Detailed Project Report (DPR) on reclaim rubber (rubber reclaimation unit)

RECLAIM RUBBER 

(RUBBER RECLAIMATION UNIT)

[CODE NO.4250] 

Reclaimed or Re-generated rubber is the product resulting from the treatment of ground vulcanized scrap rubber tires, tubes and miscellaneous waste rubber articles by the application of heat and chemical agents, followed by intense mechanical working. The regenerated rubber has almost the original plasticity of virgin rubber, permitting the same to be compounded, processed and re-vulcanized or reused.

In reclaiming of scrap vulcanized rubber, the scrap is normally ground and is then treated with the application of heat, chemical peptizers and is then intensely worked upon mechanically to partially de-vulcanize (break the bonds between rubber polymer chains) the rubber component. This partially de-vulcanized product is commonly called reclaimed or re-generated rubber and can be compounded, processed and re-vulcanized much like virgin rubber. The availability and processing characteristics of suitable scrap sources has dictated the types of reclaim produced. Reclaimed rubber has become widely accepted as a raw material which possesses processing and economic characteristics that are of great value in the compounding of natural and synthetic rubber compounds.

Re-generated or Reclaimed rubber is produced by partial de-vulcanization of rubber granulate obtained from end-of-life tyres and other rubber products. The regenerated rubber has almost the original plasticity of virgin rubber, permitting the same to be compounded, processed and re-vulcanized or reused.

Regeneration can occur either by breaking the existing cross links in the vulcanized rubber (partial de-vulcanization) or by promoting scission of the main chain of the polymer (breakage of C-C bonds) or a combination of both processes.

Partial De-vulcanization means selective cleavage or breakage of Disulphide (S-S) chemical bonds (see: Figure below) leading to the separation of natural rubber polymer chains using heat, mechanical shear force and assisted by peptizers (like process oil & pine tar oil) and reclaiming agent (like Disulphides). The de-vulcanization is partial i.e. some and not all Disulphide (SS) chemical bonds are broken. The main mechanism of de-vulcanization is by means of thermal – oxidative degradation and high shear force acting on the material.  

 Figure: Vulcanized Natural Rubber (with Sulphur)

By the application of heat and chemical agents followed by intense mechanical working to ground vulcanised scrap or worn out rubber tires, tubes and waste rubber articles, a substantial regeneration on devulcanisation of the rubber compound to its original plastic state is effected, thus permitting the product to be compounded, processed and revulcanised. Reclaiming is essentially depolymerisation and misnomerically called "devulcanisation" although combined sulphur is not removed. By this depolymerisation, the reclaimed rubber shows decreased resistance to deformation at ordinary temperature; thus losing its elastic nature and become less resistant to compression, stretching or swelling. Reclaimed rubber was born because a secondary source of rubber was urgently needed. Entire rubber industry was growing so fast in the early days and there was no enough crude rubber to substantiate the demand. Reclaim rubber soon become indispensable. Apart from this, tire pose a disposal problem and therefore utilized as basic raw material in the form of ground vulcanised waste (crumb rubber) or converted to reusable state-reclaimed rubber.

Because of short break-down and mixing time, the power consumption during break-down and mixing, low temperature required in calendering and extrusion, non-critical calendering temperature penetration to fabric, tack improvement, minimising sulphur bloom, forming of uncurved stock, low swelling and shrinkage on extrusion and calendering, low thermoplasticity, high rate of cure and cheaper rubber/filler are important considerations in the mind of the compounder in deciding upon regular use of reclaim for low cost, energy, conservation and efficient processing steps even with new generation polymers to achieve desired optimum properties. Reclaimed rubber is primarily used in the manufacture of cycle tyres, Rickshaw tyres, Battery Boxes, Automobile tyres and other moulded rubber goods.

