Recycling car tires into crumbs. Recycling tires into crumbs at home and at the factory. Mechanical shredding of tires

The problem of recycling used tires is acute in many countries. In this matter, not only the environmental aspect is important, but also the economic one, because the material obtained during processing is a good raw material for the chemical industry. We will 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.

The processing of tires by these methods is different in terms of the principle of operation and the raw materials obtained. Each of them has its own advantages and disadvantages, which are worth discussing in more detail.

Mechanical shredding of tires

This method 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, bead rings are removed and cut into large pieces.
2. Raw material is cleaned from metal cord by means of magnetic separation.
3. The pieces are then heated (for processing at elevated temperatures) or cooled (for the cryogenic method).
4. Rubber is crushed by cutting, impact, explosion, compression or abrasion.
5. The resulting raw material is ground to obtain a crumb 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. The cost of electricity is also high - up to 1000 kWh per 1 ton of processed raw materials.

At the same time, shredding has significant advantages over chemical tire recycling methods: technical simplicity, no toxic emissions (unlike incineration or pyrolysis). Recycling rubber by grinding preserves the technological parameters of the material.

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

About how tires are processed into crumb rubber and what equipment is used, the following video

Other tire shredding methods

There are other methods for shredding old tires, but for various reasons, many of them are not widely used. The most famous processing methods:

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

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

Recycling tires using the ozone knife method includes the effect of ozone on worn rubber in a special chamber and subsequent mechanical grinding. Ozone contributes to the destruction of the rubber structure, facilitating further grinding of the tire by mechanical methods. As a result, clean crumb rubber and metal are obtained from the old tire, and there is no need for separation, since the metal and rubber separate from each other when exposed to ozone.

When processing by the baro-destruction method, the tires are first cut and crushed, and then in a special chamber, under the influence of high pressure and temperature, the rubber is brought to fluidity, separating it from the metal cord. The result is a small rubber crumb with a granule size of about 0.8 cm.

Processing methods that change the chemical structure

Recycling 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 the final raw material is quite high.

Among the chemical methods of tire recycling, the following are the most common:

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

Pyrolysis is called thermal decomposition, which occurs in a special chamber without air access. This method is most often used to obtain thermal energy. The processing of rubber by combustion and pyrolysis has a number of limitations, they are associated with the release of 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. This method is used in the cement industry and for heat generation.

The dissolution of old tires is considered by many experts to be a promising and very effective method, although it has not yet been widely used. Under the action of the solvent, a raw material is obtained that can be successfully used in metallurgy and the chemical industry.

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

Tire recycling in Russia and Europe

European countries boast recycling levels of old tires reaching 90%. About 20% of them are restored and reused, 40% goes to heat, and more than 30% turns into crumbs.

Unfortunately, global averages are not that high - less than 40% of tires are recycled and 60% of unrecycled rubber ends up in landfills.

Important! Every year, about 10 million tons of new waste from old car tires appear in the world, which makes the ecological 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 quite sad, although it is gradually improving from year to year. Now the volume of tire recycling is about 10%, and over the past few years it has grown by a quarter. Tire recycling organizations in Russia are not yet very active, in our country people are not used to investing in secondary production, recycling and recycling.

One of the additional problems is that it is more difficult to recycle domestic tires, common in Russia, Belarus and other countries of the near abroad, than European ones. Our old tires are additionally reinforced with a radial synthetic cord, and a large admixture of textiles makes it very difficult to process. As a result, the processing of 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 canceled that pyrolysis is prohibited in some developed countries due to the harmful effects on the environment. However, domestic entrepreneurs consider more expensive processing methods to be too expensive, so they are used much less frequently.

Selling tires 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, Vyazma. A processing center was built in Primorye, many enterprises operating in this industry were helped to launch production by franchising.

Almost every major car service center in Russia accepts old tires from motorists. Often you have to pay extra for the delivery of tires, although some services accept them for free. Companies are increasingly entering into agreements with recycling companies, handing over significant volumes of old rubber for recycling.

You can hand over tires for recycling at factories and complexes that are engaged in obtaining secondary raw materials, as well as in car services. At the same time, it should be taken into account that large enterprises usually do not accept tires from the population due to the small volume of the delivered product, so citizens have to track stocks in car services in order to get rid of one or two sets of rubber.

Economy and ecology

The economic benefits of tire recycling are undeniable. In a number of countries, combustible gas, which is released during the heat treatment of tires, is used to heat rooms, and also generate electricity with its help. Liquid pyrolysis products are used in the production of plastics, 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 washed out of old tires. All of them remain in the soil, and then are washed out by groundwater and rainfall, falling into drinking water sources and agricultural facilities.

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

The situation in Russia is still reminiscent of the state of affairs in African countries, but the principles of responsible consumption are gradually penetrating the consciousness of our citizens as well. In a few decades, both motorists 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.

