Technologies and equipment for tire processing. Will tire recycling as a business pay off: reviews from entrepreneurs and nuances All about the business of tire recycling

Of the total volume of deteriorated automobile slopes, only about a quarter are subsequently used as recyclable materials. The remaining mass of environmentally harmful material, due to unprofitable processing technologies, is stored at special landfills and natural landfills, representing great danger. It is precisely 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 feasibility of civilized disposal of tires is explained by the shortage of space for their disposal, especially in East Asia. But in EU countries such burial is not permitted by law (a tire decomposes in the ground for about 150 years).

Grinding of worn tires to produce 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 compliance with the basic technological parameters of rubber while maintaining molecular bonds. Although it has one drawback - unprofitability.

Grinding technologies

The following grinding technologies are distinguished:

• 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 circulation of explosion products, recognized as the most effective and inexpensive destructive means. Equipment and 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 size of 10 to 50 mm are obtained. Then, for the purpose of separation, they are transformed into granules of 3-10 mm. The crumbs are freed from cord, fiber, and foreign elements on sieves, in drums and separators.

Methods for modifying crumb rubber

Distinctive feature crushing of waste is that the resulting particles are smooth, like broken glass. For improvement 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, and steam technologies.

Areas of use of crushed rubber

Every year, at least 34 million tires are turned into crumble, used for the construction of coatings and surfaces, additives in mortar, as well as for the manufacture of tires, rugs, and soles. And also this one cost method has successfully taken root in the construction of highways.

Recycling of used tires

In Russia, only 7% of used tires are recycled, while the world average, let us recall, is 23–30% (which is perhaps not so much for the 21st century). Question future fate The problem of worn tires became especially acute with the advent of metal cord carcasses. 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 fall into disrepair every year and remain unclaimed, and 9/10 of this amount are automobile slopes.
The capital and St. Petersburg and the region account for almost 200 thousand tons.

The main reason that such an industrialized country as Russia has a tire recycling rate comparable to the level of recycling in African countries is the Soviet mental legacy. We are traditionally not used to investing money in economical secondary production, and with rare exceptions, there are no prerequisites for stimulating it at the government level.

Passed law on waste generally had a positive impact on the implementation of civilized programs for the disposal of rubber goods. But what exactly can Russian proponents of the “waste into income” principle write down as a “rubber” asset? Let's list it.

An enterprise with a stable operating reactor has been created in Kaliningrad, where high-quality fuel oil is generated through pyrolysis as a thermal fuel, as well as a substitute for activated carbon.

At complete refusal From tire burning in the first 15 years of independence, the volume of crushing of used tires increased from 5 to 10%, and now reaches 30%.

The Tushino Machine Plant has mastered the production of crumb tires using two lines with an installed annual capacity of 5 thousand tires, and has also increased the production of especially relevant tires. this moment and panels for railway crossings.

Commissioned ecological production with imported manufacturing equipment in Tver, Kursk, Vyazma, Samara.

In Primorye, Templar Center CJSC produces roofing materials from crumbs. Moreover, it revives the complete closed cycle of regenerate production using a thermomechanical method.

It is noteworthy: this leap became possible due to the use of a mechanical grinding method with normal temperatures. Alternative (cryogenic) technologies are not widespread throughout the world due to the high cost of low-temperature crumbs, and efforts to harness the power of an explosion or an “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.

Recycling hazardous types of waste is relevant in Russia. With the increase in the number of cars, the number of used tires increases (according to statistics, it reaches 1 million tons per year).

There are not enough enterprises involved in their processing, although every year 50 tons of rubber that has become unusable accumulates in each region. Not all cities have places to store this type of waste. Discarded tires are found on the side of the road or adjacent to suburban roads.

The greatest experience in recycling tires is in the Moscow region (2 specialized plants operate), but they only recycle 10%. Therefore, the business of processing car tires will fill an empty niche.

The advantage of such a business is the opportunity to receive old tires for free. Processing tires into crumb rubber is a promising type of business.

