Tire recycling as a business. Production of crumb rubber from tires: technologies and methods. Recycling tires into crumbs at home Grinding tires into crumbs

23.06.2020

There are more than 1.1 billion cars in the world. The number of registered cars in Russia is about 46 million. This means that if trucks are added here, then about 5 billion tires run on the roads of the world. The number of tires in the world's landfills is not exactly known. In Russia, according to various estimates, from 30 to 45 million tires are thrown away per year. There is no need to talk about the harm that such waste causes to the environment.

The issue of recycling and disposal of car tires is acute all over the world.

There is not a single country in which this problem is considered solved. In our country, according to various sources, from 8 to 12% of old tires and conveyor belts are recycled. These figures show that tire recycling as a business has a good future.

However, once you decide to run a rubber recycling business, you must choose your recycling method carefully and be aware of all the pitfalls of such a business. Choosing a recycling method, and therefore the direction of your investment, is a very difficult task. Enterprises producing equipment for one or another processing method, naturally, praise their method and carefully hide its shortcomings. In this article, we will try to facilitate the task of choosing a processing method. Remember that there is no perfect method. All have flaws. Here are the main ways to recycle car tires:

reuse by applying a new tread (in this case, the tires still need to be recycled after reuse);
combustion for the purpose of obtaining thermal energy;
heating without air access or with limited air access (pyrolysis);
grinding to obtain crumb rubber, secondary metal and textile threads;
burial and use to strengthen the coastline, install fences, etc. This method is prohibited in most countries, including Russia. We will not consider it.

We do not consider in this article the application of a new tread on worn tires (“welding”). This is a method to extend the life of tires, not to recycle them. Let's take a closer look at other methods. When evaluating recycling methods, you should have a basic knowledge of the composition of the tire material.

Tire material composition

The main components of tires are cord (metal, textile or mixed), rubber, filler (soot), auxiliary materials (thermal stabilizers, anti-ozonizers, etc.), adhesives (contain polychlorinated hydrocarbons and some other materials in small quantities. Except for metal cord (and this is a steel wire coated with brass - an alloy of copper and zinc), then the composition of the tires includes: hydrocarbons (rubber, etc.), carbon (soot), silicon dioxide, sulfur (a vulcanizing agent in rubber and as part of other components), polychlorides (as part of adhesives) and some other components in small quantities.Contrary to popular belief about the presence of arsenic in the composition of tires, it is not there.Heavy metals are also absent (except for a small amount of copper and zinc on the surface of the metal cord). Lead is also not used in modern tires. All these components undergo changes during the processing of tires and form new substances, many of which are more dangerous than the original ones. Now let's look at the advantages and disadvantages of various tire recycling methods.

Burning tires to generate thermal energy

The method seems attractive. Therefore, it is worth talking about it in more detail.

Burning one ton of tires gives about the same amount of thermal energy as one ton of thermal coal.

What is the problem? First, tires cannot be burned in conventional thermal power plants. You need special equipment and preparation of raw materials. Secondly, when sulfur is burned, it forms a large amount of sulfur dioxide (sulphurous gas). This requires a special cleaning installation. The problem is solved, but the equipment is very expensive. Thirdly, polychlorides at insufficient combustion temperature form one of the most dangerous substances - dioxin. The available international experience shows that such a method has the right to life only when processing very large quantities (more than 100 tons) per day, requires huge investments and is profitable only in case of subsidies (financial support) from the state.

Read also: Production of skimmed milk powder

Tire pyrolysis

The process is heating the material to 400–500 degrees without access to oxygen (air). This produces pyrolysis gas, liquid hydrocarbon fraction, soot and steel cord waste. You can find an excellent product calculation. For example, from 1 ton of tires you can get 500 kg of liquid hydrocarbon fraction (fuel and even gasoline!), 200 kg of gas (used to heat the reactor and save fuel), 200 kg of carbon black and 100 kg of metal. What is the problem? Ask yourself the question, where does sulfur disappear if it contains up to 10% and silicon dioxide. Very simple. Most of the sulfur turns into hydrogen sulfide (the strongest poison, a substance of hazard class 1), which is contained in pyrolysis gases. Another part of the sulfur forms carbon disulfide and other compounds that go into the liquid fraction. And, finally, in the residue, which is bashfully called technical carbon, there are metal sulfides (mainly sodium and calcium). Where did the silicon dioxide disappear - in the remainder. The fate of polychlorides is even more complicated. Some of them pass into the residue, some form hydrogen chloride (not a gift!), And some form dioxins, which can be found in all products. This "carbon black" will not be used by any responsible consumer. You can't bury it either. Having recycled tires in this way, we will create a bunch of new problems. These problems are solved, but require large capital investments, which calls into question the profitability of this method without the help of the state.

