Transcript Current an

Current and Future Assessment of the Regional
Market Potential for Scrap Tire Derived Recycled
Rubber
Dr. Martin H. Bremer Bremer
Dr. David Güemez Castorena
Ing. Ruben Cantú Damas
The main objective of this project is to follow-up on the Goal 3 of the Border 2012 Program:
Goal 3. Reduce ground pollution
To increase environmental awareness, sensitivity and citizen responsibility
regarding solid waste and water related health issues.
2
Objectives to be Achieved with this Project
• To assess the current market at the Border 2012 4 State Region,
for scrap tire derived rubber, or its derivatives, such as:
– Ground rubber, micro-pellets, tire strips, etc.
• as well as the future market, identifying technologies and
applications.
• commercial and experimental prototypes
that may use such material considering the
• Volume generation and processing capabilities
that may be implemented as close to the site as possible
• To solve the build-up issue for the long term,
• and in turn, generating local jobs.
3
Regional Demand Features for new and used tires
New tire shipments imported into México (Modern Tire Dealer, 2011)
Type of Tire
Passanger Vehicles
Qty*
13.1
5.1
2.2
Light trucks
Medium and heavy trucks
*Qty in millions of tires
Supply of new tires in Mexico in 2004 was 12,953,000
Vehicles per State (INEGI, 2012)
State
2005
2006
2007
2008
2009
2010
Average
Baja California
Sonora
Chihuahua
Coahuila
Tamaulipas
Nuevo León
1,187,451
599,007
1,001,292
622,732
971,514
1,451,581
1,281,923
709,713
1,105,386
626,344
1,054,922
1,605,120
1,362,035
798,405
1,099,296
646,417
876,005
1,743,646
1,442,539
855,110
1,135,634
703,447
892,820
1,812,944
1,475,939
889,176
1,181,161
679,745
932,874
1,890,350
1,512,796
928,336
1,207,220
707,121
969,753
1,975,586
1,377,114
796,625
1,121,665
664,301
949,648
1,746,538
Total
4,381,996
4,778,288
4,782,158
5,029,550
5,158,895
5,325,226
4,909,352
8
Regional Demand Features for new and used tires
Scrap Tire Factor per type of vehicle (Cámara Nacional de la
Industria Hulera).
Automobiles
Light trucks
Heavy trucks
1.29 tires/vehicle per year
1.82 tires/vehicle per year
2.59 tires/vehicle per year
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Regional Demand Features for new and used tires
Scrap Tire Generation per State as of 2010
State
Baja California
Sonora
Chihuahua
Coahuila
Tamaulipas
Nuevo León
Total
Avg-Number of Vehicles
1,377,114
796,625
1,121,665
664,301
949,648
1,746,538
4,909,352
Generation of Scrap tires
1,776,477
1,027,646
1,446,948
856,948
1,225,046
2,253,034
6,333,064
Annual Generation of Scrap Tires as of 2015
State
Baja California
Sonora
Chihuahua
Coahuila
Tamaulipas
Nuevo León
Automobiles
1,402,476
701,068
951,166
534,180
680,759
1,759,223
Trucks
17,800
6,816
5,588
78,547
7,412
16,998
Light
trucks
498,789
368,854
405,896
257,494
303,275
660,436
Total
1,919,065
1,076,737
1,362,649
870,220
991,446
2,436,657
Tire Generation
2,475,594
1,388,991
1,757,817
1,122,584
1,278,965
3,143,288
To obtain the tire
generatio datum,
the 2012 value and
projected value
were taken and
multiplied by the
automobile scrap
factor.
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PRIOR STUDY: Assessment of the Current and Future Potential
Market for Tire Derivate Ground Rubber in Mexico (2005)
• 275 companies were contacted, from the following industires:
– tire producers, molded products, athelitic fields, cement producers,
and asphalt producers.
– Of these 275, 110 were interviewed with a survey
• Only 11 companies use recycled rubber (2005).