The whole world is committed to a zero waste society, and in some countries, such as Sweden, all garbage is already being recycled. As for Russia, it is very far from the processing of all garbage, but every year more and more such industries appear. One of the waste recycling businesses is the tire recycling business. It is worth noting that the organization, in addition to the main mission of the enterprise - making a profit, will benefit society. After all, it is known that the period of complete decomposition of tires is about 150 years, they are highly flammable and emit harmful substances during combustion. People who live near tire dumps are more likely to get sick with various diseases, including cancer. Therefore, today tire recycling is very relevant and necessary for society.

It is worth noting that the tire recycling business initially has significant barriers to entry. Barriers are associated with a large amount of investment at the initial stage, as they require the purchase of special equipment. However, even in Russia there are suppliers who create a whole mini-factory (in other words, a line), with the help of which it is possible to immediately start production.

Competition in the market is quite low, not all cities have at least one such plant, while the need for tire recycling is increasing every year, because the number of motorists is growing. The cost of the raw material itself will be very low, since it is a waste, and many organizations, for example, transport companies, are even ready to pay for disposal (since the release is illegal and subject to a fine). Ordinary citizens do not yet realize that this type of waste is harmful to the environment and must be properly disposed of, so the plant can offer to buy tires from private individuals for a small fee.

In this way, the tire recycling business will have no problems with competitors and raw materials. The plant will quickly begin to operate at full capacity and will receive maximum profit.

Initial investment - 15 480 000 rubles

Monthly profit - 1 300 000 rubles

Payback period - 13 months

Break even - 3 months

Profitability of sales - 65%

2. Description of the business, product or service

The tire recycling plant should be located away from the city, preferably in an industrial area where there is no proximity to residential buildings. According to the law, the distance to local residents must be at least 300 meters. The area of ​​the premises of the plant itself should be about 500 m2, however, everything depends on the parameters of the purchased equipment and the size of the warehouse. The price per square meter for such premises is quite low, while you can get additional benefits when placed in industrial parks, special economic zones, etc. For example, placement in the SEZ also gives the right to tax reductions on insurance premiums and profits.

Depending on the line, the plant will receive several types of finished products. In this business plan, we will consider obtaining, after mechanical processing of tires, the following types of products:

• Rubber crumb
• textile cord
• metal cord

Crumb rubber is the main product of car tire recycling. In order for tires to be durable, high-quality components are used in their production: natural and synthetic rubbers, softening oils. Therefore, during the mechanical processing of tires into crumbs, the rubber composition practically does not change. The price of a crumb in the ranks is lower than the price of new rubber, so it is in great demand. Rubber crumb can be of different fractions: up to 1 mm, 1-2 mm, 2-5 mm. The scope is quite extensive, for example, for the construction of roads (top layers of asphalt), sports surfaces (such as a tennis court, running track), use as "artificial grass" and more.

The textile cord is a cleaned landing ring and is used in geological exploration, the production of fiber-reinforced concrete, the filling of sports equipment, the production of mixtures for plugging wells during well drilling.

Metal cord is a metal wire or shavings that can be scrapped.

3. Description of the market

The sales market is mainly designed for legal entities, that is, it works on the B2B principle. The finished product of the tire recycling plant is not a final product, so the buyers will mainly be the same manufacturers. The main activities of such organizations will be:

• construction;
• production of sports equipment;
• pavement manufacturing;
• maintenance of oil companies.

Also, the entire sales market can be divided into a segment of state and commercial enterprises.

State-owned enterprises (for example, municipal unitary enterprises) most often purchase products from recycled tires for the construction of sports facilities or road construction. Typically, such enterprises announce the opening of procurement for their activities and place the start of bidding on the site for government orders. If the conditions are met and the lowest price, you can get an order for a large supply.

Commercial enterprises are purchased for their productions, and then they use their products for retail sales.

A small percentage of buyers is also possible - individuals who buy, for example, crumb rubber for their garden plots.

The advantages and disadvantages of a tire recycling plant are shown in the table:

4. Sales and Marketing

The main sales channels for the tire recycling plant will be:

• Website presence. When looking for a supplier for their production, buyers will look for information on the Internet, so the site should be convenient, have information about the types of products, their characteristics, contacts, and also have a price list with current prices or contact sales manager.
• An ad in an Internet service for placing ads, for example, Avito.
• Information on banner structures near large factories and highways.
• Participation in government tenders for the supply of products.
• Calling the target audience (companies whose production needs rubber crumb, textile or metal cord) by managers, that is, using the "cold sales" method.

5. Production plan

Before starting activities, it is necessary to register a business. Since the business requires large investments, it may be necessary to attract investors or take out loans, so it is best to register in the form of a limited liability company.

The taxation system must be chosen based on the system of taxation of suppliers and buyers. If the majority is on a common system, then the organization must also choose a common one. If the taxation system is different for everyone, then you can choose a simplified system, with the object of income reduced by the amount of expenses.

