Crumb Rubber from Scrap Tyres (Production rate 24 Tons per day)

CRUMB RUBBER FROM SCRAP TYRES (PRODUCTION RATE – 24 TONS PER DAY)

[EIRI/EDPR/4564] J.C.: 2781XL

INTRODUCTION

Crumb rubber is the name given to any material derived by reducing scrap tires or other rubber into uniform granules with the inherent reinforcing materials such as steel and fiber removed along with any other type of inert contaminants such as dust, glass, or rock.

Crumb rubber is manufactured from two primary feedstocks: tire buffings, a byproduct of tire retreading and scrap tire rubber. Scrap tire rubber comes from three types of tires: passenger car tires, which represent about 84 percent of units or approximately 65 percent of the total weight of U.S. scrap tires; truck tires, which constitute 15 percent of units, or 20 percent of the total weight of U.S. scrap tires; and off-the-road tires, which account for 1 percent of units, or 15 percent of the total weight of U.S. scrap tires. End product yields for each of these tire types are affected by the tire’ s construction, strength and weight. On average, 10 to 12 pounds of crumb rubber can be derived from one passenger tire.

Overall, a typical scrap tire contains (by weight):

70 percent recoverable rubber

15 percent steel

3 percent fiber

12 percent extraneous material (e.g., inert fillers)

Crumb rubber is not a finished rubber product, but it is only a refined form of raw rubber. For the production of crumb rubber, unlike in the case of sheet or crepe rubber improved processing methods.

Since crumb is technically graded, the world market shows a preference and attaches a premium to crumb over the conventional sucked sheet are crepe. It has been visualized that crumb rubber is a good substitute for synthetic rubber using to its uniform quality and guaranteed properties with regard to dirt content, plasticity etc. There is a ready market for crumb rubber by the manufacturers of rubber products of particularly the Tyre manufacturing units in view of its superiority over the conventional grade of sheet rubber.

By the application of heat and chemical agents followed by intense mechanical working to ground vulcanized scrap or worn-out rubber tires, tubes and waste rubber articles a substantial regeneration on devulcanization of the rubber compound to its original plastic state is affected, thus permitting the product to be compounded, processed and devulcanized. There are several types of rubber powder made in different ways. They may be lightly vulcanized and may contain appreciable quantities of anti-agglomerating agents to prevent massing on storage. The trend now-a-days is towards automation in production of rubber goods during handling, mixing and processing.

COST ESTIMATION

Plant Capacity            24 MT/Day  

Land & Building (4035 sq.mt.)    Rs. 4.64 Cr    

Plant & Machinery                    Rs. 3.11 Cr 

Working Capital for 0.5 Months    Rs. 47 Lac 

Total Capital Investment          Rs. 8.62 Cr 

Rate of Return                          37%

Break Even Point                      49%

CONTENTS

INTRODUCTION

CRUMB RUBBER

UTILIZING CRUMB RUBBER FROM SCRAP TYRES

CRUMB RUBBER RECYCLING & GRADING

USES/APPLICATIONS

PROPERTIES

CRUMB RUBBER STANDARD & GLOSSARY OF TERMS

MARKET OVERVIEW

STANDARD OPERATING PROCEDURE 

MOEF PERMISSION FOR THE IMPORT OF USED TYRES IN INDIA

MOULDING TECHNOLOGY

SPRAY TECHNOLOGY

BOND AGENT SELECTION AND MIX DESIGN

SPRAYING DEVICES AND PROCESSES

SPECIFICATION OF CRUMB RUBBER

MANUFACTURERS/SUPPLIERS 

MANUFACTURING TECHNOLOGY

MANUFACTURING PROCESS 

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERIES

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT 

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

ANTICIPATED ENVIRONMENTAL IMPACTS 

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

PRELIMINARY LAYOUT

CONCLUSIONS

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)