COST ESTIMATION

Plant Capacity                            24 Ton/Day

Land & Building (2 Acres)  Rs. 4.08 Cr

Plant & Machinery                      Rs. 5.50 Cr

Working Capital for 1 Month    Rs. 1.60 Cr

Total Capital Investment          Rs. 11.65 Cr

Rate of Return                            36%

Break Even Point                       55%

INTRODUCTION

FIGURE: VULCANIZED NATURAL RUBBER (WITH SULPHUR)

WHAT HAPPENS DURING RECLAIMING

USES APPLICATION AND ADVANTAGES

ADVANTAGES OF RECLAIM RUBBER

RAW MATERIALS

RUBBER WASTE (USED TYRE AND TUBE SCRAP):-

B.I.S. SPECIFICATIONS

1. SCOPE:

2. REQUIREMENTS:

RECLAIMED RUBBER

3. PACKING:

4. MARKETING:

5. SAMPLING:

MARKET OVERVIEW FOR RECLAIM RUBBER

SO WHAT EXACTLY IS RECLAIM?

DIFFERENT MANUFACTURING PROCESS OF RECLAIM RUBBER

DIGESTER PROCESS

PAN PROCESS

HIGH PRESSURE STEAM PROCESS

BANBURY PROCESS

RECLAIMATOR PROCESS

CRUMB RUBBER AND RECLAIM RUBBER PROCESS

TIRE BEAD SEPARATOR

TIRE SHREDDER

CRACKER MILL

MAGNETIC METAL & NYLON FIBER SEPARATOR

FIBER SEPARATOR

RUBBER CRACKER MILL WITH MAGNETIC METAL SEPARATOR, BELT CONVEYER AND VIBRATING SIEVE

SEQUENCES IN CRUMB RUBBER AND RECLAIM RUBBER FROM WHOLE SCRAP TYRE

DEVULCANIZER (AUTOCLAVE)

KNEADING MIXING MILL

TWO ROLL MIXING MILL

STRAINER EXTRUDER

STRAINER EXTRUDER HEAD

REFINING MILL

EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE

TYPICAL COMPOUNDING RECIPES FOR INCORPORATING RECLAIMED RUBBER

MANUFACTURING PROCESS IN DETAILS OF RECLAIMED RUBBER

METHOD OF RECLAIMING RUBBER

FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER

TESTING & EVALUATION OF RECLAIMED RUBBER

A) CHEMICALS

B) PHYSICALS

RECLAIM RUBBER PRODUCTION FOR CROSS PLY TYRES

PROCESS FLOW DIAGRAM OF CRUMB AND RECLAIM RUBBER FROM TYRES /TUBES

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

DETAILS OF RECLAIM RUBBER MACHINERY

RUBBER GRINDER MILL

RUBBER REFINER MILL

PRE - REFINER MILL

DE-BEADER MACHINE

STRAINER

AUTOCLAVES

PRESSURE RATING:

TYPES OF DOOR:

TEMPERATURE INDICATION:

FORCED AIR CIRCULATION:

STANDARD ACCESSORIES:

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR RECLAIM RUBBER

SUPPLIERS OF RUBBER PROCESSING MACHINERY

SUPPLIERS OF RUBBER MIXING MILL

SUPPLIERS OF VIBRATING SCREENS

SUPPLIERS OF AUTOCLAVE, OVENS

SUPPLIERS OF CONVEYOR BELT

SUPPLIERS OF CHOPPER MACHINE

SUPPLIERS OF MERIT INDUSTRIES LIMITED

SUPPLIERS OF BOILERS

SUPPLIERS OF PORTABLE GENERATOR

SUPPLIERS OF CHEMICAL STORAGE TANKS

SUPPLIERS OF RECLAIMED RUBBER

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF RUBBER MANUFACTURING CHEMICALS

SUPPLIERS OF COAL TAR PITCH

SUPPLIERS OF SODIUM HYDROXIDE

SUPPLIERS OF BENZENE

SUPPLIERS OF CARBON BLACK

SUPPLIERS OF ZINC OXIDE

SUPPLIERS OF CHINA CLAY

BUYERS OF RECLAIM RUBBER

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)