• Mexico’s potential market for ground rubber was 3,373 tons per month
(2005)
– considereing only a particle size of less than 0.5mm
• Mexico’s potential market for ground rubber was 44 tons per month (2005)
– considereing only a particle size of between 0.5 -1.0
mm
Source: Reyna, R. (2005). Apreciación del Mercado Potencial Actual y Futuro del Polvo de Llantas en México.
Monterrey, N.L.: Centro de Calidad Ambiental, ITESM.
Sponsor: Grupo Domos
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Market Research
Relevant Point for the survey, its validation and application:
•Research Focus. Phone surveys were applied among companies
that are found in the database created by the Environmental
Quality Center at the Monterrey Tech.
•Sample Profile. Companies that use or could use scrap tire
rubber directly or indirectly , that their facilities are located in any
of the border states: Coahuila, Nuevo León, Tamaulipas y
Chihuahua.
The survey questionaire is attached herein:
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Market Research
976 individuals from the list of companies, of which 485 completed the survey at least
partially; 103 rejected the interview, 14 were not the right persona, 306 did not take the
phone call or was not possible to conatact them, 3 were wrong numbers, 14 were cases in
which the telefonowas not available, and 51 were dropped suveys, where the interview as
not completed.
Status of contacted companies
The 485 companies that participated in the
study, belong to the following industries:
125 Manufacturing, 113 Commercial, 247
Services
50%
31%
11%
5%
113 Comercial
247 Service Industry.
1%
1%
0%
Industry
0%
Manufacture
Commercial
31%
69%
Services
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Market Research
Because of the nature of the study, the companies belonging to
the Comercial Industry had to be excluded, thus the sample
dropped to 372 records.
Line of Business of the industrial companies (372 interviews)
58%
24%
7%
Construction
Other
6%
5%
Liners, Insulators, Molded Products Asphalt and Readyand paint
Mix concrete.
Of the other lines of business, the most mentioned were:
Production of
• Oils mentioned 33 times,
• chemicals: 11,
• petrochemical products: 4
• packing and seals: 3,
•
•
•
•
Water treatment: 5
Polyethylene bags: 2,
Synthetic Fiber 2
Rossin, Resine 1
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Market Research
29 of the 372 companies use rubber to manufacture their productos or provide their services
Companies that use rubber(total
of 372 companies)
with rubber:
Types of products the surveyed companies manufacture
Yes
8%
Product
No
92%
Type of Rubber Companies Use
15
10
Synthetic,
14
5
Both, 10
Natural, 5
0
Natural
Synthetic
Both
Frecuencia
%
Packing Seals
7
26%
Other
3
11%
Asphalt strip
2
7%
Polyutherane
2
7%
Paint and liners
2
7%
Building materials
2
7%
Rollers
2
7%
Rubber foam
1
4%
Civil Works
1
4%
Weather proofing
1
4%
Vaccum Sweepers
1
4%
Power lines
1
4%
Tarps.
1
4%
Hoses
1
4%15
Market Research
List of Rubber Suppliers Mentioned
15 of the companies who responded the suvey use natural
rubber, of which 86% use between 1 and 2 tons per
month, while the rest uses more than 2 tons.
Most common prices per ton of virgin rubber is between
$10,000 and $30,000 MXP/ton.
None of the people surveyed, who use natural rubber,
know the size of the particle they use, thus no ratio was
identified between the price paid and the particle size.
When asking about the adequate presentation of the
recycled scrap tire rubber to be used in their process, 6
responded they need ground rbber, 3 need shredded
rubber, and 3 need the whole tire. (Three did not
respond).
Suposing the required presentation of recycled rubber is
the same as they currently use with natural rubber, there
was no relationship found between the price paid and te
presentation of the rubber/stock.