There is no tire recycling system in Russia; experts attribute this to imperfect legislation.

Advantages and disadvantages of the processing business

The advantages of this business include:

• inexpensive raw materials in large quantities;
• location close to sales locations;
• few competitors;
• the ability to use any room;
• economic benefit.

Flaws:

• initial investment required;
• selection of raw materials with the same composition.

Selecting a room

The main parameters are the area of ​​the premises and the rental price. When choosing a room you need to consider:

• the area must be sufficient to accommodate production equipment;
• places for loading and unloading;
• necessary auxiliary premises;
• connection to water supply and power lines;
• convenient access roads;
• distance from residential area 300 m or more.

An industrial zone located outside the city would be the most suitable location.

Required documents

To open a business, you will need documents confirming or, the conclusion of the sanitary-epidemiological and fire service, an agreement for the supply of electricity. Licensing for this type of activity was canceled by Federal Law No. 93 of June 25, 2112.

What documents will be required to register an individual entrepreneur and how to prepare them correctly in accordance with legal requirements - read

Registration of activities

You should approach your choice responsibly: this affects the registration procedure, payment of taxes and other factors. When opening an LLC, the following responsibilities arise:

• as a legal entity;
• as individuals, founders and participants.

The LLC is liable for its obligations within the limits of its property. If it is impossible to repay debts during bankruptcy, obligations may pass to the founders and participants.

For individual entrepreneurs, when debt obligations arise, property is not considered personal and is not used for business activities (this also applies to property acquired before the start of business activities).

Industrial processing of tires into crumbs: business plan with calculations

The technological line that processes tires into crumbs has a capacity of up to 700 kg/hour. The yield of finished products from the initial mass of raw materials is 60 - 70% of the granulate, which is in particular demand (fraction 2 - 4 mm).

Room area 250 m2, number of workers 4 people, electricity consumption 120 kW. The annual production of crumb rubber will be 2000 tons.

• The cost of main equipment is 10.75 million rubles.
• Delivery and setup 250 thousand rubles.
• Additional expenses 30 thousand rubles.
• A machine that sews bags 10 thousand rubles.
• Scales 20 thousand rubles.
• The cost of crumb bags is 20 thousand rubles.
• Staff salary is 100 thousand rubles.

At minimum monthly processing 150 tons of tires, the yield is:

• metal cord 30 tons;
• rubber crumbs 100 tons;
• textiles 20 tons.

Income from product sales

• 1500 thousand rubles. from crumb rubber (100 t x 15 rubles/kg);
• 90 thousand rubles. metal cord (30 t x 3 thousand rubles/t);
• 40 thousand rubles. textiles (20 tons x 2 thousand rubles/t);
• 150 thousand rubles. acceptance of tire recycling from individuals and enterprises.

Total: 1780 thousand rubles.

Production costs

• 100 thousand rubles. staff salaries;
• 4 thousand rubles. for packaging bags;
• 20 thousand rubles. communication services, economic;
• 100 thousand rubles. electricity (120 kW x 4.5 rub.);
• 50 thousand rubles. rental of premises;
• 50 thousand rubles. line maintenance;
• 20 thousand rubles. garbage removal.

Total: 344 thousand rubles.

The profit is 1780 – 344 = 1436 thousand rubles. Return on investment 8 months.

With an increase in the output of finished products and their sale at a price above the minimum, monthly profit indicators will increase.

Starting a business requires large investments, and this is scary for novice entrepreneurs. You can use bank loan or get a subsidy state program. To do this you will need a business plan with calculations.

and tips for their implementation are contained in our new article at the link.

Possible risks

The production cycle includes the supply of raw materials, operation of equipment and sale of finished products. Risks that may arise:

• breaking technological equipment(to reduce this risk, the line should be serviced in a timely manner, recommendations for its operation should be followed, worn-out mechanisms and consumables should be replaced);
• interruptions in the supply of raw materials (a contract for the supply of raw materials can be concluded simultaneously with the search for equipment);
• difficulties with sales (it should be concluded long-term contract with an enterprise that needs crumb rubber and establish a distribution channel to nearby regions);
• spoilage of products during storage (special conditions are not required, but crumb rubber is afraid of moisture).