Grinding tires in order to obtain crumb rubber

The essence of the method is very simple. Tires are shredded. In this case, three products are formed - metal, rubber crumb (we will consider the directions of its use below) and textile cord waste.

With such processing, there are practically no chemical changes (no new toxic waste is formed).

This is the main advantage of the method. What are the problems? It is very difficult to separate textile threads from crumb rubber and the textile material obtained in this way is practically a new waste. We will show below how to solve this problem. But at the initial stages it is better to deal with the processing of pure steel cord tires. This will significantly reduce capital costs. The key issues in building a mini tire recycling plant are the following issues.

Selecting a location for production. Construction or use of existing facilities.
Selection, purchase and installation of equipment.
Obtaining a license for processing.
Formation of reliable channels for obtaining raw materials and marketing finished products.

Let's consider everything in order.

Production site and buildings

Even a mini tire recycling plant requires a fairly large site. Most of the production site will be occupied by a warehouse of raw materials (tires) and finished products. The tire recycling line occupies a fairly large area - 150–300 m2. This is best clarified after choosing the equipment. The height of the building (or hangar) is 5–6 meters. The production site should be sufficiently removed from the residential area. The minimum distance is 200-500 m. The best place is the industrial zone. During the processing of tires, the material heats up quite strongly and releases volatile substances with a specific odor. Local ventilation is required. It is necessary to provide special absorption cartridges as part of the ventilation equipment. They are produced industrially.

Tire crumb recycling equipment

For processing tires into crumbs, the price of equipment is not prohibitive. However, the cost of a set of equipment of 10–15 million rubles should be considered minimal. The choice of equipment for processing tires into crumbs is quite wide. There are lines of Russian production and import. When choosing equipment, do not pay too much attention to brands.

Tire recycling line

If possible, visit an already existing production facility and hear all about the problems of this production facility. When buying equipment, it is better to focus on complete lines, however, some components can be used or purchased separately. Here is the minimum equipment list:

shredders (shredder, hydraulic shears, tape cutter);
separators (air and magnetic);
conveyors;
vibrating screens.

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

There are not enough enterprises involved in their processing, although each region annually accumulates 50 tons of worn-out rubber. Not all cities have places to store this type of waste. Discarded tires are found on the side of the road or near suburban roads.

The Moscow region has the greatest experience in the recycling of tires (2 specialized plants operate), but they process only 10%. Therefore, the tire recycling business will occupy an empty niche.

The advantage of such a business is the ability to get old tires for free. Recycling tires into crumb rubber is a promising type of business.

In Russia, there is no system for recycling tires, experts attribute this to the imperfection of the legislation.

Advantages and disadvantages of the processing business

The benefits of this business include:

inexpensive raw materials in large quantities;
location near the places of sale;
few competitors;
the ability to use any room;
economic benefit.

Disadvantages:

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

Room selection

The main parameter is the area of the premises and the cost of rent. When choosing a room, consider:

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

An industrial area located outside the city will be the most suitable place.

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. The licensing of this type of activity was canceled by the Federal Law No. 93 dated 06/25/2112.

What documents are required for registration of an individual entrepreneur and how to properly issue them in accordance with the requirements of the law - read

Activity registration

The choice should be approached responsibly: this affects the registration procedure, payment of taxes and other factors. When opening an LLC, the responsibility arises:

as a legal entity;
as individuals founders and participants.

An LLC is liable for its obligations to the extent of its property. If it is impossible to repay debts during bankruptcy, obligations can be transferred to the founders, participants.

For an individual entrepreneur, in the event of debt obligations, property is not considered personal and that which is used for entrepreneurial activity (this also applies to property acquired before the start of entrepreneurial activity).

Industrial processing of tires into crumbs: a business plan with calculations

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

The area of the premises is 250 m2, the number of workers is 4 people, the electricity consumption is 120 kW. The annual output of crumb rubber will be 2,000 tons.

The cost of the main equipment is 10.75 million rubles.
Delivery and adjustment 250 thousand rubles.
Additional expenses 30 thousand rubles.
Machine that sews bags 10 thousand rubles.
Scales 20 thousand rubles.
The cost of bags for crumbs is 20 thousand rubles.
Staff salary 100 thousand rubles.

With a minimum monthly tire recycling of 150 tons, the output is:

metal cord 30 tons;
crumb rubber 100 tons;
textiles 20 tons.

Income from product sales

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

Total: 1780 thousand rubles.