Vendor
Suministros y
Especialidades Químicas
Dupont
Frequency
%
3
11%
2
7%
Brentac
1
4%
Cartonera de plástico
1
4%
Cici plásticos
1
4%
Colombinaire Monterrey
1
4%
Comercial Vicsol
1
4%
1
4%
Comercializadora Los
Ángeles
En la obra
1
4%
Euzkola
1
4%
Galván
1
4%
Hulera Mexicana
1
4%
Materiales Jerez
1
4%
ML Tec
1
4%
Moix S.A. de C.V.
1
4%
Oxiasfalt
1
4%
PEMEX
1
4%
Promoplas
1
4%
Rehijold
1
4%
Particular
1
4%
SKR
1
4%
Uniroyal
1
4%
LCY Texcon
1
4%
Industrias Bengar
1
4%
Polioles de México
1
4%
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Market Research
The polymeres mostly used by the surveyed
companies are the ABS, used by 7 companies,
the SAN, used y 8, and the Polybutadiene, used
by 23
Polymeres used
42%
15%13%
11% 9%
5 companies (of the 29 who use rubber) have
soving used it is because their productio process
“does not require it”
Reasons for not using recycled rubber
44%
22%
11%
11%
6%
6%
4% 2% 2% 2% 2%
Of the 5 companies who have used recycled tire
rubber as raw material, 4 mentioned they used it
shredded, and one ground.
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Market Research
• Of the 23 companies, 6 mentioned they
would be intereste in incorporating it
into their processes
• Products manufactured by companies
who showed interest are: rollers,
packings, asphalt pavement, seals,
tarpaulins, liners.
• Volume of rubber used by these
companies varies between 200 K up to
2000 K/month.
• The main reason why they would not be
interested is because they consider this
material can not be incorporated into
their products
Desired presentation and companies
interested in using recycled rubber
Whole
tire
33%
Strips
17%
Rubber presentation
Shredded
33%
Ground
Rubber
17%
Products mentioned as a possible use
of this raw material: Asphalt, packing,
flooring, liners, bumps and tarps.
18
Market Research
19 companies responded that they would like for there to be an incentive if they use
the ricycled tire rubber as raw material.
Types of Incentives
55%
23%
9%
Tax or financing
Others
Cost support
9%
5%
Credits and Grants Recycling support
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Scrap tire rubber use and processing technologies
Technology
Rebuilt
Definition
Considerations
Depneidng on the renovated surface, 3
systems can be identified:
Replace old tires and
• Integrated rebuit: Crown and sides are
rebuild its original
renewed.
structure, turning it into a • Semi-integrated rebuilt: Crown and part
tire similar to the new one of side face is rebuilt.
• Only the crown is rebuilt
Advantages
• Saves on raw
material, since only
25% of new material is
added.
Re
• Reufacturing costs
30-50%.
Devulcanization processes can be divided
in two groups:
• Physical Processes: Uses external source
of energy. (Mechanical, thermo-mechanic,
Transforms rmoplastic
crio-mechanic, microwave and ultrasound.
Devulcanization material (non vulcanized • Chemical Processes: Most commonly
Decomposes tire
(Regeneration
rubber) in a thermostable used in industry. Chemical agents used ar
components
Techniques)
hard and elastic material normally disulfures or organic
mercaptanes used for high temp mechanic
(vulcanized rubber)
work, besides other inorganic agents and
other type of processes, sucha a fase
transfer catalysis.
Disadvantages
Limited number of
rebuilts.
Reduces quality and
durability.
Rubber obtained
with physical
properties of lower
quality than the
original material.
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Scrap tire rubber use and processing technologies
Technology
Definition
Considerations
Advantages
Disadvantages
Consists of two technologies:
Reclaiming
Regeneration
Technologies
Conversion of 3-D crossweave to
a 2-D linkage, resulting in a soft, • Shredded rubber is gound into fine Allows reuse of rubber
It’s important to have a
plastic, low-module material,
particles (powder).
components of scrap tires for good choice of raw
processable and vulcanizable,
• Powder is subjected to heat along manufacturing of different material and process
thermoplastic materials that
conditions
simulate the properties of virgin with other chemicals, followed by elements.
intensive grinding by friction.
rubber.