A business based on processing car tires into crumbs will be profitable if the entrepreneur manages to resolve the issue of marketing the finished product. This direction is promising and consistently brings good profits.

You can find out how lines for processing tires into crumbs function in practice in the following video:

The problem of recycling used tires is acute in many countries. In this matter it is important not only environmental aspect, but also economic, because the material obtained during processing is a good raw material for chemical industry. Let's find out what processing methods are currently used in the world, how effective and safe they are.

Types of recycling of used tires can be divided into two groups:

• electromechanical grinding;
• processing that changes the chemical structure.

Tire processing using these methods differs in the principle of operation and the resulting raw materials. Each of them has its own advantages and disadvantages, which are worth talking about in more detail.

Mechanical tire shredding

This method It is considered relatively safe from an environmental point of view and is widely used throughout the world. Tires are subjected to the following processing:

1. Old tires are washed, the beads are removed and cut into large pieces.
2. Raw materials are cleaned from steel cord using magnetic separation.
3. The pieces are then heated (for elevated temperature processing) or cooled (for cryogenic processing).
4. Rubber is crushed by cutting, impact, explosion, compression or abrasion.
5. The resulting raw material is ground to obtain crumbs of the desired size.

The disadvantage of this method is the high cost of the final product, since tire shredding requires special equipment and is considered an expensive processing method. Electricity costs are also high - up to 1000 kWh per 1 ton of processed raw materials.

At the same time, shredding has significant advantages over chemical methods of tire processing: technical simplicity, lack of toxic emissions (unlike combustion or pyrolysis). Rubber processing by grinding preserves the technological parameters of the material.

Crumb rubber obtained by grinding is widely used in industry and construction: for the manufacture of household products, additives in mortar, and for laying roads.

The following video shows how tires are processed into crumb rubber and what equipment is used.

Other Tire Shredding Methods

There are other methods for shredding old tires, but various reasons many of them did not receive wide application. Most known methods processing:

• using a rotary disperser;
• ozone knife method;
• barodestruction method;
• shock wave grinding (explosive circular).

For the rotary disperser, the tire is crushed into small pieces. The rubber is then compressed in the sleeve and passed through a hole with a diameter of about 1 mm. The result is fine rubber dust with a highly developed surface that can effectively react with other components of the mixtures. Such dust is used for the manufacture of sorbents, new tires, roofing materials, etc.

Tire recycling using the ozone knife method involves exposing worn rubber to ozone in a special chamber and subsequent mechanical grinding. Ozone promotes the destruction of the rubber structure, facilitating further grinding of the tire by mechanical methods. As a result of old tire the result is pure rubber crumb and metal, and there is no need for separation, since the metal and rubber themselves separate from each other when exposed to ozone.

When treated with the barodestruction method, tires are first cut and shredded, and then in a special chamber under the influence of high pressure and temperatures bring the rubber to fluidity, separating it from the metal cord. The result is fine rubber crumbs with a granule size of about 0.8 cm.

Processing methods that change the chemical structure

Recycling of car tires, which changes the structure, is also not very profitable. The rubber component disappears after processing, and the resulting product has a lower cost than in the case of mechanical processing. At the same time, the cost of final raw materials is quite high.

Among the chemical methods for recycling tires, the most common are the following:

• pyrolysis;
• thermal destruction (combustion);
• dissolution.

Pyrolysis is a thermal decomposition that occurs in a special chamber without air access. This method is most often used to obtain thermal energy. Rubber processing by combustion and pyrolysis has a number of limitations, they are associated with the release carbon dioxide and toxic substances. This method requires more attention from an environmental point of view.