Also, for activities that work with dangerous income, a license is required (tires have a fourth hazard class). In order to obtain a license, an organization must provide permits from Rosprirodnadzor, Rospotrebnadzor and the fire inspectorate. To do this, it is necessary to provide a number of documents, purchase fire fighting tools, prepare orders and instructions for personnel training. Also, in order to obtain a license, it is necessary to have a ready area on which the plant and working equipment will be located.

The next step will be preparation directly for work. To do this, it is necessary to hire and train personnel, to study the operation of the equipment. Understand how the equipment works. For example, the technological process for obtaining rubber crumb consists of the inspection stage (the surface of the tires should not have foreign objects), cutting into small segments, cutting through a shredder into smaller particles, grinding through an impact crusher, passing through a separation system to remove metal and textile cord and sorting by fractions.

6. Organizational structure

In order for the plant to function, it is necessary to have administrative (financial) and technical personnel. The administrative staff will include the director, sales managers and accountant, while the technical staff will include an engineer, workers and a driver.

The director is a responsible person in the work of the organization, solves strategic and operational tasks, is engaged in the search for suppliers, marketing, work with personnel. His responsibilities also include following a specific production schedule that the organization has set.

Sales managers are engaged in direct sales via telephone and personal meetings, monitor the shipment and issue of necessary documents (invoices, certificates of completion), are interested in sales growth, since the company's revenue is directly related to their premium part.

The accountant is responsible for accounting and tax reporting, calculation of wages, controls the work of employees in obtaining documents.

The administrative department works in the company's office with a work schedule of 5/2 from 9.00 to 18.00.

The technical staff works directly at the production site in shifts with a schedule of 2/2. An engineer supervises the work of the entire department, who is also responsible for technical malfunctions of equipment, monitors the quality of finished products and trains personnel - workers.

The staff list will include six workers who work in shifts of three. People without higher education and special skills are accepted for such work, however, experience in production will be an advantage.

The driver works on a floating schedule, depending on whether the car is needed for transportation or not. Requirements for the driver is the presence of rights of category C and E.

The number of used tires is growing exponentially. Mountains of bald tires near tire stations create a lot of inconvenience, take up space and pollute the environment. What to do with them? But you can earn money on them. Tire recycling: we will tell you how to do it and get the maximum income. Not only in our country, the problem of their processing has not yet been completely solved. According to statistics, only a fifth of tires are recycled in the world. In most countries, the state allocates subsidies for such processing.

Now developed methods for the effective disposal of tires. With the right management, a tire recycling business can help you recoup your investment in six months. At the same time, you will also help improve the environmental performance of the region.

Tire recycling can be a profitable business. The tire is a source of valuable polymers. From a ton of used tires you can get 700 kg of rubber. It is used to produce fuel, building materials, rubber products. But burning tires is extremely harmful to the environment and all living things. At the same time, 450 dangerous toxic gases and 270 kg of soot are released.

Recycling tires provides an opportunity to obtain valuable recyclables– crumb rubber, metal cord and liquid fuel. The rubber crumb is applied in many branches: oil, chemical, mechanical engineering, in life. Rubber is used to make hydro- and heat-insulating coatings. It is used for the production of pavement, sleepers and rail pads. A rubber modifier is often added to asphalt. It doubles its lifespan. And also rubber is hoses, shoe soles, etc.

In large plants, it is difficult to obtain significant economic benefits from tire recycling. Tire recycling is an idea for a small business. It is enough to acquire a mini-factory for their processing.

By the way, now the State Duma has a draft law under which the manufacturer will be responsible for the recycling of tires. So the disposal of rubber can be controlled by the state.

Step one. You need to get a license. It is mandatory if the business is based on waste processing. Tires are considered one of the most low-hazard waste, so the license should not be a big problem. But they can still be small.

step two. Need to rent space for a processing mini-factory. It is better to give preference to a place outside the city. It is better to place such an object away from the settlement. The advantage of such a place is also that its rent will cost an order of magnitude cheaper than in the city. The average rent for such an object will cost 50 thousand rubles.

Step Three. A small truck will be needed to deliver raw materials and export finished products.

Step Four. Equipment. You will need to buy or lease a mini tire recycling plant. This is a small collapsible complex. Its area is about 17 sq. m. In a day, he will be able to process 5 tons.

When planning a mini-factory, you need to allocate zones for:

• tire storage;
• cuts;
• product warehouse.

The plant itself is installed quite quickly - in a couple of weeks.

Step five. Staff. The plant can work in two shifts. Each will require two people. Plus, we need staff for the export of products and the delivery of tires (a couple of people), as well as an accountant.