Production costs

100 thousand rubles staff salaries;
4 thousand rubles on packing bags;
20 thousand rubles communication services, economic;
100 thousand rubles electricity (120 kW x 4.5 rubles);
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, selling them at a price higher than the minimum monthly profit indicators will increase.

Starting a business requires large investments, which scares aspiring entrepreneurs. You can use a bank loan or receive a subsidy under the state program. To do this, you need a business plan with calculations.

and tips for implementing them are contained in our new article at the link.

Possible risks

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

breakdown of technological equipment (to reduce this risk, it is necessary to maintain the line in a timely manner, follow the recommendations for its operation, replace worn-out mechanisms, consumables);
interruptions in the supply of raw materials (it is possible to conclude a contract for the supply of raw materials simultaneously with the search for equipment);
sales difficulties (a long-term contract should be concluded with an enterprise that needs rubber crumb and a distribution channel should be established to nearby regions);
damage to products during storage (special conditions are not required, but crumb rubber is afraid of moisture).

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

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

Of the total amount of used tires, only 20% is recycled, despite the fact that a ton of tires contains approximately 70% of recyclable rubber into fuel, products or building materials. When burning this amount of tires, 460 kg of harmful gases and 280 kg of soot are released into the atmosphere! Tire recycling equipment pays off in 6-12 months, there are never any problems with raw materials and sales of finished products.

Types of tire recycling

There are two recycling technologies, during which car tires are made from:

powder, granules, crumb rubber, chips;
liquid fuel.

For the production of the first four types of raw materials, the same type of machines and equipment are used. The process consists in grinding and separating raw materials. The entire cycle takes place without the use of chemicals and the release of harmful products into the atmosphere.

When processing into liquid fuel, pyrolysis is used - the thermal decomposition of rubber with the release of gas. Part of the gas is released into nature, so such equipment is necessarily equipped with purification stations.

crumb production line

The tire recycling line operates in a semi-automatic mode. This prefabricated equipment occupies about 200 square meters. meters. The productivity of a small workshop per hour is 200 - 1000 kg of finished crumbs, up to 200 kg of metal per shift, up to 1000 kg of textile wool per shift. To service the machines, 3-4 unskilled workers are needed. The line recycles used tires, separating metal and textile inclusions.

Not all tire recycling equipment contains stud and cotton textile separators. This should be taken into account when selecting machines.

In addition to the area for equipment, it is necessary to prepare a warehouse for raw materials and finished products. The basis of the line is roller-type shredders. Most mini-factories are designed to process tires up to 120 cm in diameter, it can be upgraded to 170 cm. Not only tires, but also any rubber waste (gas masks, conveyor belts) can be processed. The output is:

crumb rubber;
crushed steel;
textile cotton.

The yield of rubber is from 60 to 80% of the total mass of tires. The properties of crumb rubber may vary depending on the quality of the scrap.

Averages:

pure rubber content 99.9%;
metal content up to 0.1%;
textile content up to 0.2%;
division into fractions;
black color;
does not oxidize under the influence of temperature.

The machines produce crumb rubber with particle sizes from 0.8 to 3 mm. The amount of crumbs of different fractions depends on the degree of wear and rigidity of the original product. With the help of a vibrating separator, it is possible to clearly separate the crumb into fractions.

Diameters can be set by adjusting crushers and changing screens. The smaller the particles, the longer it takes to produce them. For the production of rubber dust, an additional grinder is installed, which produces particles smaller than 0.1 mm.

Processing technology

A landing ring is cut out of the tire, the metal is squeezed out, rubber remains.
The tire is spirally divided into tapes 3-5 cm wide.
The second metal ring stands out.
The tape is cut into thin and short pieces.
Billets are crushed on rolls into crumbs and dust.
Rubber, metal, cotton wool are released on the separators.
Finished products are sent to the warehouse.

Tire shredding equipment

The production process is divided into two stages, taking place in different areas:

preliminary;
abrasion.

The preliminary stage takes place on the machines:

landing ring highlighter;
tire separator into strips;
strip separator;
ring extractor.

Equipment for the main stage:

main eraser;
coarse vibrating sieve;
magnetic sifter;
air sifter;
belt conveyors;
fine vibrating screen.

The grinding machine is the main equipment in the workshop for the recycling of automobile tires. To accommodate the machines, a hard concrete or asphalt floor covering is required.

Crumb implementation

The end product of tire recycling is used:

in the manufacture of various types of fuel: pyrolysis gas, fuel oil, gasoline;
in the construction of roads: the production of special plates for areas of special danger, brake modules, fences for car parks, noise-insulating panels, railroad and tramway crossings, bitumen-based mastics, sports and play surfaces;
in the manufacture of shoe blanks, floor coverings;
in the production of rubber products, roofing;
for preparations for the adsorption of oil and its derivatives from water and land.