When burned in cement kilns, tires replace combustible materials such as coal and fuel oil. Applicable this method in the cement industry and for heat generation.

Many experts consider the dissolution of old tires to be a promising and very effective method, although it has not yet been widely used. Under the influence of the solvent, raw materials are obtained that can be successfully used in metallurgy and the chemical industry.

It is expected that this technology will help to effectively recycle tires of all types and sizes in the future.

Tire recycling in Russia and Europe

European countries boast recycling rates of old tires reaching 90%. About 20% of them are recovered and reused, 40% is used to generate heat, and more than 30% turns into crumbs.

Unfortunately, the global average is not that high - less than 40% of tires are recycled, and 60% of unrecycled rubber goes to landfill.

Important! Every year, about 10 million tons of new waste from old car tires appear in the world, which makes the environmental situation simply catastrophic. It is very important to pay close attention to this problem and introduce recycling methods in countries where it is not developed.

In Russia the situation is completely sad, although it is gradually improving year by year. Tire recycling currently accounts for about 10%, and has grown by a quarter over the past few years. Tire recycling organizations in Russia are not yet very active; in our country, people are not used to investing money in secondary production, disposal and recycling.

One of the additional problems is that it is more difficult to recycle domestically produced tires, common in Russia, Belarus and other neighboring countries, than European ones. Our old tires are additionally reinforced with radial synthetic cord, and a large admixture of textiles creates great difficulties for processing. As a result, processing domestic tires is much more expensive and more difficult than Western-made tires with an all-metal cord type.

Additional Information! The most common processing methods in Russia are crushing and pyrolysis. It should be noted that pyrolysis is prohibited in some developed countries due to harmful effects on ecology. However, domestic entrepreneurs consider more expensive processing methods to be too expensive, so they use them much less frequently.

We hand over rubber for recycling

However, there is still reason for optimism - over the past few years, new environmentally friendly and safe complexes for the production of crumb rubber have appeared in Russia. In particular, such complexes operate in Samara, Kursk, Tver, and Vyazma. A processing center was built in Primorye, and a franchise helped many enterprises operating in this industry launch production.

Almost every major automobile service center in Russia it accepts old tires from car enthusiasts. You often have to pay extra to return tires, although some services accept them for free. Companies are increasingly entering into contracts with recycling companies, handing over significant volumes of old rubber for recycling.

You can hand over tires for recycling at factories and complexes that produce secondary raw materials, as well as at car service stations. It is worth considering that large enterprises They usually do not accept tires from the public due to the small volume of the product being handed over, so citizens have to monitor promotions at car service stations in order to get rid of one or two sets of tires.

Economics and ecology

The economic benefits of recycling tires are undeniable. In a number of countries, flammable gas, which is released during the heat treatment of tires, is used to heat rooms, and it is also used to generate electricity. Liquid pyrolysis products are used in the production of plastic, and crushed rubber particles are an excellent raw material for asphalt bitumen.

Note! The decomposition of tires in the ground continues for more than 100 years, all this time dangerous and toxic compounds, such as phenanthrene, diphenylamine and many others, are constantly being washed out of old tires. They all remain in the soil and are then washed away groundwater and rainfall, falling into sources drinking water and agricultural objects.

Thus, in the coming years, tire recycling methods will be improved, and the volume of rubber recycling will grow. This is especially true for developed countries, where environmental issues and reuse materials have long been under close attention both the citizens themselves and the authorities.

The situation in Russia is still reminiscent of the situation in African countries, but the principles of responsible consumption are gradually penetrating the consciousness of our citizens. In a few decades, both car enthusiasts themselves and business representatives will know exactly what and how to do with old tires in order to get the maximum benefit from them for themselves and the environment.

An industrial business idea to launch a mini-factory for the production of crumb rubber by processing tires is attractive due to its excellent ratio of large cash turnover and short payback periods. And most importantly, recycling is the production of money from garbage. We present to your attention a business plan for the production of crumb rubber with calculations and analysis of possibilities. For example, it is worth paying attention to the additional income from extracting metal from tire cords, which contain as much as 7%. Which ones else does he keep? useful secrets Let's look at this production in more detail.