Recycling

Recycling rubber allows you to extract rubber from used tires. This can be done in several ways:

1. Chemical. The most toxic and harmful to the environment.
2. Mechanical. Tires are shredded and exposed to high temperatures.

It is the second option that is now used in the processing of tires. It is very popular, but more expensive. Please note that recycling tires also allows you to get metal waste. During processing, metal cords are separated from synthetic ones.

Now the number of vehicles is constantly growing. The amount of waste, including tires, is also increasing. There are still not enough enterprises for their processing in our country. If the recycling is properly organized, the recycling of car tires can bring a huge income.

In order for tire recycling to make a profit, everything needs to be thought through. Let us dwell in more detail on the organization of this business. You will need vehicles, because old tires will need to be collected and brought to the warehouse. Metal parts are removed there, and the rubber is cut. Tires should be cut into small pieces. For this purpose, the mini-factory has powerful scissors. Shredded tires are poured into the bunker of the factory reactor.

Under high temperature, the tires in the reactor decompose. Recycling car tires allows you to get a number of products at once:

1. liquid fuel;
2. residue containing carbon;
3. metal.

To support the recycling of tires, part of the gas is returned to the reactor. The rest of the gas enters a special pipe. In terms of volume, its amount can be compared with the exhaust of a truck. The residue with carbon is sieved to separate the steel cord.

After processing, you will have a residue with carbon, liquid fuel and steel cord. Rubber crumb is bought by many enterprises that manufacture products from rubber. She is always in demand. Steel cord and liquid fuel are also in demand.

The peculiarity of tires is also in their weight. Each one is quite heavy. Such large-tonnage wastes become a good source of polymers. There are many of them even in small towns, because the recycling of car tires will always be a popular service. The main thing is to establish the process itself and get all the permissions.

And the recycling of car tires will save nature from pollution, because tires naturally decompose for hundreds of years.

Equipment

Recycling of rubber tires is possible in a small factory. You will need to select equipment. The average installation is capable of processing 5 tons in 24 hours. Recycling rubber tires per day will bring about:

• 2 tons of liquid fuel;
• 0.5 tons of steel cord;
• 1.5 tons of solid residue with carbon;
• 1st ton of gas.

As you can see, tire recycling is very cost-effective. These are quite high performance indicators.

The peculiarity of such an installation is that it works without interruption. It is cyclically supplied with the gas that comes out during the processing of tires. It must be installed in an open area.

The unit can be operated by only two people per shift. It consumes about 14.5 kW / h.

Start-up capital

The average installation costs about 1 million rubles. Shipping cost is not included. Disposal of bus tires is associated with the accumulation of fuel oil. You will need to buy tanks for it. Fuel prices change, so it's better to store fuel when they decline. And we recommend selling it when prices rise. So the profit will increase.

You can buy used tanks. The average price for them is 20-26 thousand rubles / piece. Enough six or seven tanks.

You will also need storage equipment, overalls, and various tools. This is about another 100 thousand rubles. Do not forget about rent, delivery, installation of equipment, paperwork. In general, the costs may amount to 1.5 million rubles.

Expenses

Work in two shifts, 2 people each. This is the salary for four people. (for 10 thousand / month). We need an office for bookkeeping. It will take a couple of workers to supply tires and sell products. This is about 70 thousand rubles. per month for taxes, salaries and office rent.

Electricity per month about 10440 kW will be consumed. In total, for the operation of such a mini-factory, about 100 thousand rubles per month will be required.

Income

The advantage of this project is that raw materials will be practically free. Sometimes it turns out to earn even when collecting it. Large enterprises pay for the disposal of old tires, because they are not taken to landfills. In this case, an agreement is concluded with the enterprise, and it pays monthly for the export of tires. The cost of export is about 2-3 thousand rubles. rub.

Scrap metal can be handed over for recycling at 4 thousand rubles. per ton. A ton of carbon is taken at 3-4 thousand rubles. All kinds of coatings are produced from it.

Outcome

According to average estimates, the total monthly income can be 370-380 thousand rubles. (fuel oil + carbon + scrap metal). Costs each month - 114,600 rubles. (salary + office rent + electricity). The payback will be about six months from the launch of the mini-factory.

Difficulties

1. There are not so many vacant lots in big cities. There are many residential buildings around.
2. The distance from the mini-factory to the houses should not be less than 300 m.
3. It will be difficult to pass the examination.
4. Difficulties may arise with residents of nearby microdistricts. Many do not want to live near a tire recycling plant.

It is better to organize such processing at an already finished enterprise. The main thing is to find a suitable platform that is inactive. But this territory already has all the approvals and permits. Try to negotiate with the company itself on mutually beneficial terms.

Most likely, you will also need a cleaning unit. It will prevent environmental pollution.