Fuel production line

The second type of device converts tires into liquid fuel. The machine occupies about 18 square meters. meters at a height of 10 m. Tires are cleaned of metal rings and discs, crushed and transported to the reactor receiving tank.

The reactor is maintained at a temperature of about 460 degrees, at which the rubber decomposes into liquid fuel, gas, carbonaceous matter and metal wire. Part of the gas is used to operate the reactor itself, the excess is released into the atmosphere. Their number is insignificant, therefore, does not harm the environment.

Liquid fuel is poured into containers and sent to a warehouse for further sale. The carbon-containing substance is cooled, quenched, and metal is released from it. All processed products are ready for sale.

Such equipment processes up to 5000 kg of tires per day, producing:

liquid fuel - about 2000 kg;
metal - 500 kg;
carbon-containing substance (solid residue) - about 1500 kg;
gas - 1000 kg.

Equipment is mounted on the street, on a concrete or asphalt site. The continuously operating workshop is serviced by 2 workers per shift. On average, the machine consumes 14 kW per hour. The fuel used is gas obtained from the recycling of tires.

The first video tells about the process of recycling car tires, the second shows the processing of tires into crumbs, the third one is about a home-made pyrolysis plant for the production of fuel from tires:

Every year, thousands of tires go to landfills and landfills, despite the fact that for an enterprising person they are a free resource from which crumb rubber can be produced.

If it was needed only once, you can buy it in the right amount from manufacturers.

But where can you get crumb rubber if you need it on an ongoing basis and in large quantities?

Consider purchasing your own tire recycling equipment.

However, not everyone can afford a full-fledged installation, and such an investment will not be profitable for everyone. The way out is to create equipment with your own hands, and use it to produce crumb rubber from tires at home.

Recycling small amounts of rubber at home

If you need very little raw materials, you can do without equipment at all.

This will require only scissors and a cutter.

The metal cord is first removed from the tire, then it is divided into strips and crushed into smaller fractions to the required size.

At this point, the process is considered complete.

Material for the design of paths, flower beds or a separate playground is ready to use.

But to get more raw materials or have an income from tire recycling at home, you need the right equipment.

Tire crusher construction

Three main methods of crumb production are used:

Tire crushing after cooling with liquid nitrogen to -190 degrees.
Obtaining crumbs on industrial equipment of a full cycle with the removal of the cord and subsequent grinding of rubber.
Recycling using universal crushers, which you can do yourself at home.

The first two methods require large investments. The third option is available to anyone who has the ability and desire to make a crusher at home.

The necessary units can be made independently in the workshop or at the production site - where there are metal-cutting machines (turning, milling) and a welding machine for the manufacture of component parts.

If it is impossible to perform the machining of blanks on your own and you have to order them according to your own drawings, the cost of tire processing machines will still be several times cheaper than similar purchased units.

The main component of the tire recycling line is a shredder (rubber grinder). Let us consider in more detail the purpose of the nodes of this machine.

Unit device

The machine consists of the following main units:

electric motor 5 kW - 2 pcs;
housing with disc shafts;
lattice;
worm gearbox - 2 pcs;
shredder frame;
loading bunker;
guide tray;
control cabinet.

Details of the installation are mounted on a powerful frame welded from channels.

Box with cutting discs

The main unit of the crusher for rubber is the body with milling rolls.

At the same time, the cutting knives are made of high-strength steel and heat-treated, which significantly reduces their wear. They practically do not require sharpening during operation.

The calculation of the openings of the box, shafts and cutting elements must be accurate, so it must be done by a specialist in this field (designer).

Grid for crumb calibration

In order to obtain a calibrated fraction of tire raw materials, shredders are equipped with a special grate, which is installed under the rolls.

Worm gear

The rotation of the shafts with disk cutters is carried out separately, directly from the worm gearboxes connected to the electric motors through couplings.

The gear ratio is selected from 25 to 35 so that the cutting is without sticking and at a sufficient speed.

Machine frame

The frame is welded from profile elements, ensures the reliability and stability of the unit during operation, as well as loading and unloading operations.

loading hopper

The tire recycling plant is equipped with a tire loading hopper and a tray for removing finished crumb rubber.

Thanks to its design, the hopper eliminates the formation of blockages from the raw materials and guarantees a directed movement of the mass towards the rotating rolls.

Tire cutter

The tire cutting and cord removal plant consists of a carrier frame and a stand.

On the carcass is a tire clamping mechanism that rotates with the tire during cutting. The engine speed is reduced due to the different diameter of the pulleys. There is a built-in wedge-shaped cutter on the stand, which is adjusted to a certain size by moving the quill.