• Decomposition of tire
PyrolysisThermolysis
components:
Pyrolytic gases hav a high
In this process tire chips (1 -3 cm)
content of calorifi power.
are heated at a moderate temp of
Carbon black can be reused
Physical-chemical Process
400 . 800°C, with limited or no
to manufacture new
Where organic materila or
oxygen. Thermal degrading of
products.
solid waste decomposes by material decomposes the tire, where
Does not generate
heat, in an oxigen deficient the organic volatile elements
contaminant gases, such as
atmosphere, and transforms (rubber chains) decompose into
NOx, sulfates, but generate
into a mixture of liquid HC,
gases, liquids, while inorganic
residual forms of substances
fuel gas, solid carbon waste elements (chiefly steel and carbon
such as nitrogen gas, and
and water
black remain as a solid waste. The
solid sulfure. Chlorine and
pyrolytic gases have a great caloric
Fluor are reduced to
power (68-84MJm-3).
chlorines and fluorines that
can be precipitated with
calcium
• Issues with the
application orf
condensate oils.
Product Quaity depends
on process conditions
Investment requires for
a pyrolytic plant is high,
although the investment
can be recovered by
using the by-products
particularly as fuel in the
generation of steam
and/or electricf power.
21
Scrap tire rubber use and processing technologies
Technology
Definition
Mainly consists of rotating blades
that shred the tires. Then, other
Room temp
processes are added, such a
Grinding (Size
magnetic separators, granulators,
reduction
sieves. These are repeated several
technology)
times depending on the particle
size required.
Considerations
Advantages
Disadvantages
For a recycl.ing plant to operate
efficiently it must be
proportional to the volume of
scrap tires at the zone,
considering that it is not costeffective to transport the tires
for more thamn 300 Km.
It can reduce
High cost because of
sizes for 500 mm
continuous maintenance of
to lowe than 500
equipment
m [sic]
The use of liquid nitrogen in
• High cost of liquid nitrogen
At very low temp (-200°C) rubber cryogenic griniding is necessary
use, because two tons of LN2
becomes brittle as it loses its
to manufacture high qualilty
are needed per ton of tires.
elasticity, thus it is easyly
products. The powdered material It allows particles
Cryogenic
disintegrated. In case Cryogenic
is transferred to a criogenic
of lesser size,
• Plastic ground with a
Grinding (Size
grinding , one grinding stage
worm wher the material is
softer suface and typical particle size rarely
reduction
suffices to separate the
sprayed with liquid nitrogen to les superficila
meets the required spec to
technology)
components and obtain a wide
cool it.
oxidation.
be used in many applications
range of granulometry.
Then, the product and liquid
regarding its characteristics
nitrogen are introduced to the
and certain functional
mill.
effects.
22
Ground rubber tiles and flooring
•
•
•
•
Little development in Mexican floor market
High venture capital (mechancal or cryogenic)
High maintenance costs
Several facilities have been unseccessful in the
border region.
Tire Ground Rubber Applications
 Advanages of ground tire asphalt:




Lower cost throughout the life cycle
Noise reduction
Long term performance improvement
 Fracture resistance
 Aging resistance
Environmental
R.Garry Hicks, 2005
R.Garry Hicks, 2005
Scrap tire rubber use and processing technologies
The table with more than 13 applications of scrap tire rubber is in the
following attached file:
Main applications:
•Cement Additives for construction
•Insulation (thermal and acoustic)
•Septic pits drainage
•Landfill drainage
•Erosion control
• Dikes and levees
•Fillers
•Additives for asphalt
•Stabilizers for clay ground and slopes
•Paints and primers
•Athletic Fields and synthetic carpets
•Shoes
•Recreational items
•Furniture
•Auto parts
•Molded products
•Alternate fuels
27
Before raining
[email protected]
After raining
D.R. ©2006 ITESM, Eugenio Garza Sada 2501, Col. Tecnológico, Monterrey, N.L. C.P. 64849.