Another complication is the unexpected costs. They may appear already in the process of processing. Most likely, there will be difficulties with firefighters, environmentalists. If tanks for fuel oil are installed, it will be necessary to install a fire shield, conduct staff briefings, post safety instructions, etc. Such objects always attract the attention of fire inspectors.

prospects

How profitable is this business? It can bring in good income. In a small town, at least one and a half tons of used tires are accumulated per year. There will definitely not be a shortage of tires. Having processed this amount of waste, you will get about 50 tons of fuel oil. The big advantage of such a business is that you do not need to spend money on the purchase of raw materials.

It is also important to install special filters so as not to pollute the environment. Pay your environmental fee on time. Then environmentalists will have no reason to find fault with you.

Information for thought

In order for tire recycling to develop, it is important that the state supports this industry. State subsidies for such processing are practiced in many developed countries. It is important to pass a law that increases the responsibility of the manufacturer. It will not be superfluous to also create waste tire collection points. It is logical if they will be based on tire shops.

Tire recycling as a business can bring good income, but you will need to spend a lot of effort, time and money. Such a service will always be in demand, as the number of tires is only growing.

The tire is a source of valuable polymers.

Each of us knows that a vehicle cannot do without tires. However, not everyone thinks about where the worn rubber goes. There are two ways: either the tire is sent to a landfill and thereby pollutes the environment, or it is recycled. It's safe to say that rubber is a dangerous pollutant, so they always try to dispose of it. For this simple reason, there are all the prerequisites for creating your own small plant, where tires will be processed.

What everyone should know

Every year the number of cars on the roads increases by about 5-10%. Based on this, the amount of worn rubber increases by about 1 million tons. In many countries, the issue of recycling is very acute. You can partly solve this problem if you set up your own small production. You have several business development options. For example, it can be the processing of car tires into fuel oil or crumbs. If you want to get fuel, you will have to spend a little more money, since the production line is quite serious. Pay attention also to the fact that you can work not only with tires, but also with plastic products, which will slightly increase the profitability of the enterprise. This business has several undeniable advantages, now we will consider each of them.

Firstly, you do not need to inject a lot of money into the purchase of raw materials. This is due to the fact that worn rubber is thrown away. Local authorities, if they, of course, are worried about the ecology of their city, will deliver everything to you. But that's not all, as the municipality is ready to pay for the fact that your company will process car tires. Agree, getting almost free raw materials, and even making a profit from the fact that you are doing this business, is not bad at all. Of course, everything does not end there, since our main goal is not only to save the environment, but also to make a net profit. Fixed assets will come from the sale of the same fuel oil, which is an extremely popular type of fuel in agriculture. By the way, you can also get free raw materials at tire fitting points, which are more than enough in big cities. The thing is that service station employees, etc. pay additional funds for the removal of old tires and their disposal.

Recycling rubber tires: pros and cons

It is impossible not to say a few words about the fact that this niche has not yet been fully filled. The number of entrepreneurs in this area is relatively small, about 20% of the optimal figure. This means that only a fifth of the worn rubber is disposed of and recycled, the rest goes to landfill. You must understand that 1,000 kilograms of burned tires is 450 kg of various toxic gases, as well as 250-270 kilograms of soot. But if the same amount of rubber is properly disposed of, then about 700 kilograms of full-fledged rubber can be obtained from mining, which can be used to make fuel and rubber products. It hardly makes sense to talk about the industrial scale of the enterprise, but it is very possible to establish a small tire processing plant.

The complex itself is relatively small, but its size directly depends on production volumes. So, for processing 5 tons per day, you need a room of 18 squares and 10 meters in height. There must be a warehouse on the site where you will store tires, plastic, etc. There must be a site for the preliminary preparation of raw materials (cleaning, cutting rubber). You can not do without a room for storing finished products. In this case, it all depends on what exactly you get. It could be fuel and so on. For example, for fuel oil, you will need to purchase several large-capacity tanks. They don't have to be new, it's even better to buy used, it's much cheaper. Please note that recycling rubber tires is a difficult and dangerous business. Therefore, technology must be carefully observed. Let's talk about this in more detail.

Technological process

In fact, there is nothing complicated here, but it is necessary to control the process at all stages of production. At the very beginning, you have to start collecting tires. Then you must take them to the warehouse of your enterprise for further processing. In order not to damage the scissors, which, by the way, are not cheap, it is necessary to inspect all raw materials for the presence of metal objects, such as discs or rings. As for the cutting tool, ideally it should be hydraulic shears, but this is not at all necessary, we will talk about this a little later. Next, the crushed rubber is sent to the reactor - a special tire recycling plant that operates at a given temperature, most often 450 degrees Celsius. Decomposition leads to the fact that we get several semi-finished products, such as gas, metal cord, fuel fraction.

