Detailed Project Report on Reclaim Rubber (Rubber Reclaimation Unit)

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RECLAIM RUBBER (RUBBER RECLAIMATION UNIT)

[EIRI/EDPR/1347] J.C. 110

INTRODUCTION

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 loosing 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 15 MT/Day

Land & Building (5000 sq.mt.) Rs. 5.62 Cr

Plant & Machinery Rs. 2.10 Cr

Working Capital for 3 Months Rs. 4.89 Cr

Total Capital Investment Rs. 13.08 Cr

Rate of Return 55%

Break Even Point 36%

CONTENTS

INTRODUCTION

WHAT HAPPENS DURING RECLAIMING

USES APPLICATION AND ADVANTAGES

RAW MATERIALS

RUBBER WASTE (USED TYRE AND TUBE SCRAP):-

BIS SPECIFICATIONS

MARKET SURVEY FOR RECLAIM RUBBER

SO WHAT EXACTLY IS RECLAIM?

EXTRACTION OF RUBBER SCRAPS FROM WASTE TYRE

SOME FORMULATIONS FOR RUBBER RECLAIMED

RECLAIMED RUBBER

GENERAL

FINISHED RECLAIMED RUBBER:-

MANUFACTURING PROCESS OF RECLAIMED RUBBER

METHOD OF RECLAIMING RUBBER

FLOW DIAGRAM FOR PRODUCTION OF RECLAIMED RUBBER

TESTING & EVALUATION OF RECLAIMED RUBBER

THE PRINCIPAL TESTS APPLICABLE TO RECLAIMED RUBBER ARE:-

OTHER METHODS

METHOD FOR RECLAIMING RUBBER

APPARATUS

EXAMPLE OF APPARATUS

TEMPERATURE

REVULCANISATION

PROCESS OF RECLAIMING RUBBER AND ITS REFINING

DESCRIPTION OF REFINING EMBODIMENTS

COMPARATIVE RECLAIMING DATA

METHOD OF PRODUCING RECLAIMED JOINT SHEET

METHOD FOR RECLAIMING CURED RUBBER SCRAPS

PLANT LAYOUT

COMPLETE PLANT AND MACHINERY SUPPLIER FOR RECLAIM RUBBER

DETAILS OF RECLAIM RUBBER MACHINERY

RUBBER GRINDER MILL

RUBBER REFINER MILL

PRE - REFINER MILL

DE-BEADER MACHINE

STRAINER

AUTOCLAVES

COMPLETE PLANT AND MACHINERY SUPPLIERS FOR RECLAIM RUBBER

PLANT AND MACHINERY SUPPLIERS

RUBBER MANUFACTURING MACHINERY

RUBBER MIXING MILL

VIBRATING SCREENS

AUTOCLAVE, OVENS,

CONVEYOR BELT

CHOPPER MACHINE

MERIT INDUSTRIES LIMITED

TINYTECH PLANTS

PORTABLE GENERATOR

CHEMICAL STORAGE TANKS

RECLAIMED RUBBER

SUPPLIERS OF RAW MATERIALS

RUBBER MANUFACTURING CHEMICALS

COAL TAR PITCH

SODIUM HYDROXIDE

BENZENE

CARBON BLACK

ZINC OXIDE

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)

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