“Se prohíbe la reproducción total o parcial de este documento por cualquier medio, sin el previo consentimiento otorgado por escrito del
Instituto Tecnológico y de Estudios Superiores de Monterrey a cualquier persona y/o actividad que sean ajenas al mismo”
[email protected]
Housing with scrap material
• Use of tires and other scrap material for housing projects
–
Isla Mano de León, near the Port of Mezquital. With the support of the local DIF and the "Solo por
ayudar" Foundation, the first housing project, built by local fishermen, under the supervision of engineers
who are overseeing the program, is already at 80% completion. It consists of two bedrooms and two
bathrooms.
Fotos: Mauro de la Fuente, junio 06
Stability for
slopes
Tire strips Applications
 Some examples of
applications that are being
used by different industries.
SEMARNAT 2005
[email protected]
Housing Projects with scrap material
•
The use of tires and other scrap material to improve
the conditions of very low income homes.
– A survey was performed to learn of needs and concerns.
– 10 homes were surveyed in the Alianza Neighbourhood
– An experimental “home" was set up: 1 cubic meter
altogether, using wood, nails and cardboard
– Side cuts were installed over the roof or the hous (1 m-sq),
which were fixed with nails over the surface.
– Weatherproof tests were conducted during several rainy
days.
Cross
section
view of a
tire
Each tire is
cut in half
Sides or the
tire are cut in
four sides and
two crown
pieces
Artisan Uses of Tires
$15
$15
•
•
Analysis of the Life Cycle and the Energy
Balance
For energy balance, different incineration scenarios were set to recover its caloric
power, because it is commonly used thoughout the region. Transportation for 100
Km, 500 Km, 1,000 Km, 2000 Km and up to 10,000 Km was contemplated.
In the energy balance, we try to determine the amount of energy that may be
recovered from the manufacturing process of the tire, by using the tire rubber, in a
combustion process.
Energy needed to
manufacture a
new automobile
tire.
Energy that may be
obtained from the rubber
of a tire, depending or its
application
- combustion
35
Analysis of the Life Cycle and the Energy Balance
Comparison of the energy content of various fuels --including tire rubber..
Fuel
Carbon (sub Bituminoso)
Carbón (bituminoso)
Wood (wet)
CDLL (Tire derived fuel)
Tire
T
Tire (EPA-1997)
BTU/lb
10500
Energy Content
J/kg
kj/kg
Mj/kg
2.44E+07
24423
24.423
kwh/kg kcal/kg
6.7842 5833.3
12700
4375
2.95E+07
1.02E+07
29540
10176
29.54
10.176
8.2056 7055.6
2.8267 2430.6
15500
3.61E+07
36053
36.053
10.015 8611.1
14617
3.40E+07
34000
34
9.4444 8120.8
15983
3.72E+07
37177
37.177
10.327 8879.6
For the balance calculation we considered that the average content of an automobile
tire is 34,000kJ/kg. Also, the energy needed to produce one ton of tires using synthetic
rubber is arond 120 GJ.
Ver referencia en http://www.wb-hsm.com/Need.htm, consultada el 6/6/2012.
[2] Technical Guidelines on the Identification and Management of Used Tyres, Basel Convention, December 1999, Basel Switzerland.
[3] IBIDEM
[4] IBIDEM
[5] Comisión de Cooperación Ecológica Fronteriza, Propuesta de Estrategia y Política Pública para el Manejo Integral de Llantas de Desecho en la Región
Fronteriza, Octubre 2008, Ciudad Juárez, Chihuahua, pág 18.
[6] EPA Office of Air Planning and Standards and US-Mexico Border Information Center on Air Pollution; Air Emissions from Scrap Tire Combustion;
1997; Tabla 17, pág 33.