The same gas is used to support combustion in the furnace as a by-product fuel. Its waste is released into the environment. This is not a good solution, but the emission resembles the exhaust gases of a truck. As for the remaining mass, it passes through a magnetic separator, in simple words, it is sifted through a sieve. Metal elements are screened out and sent to the warehouse. Fuel oil is transported by a conveyor to tanks, in which the fuel will be stored until shipment. It should be noted that the plant for the processing of tires, which allows you to get pyrolysis fuel, is quite expensive - about 2 million rubles. Its productivity is about 5 thousand tons of raw materials per day, which is quite a lot.

Production of crumb rubber

And here is another rather interesting idea that has not received proper distribution to date. The essence of such a business is that you will sell shredded and processed rubber, which can be used for different purposes. In order for you to roughly understand what we are talking about, it is necessary to give general indicators in numbers. Thus, a ton of crumb rubber on the Russian market will cost no more than 20,000 rubles. As for the main consumers, these are construction companies, manufacturers of rubber products, roofing materials, coatings for building and sports tools, etc. In principle, it is quite easy to find a point of sale.

It is also necessary to take into account the fact that approximately 700-800 thousand tons of worn tires are thrown away on the territory of the Russian Federation every year. Approximately 20-25% is disposed of properly, everything else is either simply lying in landfills or burned. So, the processing of tires into crumbs can bring 5-8 billion, but this is already an industrial scale. If you are going to be doing this kind of recycling at your plant, then you will need a mechanical crusher. will have to be changed very often, which leads to high costs. Another disadvantage of this idea is that a lot of electricity is consumed, about 500 kilowatts per ton of finished products. Nevertheless, recycling auto tires in this way will be beneficial. But only if you receive appropriate support from the state.

Tire recycling equipment

Separately, we need to talk about what our production line will consist of. In principle, there is not so much equipment, and it is not difficult at all. Nevertheless, the price "bites". The main unit is a tire recycling plant (reactor), 10 meters high, 3.5 meters wide, 5 m long. This unit must be installed only in an open area, that is, under the open sky. You, as a future entrepreneur, must understand that you will have to pay quite a lot of money for electricity. The reactor itself consumes about 6 kW per hour. In addition, there are also scissors - 7-8 kW / h. In principle, this is practically all the equipment that is necessary to start production. What else is needed is a few crucibles to unload the resulting material.

As noted above, the reactor has a capacity of about 5 tons per day. But of this mass, approximately 40% will be liquid fuel. The fact is that as a result of decomposition, you will get gas (about a ton) and somewhere around 0.5 tons of steel cord. We should not forget about the solid residue (carbon-containing materials), which is approximately 30% of the total output. It is worth paying your attention to the fact that the processing of old tires in the reactor is carried out continuously. All you have to do is add tires. Combustion is supported by the gas produced inside the furnace. The reactor should be operated by two specially trained specialists. In principle, training courses can be completed fairly quickly. Now let's go ahead and look at a few more important points.

How much money do you need to get started?

This is one of the main aspects that interests absolutely all beginners. You don't need to spend a lot here. If you are going to purchase used equipment (reactor, shears), you can save up to 20% of the total amount. It is worth taking such a step or not, it's up to you. There is no guarantee that a used reactor will not fail after the first heat. In this case, no one will compensate you for the damage. One million rubles should be enough for everything about everything. This includes the cost of a reactor with a capacity of 5 tons / day, as well as shears. In addition, you will need to purchase several tanks (60 tons). If these are used containers, then you will have to pay about 25,000 rubles apiece. How many pieces you need, think for yourself, but you do not need to be limited to one or two tanks. The fact is that the processing of tires into fuel is a seasonal business.

During the period of a decline in fuel prices, it is better not to sell it, but only to accumulate it. When the period of increase comes, and this will happen for sure, you can get a good income by selling all the fuel oil at once. This tactic works and is considered quite effective. But this does not mean at all that you should completely freeze sales, it is enough to reduce them by 50-75%. You still have to pay employees. Four specialists will cost about 60,000 rubles a month, and tools and overalls - another 50,000. There are also regular monthly costs: electricity, taxes, rent, etc.

About the income of the enterprise

As you can see, tire recycling technology is quite simple. There are no fuel additives, complex chemical reactions and other points. Moreover, as noted above, the raw materials are completely free. Sometimes even collecting tires can make some money, which will pay off the monthly electricity costs. If you live in the outback, then it is unlikely that you will be paid for disposal, but in big cities the situation is completely different. There are many industries that pay good money to recycle rubber. This is due to the fact that many city dumps refuse to accept such waste. For the processing of a ton of tires, you can get a different amount, from 2 to 5 thousand rubles.

It is safe to say that even recycling tires at home will bring a good income. Thus, consumers are ready to pay 3,000 rubles for a ton of low-quality carbon. Scrap metal is accepted at the rate of 4 thousand rubles per ton, and fuel oil - 3-4 thousand rubles per ton, depending on the period. By simple calculations, you can come to the conclusion that in a month you will earn about 350,000-400,000 rubles. Approximately 50% must be paid for electricity, workers, etc. With such an intensity, the tire recycling line will pay off in six months, which is quite fast. As you can see, the idea is very interesting and promising, but not everything is so simple. In such a business, as, in fact, in any other, there are a lot of pitfalls. Let's see how not to make a mistake.