Mini-plant for processing tires into crumbs

How to correctly calculate the rate and volume of production of crumb rubber from recycled car tires? The answer to this question is not so simple. The production of crumb rubber depends on many nuances. There are two key factors, which formed the basis for the attractiveness of this activity from an investment point of view. They will help answer this question.

Factor No. 1: Entry threshold into industrial small business

First of all, you should correctly assess your financial reserves that you own (your own savings and possible loans). It is worth noting that this type of industry is possible with different amounts of investment, which means this business scales well. With small investments in the initial phase, the income may be minimal, taking into account regular expenses for electricity, transportation costs, employee salaries, taxes, etc. It is worth noting here that this concept of a business idea underlies the recycling of waste (used car tires). And according to tradition, in order to get gold from garbage, you need to do a lot of work. Therefore, investing too little increases risks significantly. You can start production on a large scale through the construction of a specialized enterprise large areas, for example, several hundred square meters which will be worth a big investment. Make the optimal choice of investment strategy in favor of the golden mean between these boundaries.

Factor #2: Production Capacity for Small Businesses

In case you have about $17,000 of money, the question of choice should not be an obstacle. For this money you can purchase a production line for processing tires into crumbs with a minimum configuration and a productivity of 100 kg/hour. In this case, the most important thing will be to search for and rent a warehouse with an area of ​​about 100 m2 and a production facility whose area should be on average 40 m2, plus several more small warehouse spaces. In this case, the production of rubber crumbs can begin from a production volume of 800 kilograms of the finished product daily (100 kg/hour in 1 work shift).

What is needed to process tires into crumb rubber?

A minimally equipped line for processing tires into crumb rubber includes the following equipment, which can be found on the Internet at prices:

1. Bead cutting machine – $2,150
2. Tape cutting machine – $2,700
3. Rubber shredder – $7,650
4. Circular sieve – $1,000
5. Conveyor with magnetic separator – $1,000
6. Machine for processing bead rings – $2,500

TOTAL: $17,000

Technology for the production of crumb rubber by recycling tires

Video clip showing schematically in the form of 3D animation technological process processing tires by grinding into rubber crumbs:

As you can see in the video, the production process is extremely simple.

If you decide to conduct this activity at a more serious level, an analysis of the sales market in the region in which you are going to launch your project will be necessary. Without this work, it is unlikely that the products will generate profitable income. You will have to include expenses for marketing research sales market for finished products in a specific region.

What is the need for this product and in what distribution channels can it be sold? Who else is interested in this industry and what is the competition in the market?

The answers to these questions need to be taken into account and, obviously, the possibilities for developing economic activity over the next few years must be calculated. It is unlikely to accurately predict the subsequent course of events, but rough calculations will at least indicate the direction in which to move. Such determination is better than acting blindly.

Business plan for the production of crumb rubber with calculations

Used, old, and defective car tires were used in the production of crumb rubber. For obvious reasons, one should not even talk about the search for raw materials and their price. Old tires can be found in large quantities. You can buy them for a minimum payment, and sometimes you can pay for delivery to your company.

The production of crumb rubber, as already mentioned, is quite affordable for small businesses. The $17,000 production line can quickly process a wide variety of tires: car, bus and other tires.

At the moment, there are two main methods by which crumb rubber is produced:

1. Mechanical crushing.
2. Crushing method shock wave.

Shock wave crushing of rubber into crumbs is a relatively new method for processing tires. The most popular is mechanical crushing.

The production of crumb rubber using a shock wave requires a special approach. In particular, you need equipment in which the products will be stored, such as refrigerated pantries, which are quite expensive. There is a noticeable advantage in installing equipment for the production of crumb rubber from car tires using the shock wave method in smaller production areas. You can save on monthly rent. At the same time, the cost of electrical energy will be less than with an analog installation. But still, such equipment is fully justified for large and medium production volumes, since it is very expensive.