36
Analysis of the Life Cycle and the Energy
Balance
• For energy balance we estimated the average
consumption of a truck as 2,426 KJ/Ton-Km.
• We estimated the internal consumption of a
whole tire is 50%, a cut tire, is 70%, a shredded
tire (1.5” chips) is 80%, and ground (mesh 10) is
90%
37
Energy Balance Scenario
Scenarios considering transportation of scrap automobile tires for 2000 km, which have been cut
with machines that use two 125 Hp motors; the energy that this mass of tires can generate,
minus the energy required to transport and cut the tires is represented by the blue line. The red
line represents the energy needed to produce the same amount of tires, using the cold emulsion
technique, and the energy needed when using the oil technique (green line).
Recovered energty
is less than as
compared to tire
manufacture
Recovered energty is greater than as
compared to tire manufacture
The energy needed to produce a ton of tire starting from oil is greater than 3.5x109KJ.
39
Conclussions
– The results of the survey are lean, possibly due to:
• Surveys were done among employees from commercial departments, who do not have
technical knowledge of the productiion pocesses.
• Companies apply pre-established productive processes, previously set by the machine
manufacturers, and the need to change raw material has not been considered.
• In businesses databases, it is not easy to distinguish those business sectors that use rubber
form those that do not use it.
• It is possible that there are few companies in the region that use rubber in their processes.
– We found a great diversity of technologies that use scrap tires
(whole, stripped, ground…,) that have been implemented mostly
only locally; somo are experimental and other are shallow
commercial successes.
• Energywise, the distance for the tires to transported and then to be used as alternate fuel, has
little bearing on the amount of energy recovered.
41
Recommendations
– To carry out awareness programs with alternatives that introduce recycled
rubber derived from scrap tires.
– Interview production personnel, since they know the technical part of the
process.
– Perform a similar study to include the region of El Bajio (Guanajuato) and the
State of Mexico.
– Adoption of new technologies is usually introduced by entrepreneurs and/or
visionary investors who promote the technoloty until they achieve its
adoption, thus, we propose:
• To incentivate the creation of new companies and support the existing ones to include
recycled rubber as raw material.
• To incentivate research of high value added applications for recycled tire rubber and
support industrial testing.
– Recurrent similar studies are recommended to prove the effectiveness of the
programs and incentives.
42
Advantages of pursuing a new life for
scrap tires}:
• Tires are practically indestructible. They can resist: :
• High/Low temperatures
• Impacts, High centerfuge forces
• Moisture and chemical products…
• As a raw material, it is a very flexible material, light,
resistant, durable, cheap and very abundant!!!
• If located in the wrong place
or if handled poorly, it can
become a problem.
[email protected]
This project was funded by the Border 2012 grant, with
resources from the US-EPA, managed by the Border
Environmental Cooperation Commission-BECC.
Our Appreciation and Acknowledgement to
•
•
•
•
•
•
•
•
Environmental Protection Agency – EPA
Comisión de Cooperación Ecológica Fronteriza – COCEF
Secretaría de Medio Ambiente y Recursos Naturales - SEMARNAT
Instituto Tecnológico y de Estudios Superiores de Monterrey –ITESM
Centro de Calidad Ambiental – ITESM Campus Monterrey
Modern Tire Dealer (information on tire imports to México)
Green Consulting Group (surveyor)
All companies who responded to the survey
44
THANK YOU
for your attention!!
[email protected]
D.R. ©2006 ITESM, Eugenio Garza Sada 2501, Col. Tecnológico, Monterrey, N.L. C.P. 64849.
“Se prohíbe la reproducción total o parcial de este documento por cualquier medio, sin el previo consentimiento otorgado por escrito del
Instituto Tecnológico y de Estudios Superiores de Monterrey a cualquier persona y/o actividad que sean ajenas al mismo”