Problems when starting a business

It happens that it is simply not possible to find a free piece of land. This is due to the fact that it is necessary to maintain a safe distance to residential buildings, which is 300 meters. The farther the plant is from the city, the greater the cost of delivering raw materials, we should not forget about this. Remember that not everyone wants tires to be recycled under their windows. Feedback from ordinary residents will be negative, even if the reactor is located at a distance of 400 meters from residential areas. For this simple reason, look for a place on the production site. Most likely, you will find it, since quite a few sites are empty. All that is required of you is to negotiate directly with the company, as a rule, this is not so difficult to do. At least, it is much easier than to conclude an agreement with firefighters and a sanitary and epidemiological station.

Do not forget that you need a license to get a permit is not difficult, since tires are non-hazardous materials (4th group). But the catch is that your production officially pollutes the atmosphere. Most likely, you will be asked (forcibly) to buy a treatment plant. Its price is usually several times higher than the entire plant. But there are several ways that will help you delay the purchase for a certain time. Experts say that it is not advisable to open an enterprise for the processing of any one material. Like it or not, decide for yourself. In any case, you can always expand your workshop and melt glass, plastic or metal there. According to statistics, 75% of entrepreneurs encounter environmentalists who are wary of this kind of production.

A few important details

As noted a little above, you will encounter the fact that the item "contingencies" will appear in your business plan. This is due to the fact that it will be necessary to resolve issues with environmentalists and firefighters. For example, to store fuel oil in new tanks, only a protective shield is needed, but used tanks require additional protection. There are special lines for fuel and gas, and fire safety instructions for personnel, and much more. In any case, you need to have a reserve in your budget of several hundred thousand rubles. This will save you a lot of trouble. The expense items are quite large, but we have already considered them, and you probably know what you will be dealing with.

Do not forget that you, as a manager, must not only observe how your employees work, but also perform a number of other equally important tasks. Among these: the constant development and growth of the boundaries of the enterprise, accounting and tax accounting, as well as the adjustment of goals and plans for the near future. In this article, one important point was not mentioned - advertising your product. There are several options here. One of them is to create your own thematic site where you can offer fuel oil, etc. Nobody has canceled ads on poles, stops and stands. Until now, this is a good and effective method to loudly declare yourself. In addition, for a nominal fee, you can rent a billboard and place your advertisement there. By the way, you need to do it wisely. It is important not to overload with unnecessary information, but also to attract the attention of a potential audience.

Conclusion

So we talked with you about what tire recycling is and how to open such a business. As you can see, everything is quite simple, but there are a lot of important points. Sometimes it happens that it is difficult to find a supplier, or the latter refuses to just give away old tires and demands money for them. In principle, you can find another, more acceptable enterprise, where they will only be happy to get rid of excess garbage, and they will even give you money for the road. Sometimes it makes sense to conclude a full-fledged long-term supply contract. So you can eliminate downtime for your business and increase income. But all these points should be discussed directly with the supplier. Remember that it is much more difficult to find a point of sale for tires than a businessman who is ready to buy this garbage. This is due to the fact that in some cities there are no tire recycling reactors at all.

If you get good fuel oil, then aim at city or private boiler houses. There you will be happy to purchase fuel, which is vital for heating water. If you are going to get crumb rubber, then you will need a machine that costs about 500,000 rubles. The cost of electricity per 1 ton of products - 90 kW. The disadvantage of this approach is that a group of knives (40 pieces) wears out after processing hundreds of tires, so they often need to be changed. In principle, for one knife you need to pay only 30 rubles, which is relatively little. So, a unit with a capacity of 20 tires per hour pays off in about six months. The results are the same as in the production of fuel oil. But in the first case, there are fewer problems with environmentalists and firefighters, since we are not dealing with either waste into the atmosphere or liquid fuel. Well, in principle, and all on this topic. The most difficult thing is to start, and then it will be much easier.

Every year, a huge mass of used car tires becomes unusable in the world, which not only litter the territory, but also cause great harm to the environment. Meanwhile, from one ton of tires, they produce 700 kg of valuable rubber, which is used in the production of all kinds of rubber products, valuable fuel, and building materials. In Russia, tire recycling is not yet at the proper level, but with proper management, this business can become very profitable.

Relevance of the problem

In Russia, the problem of recycling used tires is very acute. Every year, these wastes in millions of tons are stored at landfills, in landfills, in places not intended for this. The number of cars both from enterprises and individuals is growing exponentially. The volume of tire recycling in Russia and the CIS countries is only a little more than a million tons.