The production of crumb rubber can begin with a small production volume and at relatively low cost. 40 square meters of production area with a ceiling height of 3m is enough. A direct line for the production of crumb rubber will be installed, a power supply of 380 volts will be connected, and 2 workers will control the operation of semi-automatic equipment.

The best option when reaching the breakeven point of a business is continuous work for a whole week. To do this, three work shifts should be organized. As a result, the staff will consist of eight people. In addition, care should be taken to store raw materials and finished products. In this case, the space for storing tires should be four or even five times larger. In this regard, the surface of the room for raw materials (tires) may require up to 100 m 2, and for storing finished crumb rubber - 20 m 2.

On this basis, the cost of 100 kilograms of product per hour will change and change. In this business plan, we will determine fixed expenses for the month:

1. Purchase of tires at a price of $40 per 1 ton – $960 (24 tons of raw materials per month are required).
2. The cost of renting a warehouse will be about $400-$600 per month.
3. Salaries of workers servicing the production line cost $300-$700 per month;

A good idea is to allow customers to recycle tires for money. Having your own receiving point will help not only reduce transportation costs for the delivery of raw materials, but also immediately receive preliminary additional income, which is described below.

If a production line produces 100 kilograms per hour, working without interruptions, then in a month the amount of finished products produces 24 tons of crumb rubber (100 kg * 8 hours * 30 days = 24,000).

Taking into account the average retail price of crumb rubber of $0.28 per kilogram, we get a gross monthly income of $6,720 (0.28*24,000).

It is also worth noting that during production, metal remains in the waste (wire in tire tires). Its volume is about 7%.

Interesting fact! According to the Goodyear Tire and Rubber Company, average weight tires about 22 pounds (up to 10 kg). Moreover, it contains 0.68 kg of steel cord (it serves as a reinforcing material for the rubber structure in tires).

On the one hand, this industrial waste, and with positive side– this is a significant additional profit: 0.7 kg of metal wire and tire cord. And that’s 0.7 * 10 tires/hour * 8 hours * 30 days = 1680 kg of metal from 24 tons of tires - monthly!

The average price of scrap metal is about $200 per ton. As a result, we will receive an additional $336 in profit from selling metal wire from cord. It’s worth thinking about how to organize your recycling of car tires for money.

This amount of benefit is sometimes a more economically justified income received in the process of implementing this activity.

Tire processing products

Where is the crumb rubber from tire recycling used? This unique and durable building material is indispensable in the following industries:

1. Production of paving slabs from rubber crumbs.
2. When covering roads, asphalt and concrete fences on roads with the addition of crumbs.
3. In the production of safety coatings for sports, playgrounds and gyms.
4. In landscape design.
5. Production of hydrophobic materials.
6. Granules are used in the construction industry for the production of rubber sheets, palettes, roofing materials and the like.
7. Crumb rubber granules are also used in the production of rubber mats for pedestrians.
8. Rubber crumbs have found application in filtration different types liquids, creating thermal insulation for industrial premises.

In order to minimize the risk, the scope of production of crumb rubber can be expanded. Thus, it is possible to produce rubber plates or other shells of this material. The need for these products does not depend on the need for crumbs. Therefore, in one enterprise you can create two completely different directions activities.

One of the industry's big expectations is the production of crumb rubber. Our industry of this type is not particularly developed today.

Do not forget about such an important component, which is the sale of finished products. The popularity of crumb rubber as a building material is growing. There are more and more new competitors on the market. Bottom line, if there is the right approach to selling this product, the sales channels can be easily adjusted. This type of production does not require special skills, it is technologically simple.

Depending on the amount invested in the product, the payback time can last from six months to two years. Relatively short time payback is the next plus in the interests of this type of activity. Consequently, the high demand for the product (like all building materials), the minimization of risks and the mentioned thresholds for entry into production technology make it attractive from an investment point of view.