically and fiber through a combination of shaking screens and wind sifters. Finer rubber particles can be obtained through further grinding in secondary granulators and high-speed rotary mills. Ambient grinding is the production process use by the us as crumb rubber producer.

Raw Material Waste Tyres
Base on Vehicles
1.  PCT: Passenger Car Tyre
2.  LTT: Light Truck Tyre
3.  TBT: Truck & Bus Tyre
4.  OTRT: Off the Road Tyre
5.   AGT: Agriculture Tyre
6.  IDT: Industrial Tyre
7.  MCT: Motor cycle Tyre
8.  ACT: Air Craft Tyre
     Here we use LMV Tyres, Truck Tyres upto 1125” Niylon Tyres & Redial Tyres.
Scrap tire contains (%):
  • 70 % recoverable rubber
  • 15 % steel
  • 3 % fiber
  • 12 % extraneous material
  • Section 1:
    Reduction Process
         In this part a machine that tears apart scrap tyre rubber by passing the material between rotating serrated steel drums, reducing the rubber to various sizes. With physical method under room temperature, the tyre recycle lines separate rubber, steel and other materials so they can be recycled and reused. The production capacity of the line starts feeding from 320kg/hour, and can be expanded to 3 ton/hour. Shredder 1, 2 & Granulator Rubber, Steel and Fiber after separation the mesh size of the rubber powder / granules, the most important products of tyre recycling, is optional between 5-120 mesh, among which rubber powder of 10-40 mesh as per production demand base on market.
    Section 2:
    Separation Process
             The zig zag shifter and screens or sieves that are mounted in a production piece of equipment to separate the desired size of crumb from the other sizes, and recycle the other for the purpose of further size reduction. Sieve analysis is the most common technique for determining particle size measurement. It consists of shaking and tapping a measured quantity of crumb rubber sample through a specified number of test sieves over a specified time. The amount of sample retained on each screen is weighed and results are given as the percentage of sample retained on each screen. Rubber powder produced by the pulverizers will be classified by rubber sieve to get wanted size. Pulverize the rubber granules produced in last step with rubber pulverizer into rubber powder/ rubber crumb of 5-100 mesh. (Rubber powder size is optional with sieve of different mesh size, finer powder of over 40 mesh can also be produced in this step, however the quantity will be small). Unqualified rubber powder/ rubber crumb are automatically conveyed back into the pulverizer to be processed again. The final magnetic separating will be conducted to remove the remaining steel.
    Section 3:
    Material Flow, Fiber & Steel  

                Convey the rubber granules with belt conveyor into box magnetic separator.  The belt magnetic separator placed above the conveyor separates the steel wires mixed in the rubber granules, and the box magnetic separator then further separate fine separates the granules, 98% of the steel wire will by now be removed. Fiber Fluff 2%. All percentage will be depends waste tyres. We have using a larger than normal size hydraulic power Pac (300 h.p.) instead of the normal powered (200 h.p.) to drive the model 62 X 40HT shredder and have also using a much higher torque out-put hydraulic motor on the shredder to achieve the ability to be able to easily shred whole tyres. We will also be able to remove around 75%-80% of the wire from the rubber at this point by using a cross-belt self-cleaning magnet. We will also be able to remove a small amount of fluff at this point by using a small aspiration system. This system will come complete with all the legs, hoppers, and electrical controls needed to complete the system. We are using best branded motors for long life and less maintenance.

    Final Products:

    1.  Steel
    2.  Steel Crush
    3.  Nylon
    4.  Crumb Rubber 5mesh – 100mesh
    Applications of crumb rubber are as follows:
    Sport Surfaces: Sports Areas
    Automotive Industry: Fenders, floor Mats & Liners
    Construction: Floor Tile, Waterproofing Roof Liners
    Geotechnical/Asphalt Applications: Rubberized Asphalt for Roads
    Adhesives and Sealants: Textured and Non-Slip Paints
    Shock Absorption and Safety Products: Abrasion Lining in Mining Equipment
    Rubber and Plastic Products: Insulation and Lining

    Environmental: Process Eco friendly free from airborne waste
    Not applicable : Our process itself is defined as waste recycling of scrup tyres It won’t liberate any form of air borne waste. Our mechanism helps the ecology and saves the environment.
    Liquid effluent waste NA/NIL : Our process ensures that there will be no liquid wastes.
    Solid wastes: There is no solid form of wastes/byproduct from the process
    No unpleasant odour will evolve by the process. Only rubber smell which is highly negligible. There is no chemical odour No burning or combustion processes.
    Chemicals of Potential Characters Components of Crumb Rubber:
                    The crumb rubber used in synthetic turf systems is made primarily from recycled waste tires. The tires themselves contain several COPCs, and undergo minimal processing to become crumb rubber. Direct and indirect methods have been used in studies to determine the presence of these COPCs in the crumb rubber. These studies have found polycyclic aromatic hydrocarbons (PAHs), volatile organic compounds (VOCs), semivolatile organic compounds(SVOCs), benzothiazole, and certain metals. Studies have also identified phthalates, alkylphenols and benzene, which likely  become bonded to tires during their use. Direct analyses confirming the presence of these COPCs in crumb rubber have used vigorous extraction methods. Some COPCs have been identified through indirect methods including analysis of leachate in the environment near where recycled tire products were used or in controlled laboratory studies. Because crumb rubber is a recycled material, the presence and concentrations of COPCs is expected to vary between products and even among batches from the same manufacturer.

    Value added Focus of Project:
    Modern Industrial world external use
    Floor Liners & Mat sheet      
    Tile – Recreation Area in Civil Industry

Tuesday, July 28, 2015

Thursday, January 1, 2015

POLYOLS (Industrial Grade)

R M S (Technical Consultancy)


 Industrial Polyols - Projects

Contact us:
Execute Trading Pvt Ltd
+91 9176186091