The reason is the insufficient number of recycling enterprises and the lack of a centralized collection system for tires.

Only a small number of tires are located in special places equipped for long-term storage. But even such storage poses an increased risk of environmental pollution. Worn tires are dangerous if they ignite, since the temperature during their combustion is the same as that of coal, and it is rather difficult to extinguish the fire. In addition, during combustion, many harmful substances enter the air.

When stored for a long time in the same place, rubber does not decompose and can serve as a haven for rodents and insects. Do not forget that more and more land is required for storage. The only correct solution to this issue is tire recycling. Since 2006, burying and burning tires in the European Union has been prohibited..

Adheres to these rules and Russia. Recently, the country has a system of supervision over the timely delivery of used tires by enterprises.

Many recycling businessmen have proved the importance and profitability of this production at the government level, using worn tires as raw materials to obtain useful products: crumb rubber and metal. Thus, the relevance of creating a tire recycling production is reduced to protecting the environment and manufacturing products that are in demand on the world market.

Mechanical methods of tire recycling

All types of used tire recycling that are currently used are divided into two groups: mechanical and chemical. Each of them has its positive and negative sides. From the point of view of environmental safety, the mechanical method is relatively safe and is used in most countries of the world. Its essence is as follows:

1. Tires are washed and cut into pieces.
2. With the use of magnetic separation, the resulting raw material is cleaned from the metal cord.
3. Then all this is heated if processing takes place at a high temperature, or cooled (if processing takes place during cooling).
4. The rubber raw material is crushed.
5. Large crumbs are ground and brought to the desired size.

The negative side of this method can be called a high cost, since it is expensive to grind tires. Also, a lot of money is spent on electricity. But, unlike chemical methods, one can note the simplicity and absence of harmful substances.

In addition, technological parameters do not change at all. There are other ways to grind used tires, but some of them are not widely used.

The most famous of them:

• grinding with a rotary disperser;
• using an ozone knife;
• barodestruction method;
• crushing with an explosion.

In the rotary disperser, crushed rubber by squeezing turns to rubber dust, which is capable of reacting with different mixtures. It is used mainly in the manufacture of new tires and in roofing work. Processing with an ozone knife involves the effect of ozone on rubber in a special chamber where grinding takes place.

With the barodestruction method, tires are cut and crushed, then in a chamber under high pressure and high temperature, the rubber is brought to a fluid state and separated from the metal cord. The result is a very fine rubber crumb.

Chemical Methods

Chemical methods for processing tires are not widely used, since rubber is removed from the composition after chemical processing, and the final product is cheaper than mechanical processing. The most common chemical processing methods: pyrolysis, incineration, dissolution. Pyrolysis is a thermal decomposition that takes place in a special chamber without air. Pyrolysis and combustion release toxic substances, so the use of this method is problematic.

During the combustion process, worn tires replace fuels such as fuel oil and coal. This method is used in the production of cement and for heat generation.

As for the method of dissolution, it is recognized by many experts as one of the most promising, but is still used very rarely. The resulting raw material can be used in the metallurgical and chemical industries.

In Russia, now the volume of rubber processing leaves much to be desired. There are still not enough enterprises for the disposal of old tires. One of the difficulties is that our domestic tires, which are reinforced with a radial-synthetic cord, are more difficult to recycle.

Tire recycling mini-factory

To open any, you must first study the demand market. When opening the first tire recycling plant in a big city, this is not necessary. First you need to draw up a business plan. You can register for an individual entrepreneur or LLC (it costs 800 and 4,000 rubles). A license to work with low-hazardous waste will be required, the Federal Service for Supervision of Natural Resources issues it. Its validity period is not limited, it costs 7,500 rubles. It is also necessary to obtain permission from the sanitary and epidemiological station and the fire service.

Such business is not allowed to open in residential areas and close to them. You can rent abandoned factories or separate premises in existing ones. The area of ​​the mini-factory should be about 300 square meters to accommodate equipment, storage space for raw materials and finished products, and a living room for workers. The most difficult and costly thing in this business is to buy equipment.

You need to purchase the following equipment:

You also need to buy crumb boxes, work clothes, a computer and office equipment for accounting. 12 people are needed to work at the plant:

• site foreman - 2 people;
• operators - 4 people;
• loaders - 2 people;
• driver - 1 person;
• receiver of old tires;
• sales manager - 1 person;
• accounting worker - 1 person.

Part of the responsibilities for the management and search for consumers takes on the head. Since we have to work with waste, it is possible that people will often quit, so personnel work should be carried out. As regards the marketing of products, its main buyers should be construction organizations who needs both the crumb itself and various products made from it.

With an investment of 3,550,000 rubles, monthly expenses of 455,000 rubles, monthly income of 1,203,000 rubles, the business will pay for itself in six months. In order to develop successfully, support is needed at the state level, as is practiced in many European countries.