How to grind tires?

The technological chain consists of several preparatory stages before the production of the required fraction is obtained.

This procedure includes:

Inspection and removal of foreign objects from the tire cavity.
Cord cutting.
Cutting the tire into strips of 50-80 mm in size.
Grinding of raw materials by means of a shredder.
Separation and separation of metal from textile parts.
Calibration of crumbs into fractions using a vibrating sieve.

Equipment performance

The work of these two main units during the processing of tires is done in a semi-automatic mode.

For the normal operation of this line, a room of about 150-200 square meters is required. meters. This is due to the fact that you need a place for the location of not only equipment, but also for storing worn tires, finished tire products and metal waste.

The output of rubber crumb on this equipment per hour will be approximately 200-800 kg and up to 100 kg of scrap metal, 2-3 unskilled workers will be needed to service the machines.

In addition to tires, this equipment can process other rubber (conveyor belt, cameras, gas masks). The output is a crumb with sizes from 0.7 to 4 mm, while it is 65-85% of the total mass of raw materials.

Where to apply the obtained raw materials?

Rubber crumb can be:

The price of crumbs will depend mainly on the quality of raw materials, and secondarily on the fraction.

The most popular is the crumb, the fraction of which is 2-4 mm.

It's great for creating:

The popularity of such crumbs is due to the fact that the minimum amount of glue is used to glue these granules. A polyurethane binder is sometimes 5-8 times more expensive than crumbs.

Conclusion

Building a DIY tire crusher is a good idea for those who want to make their own rubber crumb but aren't ready to spend tens of thousands of dollars on equipment.

You can create a chopper with a carpentry workshop, as well as certain skills and materials, or use the services of people who specialize in this.

The crumb obtained at home can be used for your own needs or sold to enterprises and the public.

In contact with

Classmates

rcycle.net

Recycling tires into crumbs at home: how to do it

It has long been known that worn-out tires that are out of service are a potential source of environmental pollution and environmental damage. Recycling tires into crumbs at home is the same popular method, along with factory ones. Rubber waste from used tires is virtually non-biodegradable, taking hundreds of years to decompose.

It should be noted that this rubber waste is a flammable material, and if a huge number of tires ignite, they can pose a threat of poisoning to everyone nearby, since rubber, when burned, releases carcinogenic toxins, such as benzpyrene. Storage in landfills leads to the reproduction of rodents and insects, which are sources of dangerous infections. To avoid the deterioration of the environmental situation in Russia and abroad, proper disposal is required, namely, waste processing. Without constant recycling, an environmental crisis could set in very soon.

Recycling

Recycling is also economically beneficial. From car tires, you can get various types of valuable recyclable materials, as well as produce a huge amount of finished products. From the waste of powder rubber of a very fine fraction (about 0.2 mm), new car tires and rubber shoes are produced, this secondary resource is popular in Russia and the CIS countries.

Powder from waste of larger fractions is used in the production of composite roofing materials, rubber-bitumen mastic, waterproofing materials, and rubber coatings. Scrap metal is obtained from a metal cord, which is also used by Russian entrepreneurs. Also, textiles and rubber are obtained from tires.

Recycling at home

Especially active and advanced people have the opportunity to process rubber with their own hands. What is needed for this? Spent chambers, tires, tires and a little ingenuity. Recycling tires into crumbs at home is a rather complicated undertaking. According to their properties, cameras from old tires are more suitable. They are softer and more easily amenable to external influences.

According to one of the scenarios, the rubber should be cooled to a temperature of approximately -75°C. Agree, not everyone has such an opportunity. So let's use the traditional scenario:

Take the cameras
Remove all unnecessary elements from them
Cut them into thin strips
Grind those stripes

The rubber grinder in this case is an ax or scissors.

Mechanical processing method

The most professional way. The technological line is a sequence of installed working devices, overcoming which the material becomes a finished product.

Processing into crumb rubber goes through three stages:

Tire preparation. Initially, they are washed and cleaned of impurities, after which they are transported by a conveyor to the primary crushing unit, where they are ground with knife crushers to large pieces (30-50 mm).
At the second stage of the technological process, the primary processed raw material is fed by means of a belt conveyor to a hammer crusher, where it is re-crushed to smaller sizes (10-20 mm). It is at this stage of processing that the metal and textile cord, bead wire is separated from the rubber. Textiles are separated by a special textile removal system, and metal is separated by a magnetic separator. The collected metal waste is then briquetted.
At the final stage, processing into crumbs is already underway. As equipment for processing tires into crumbs, an extruder - grinder is used, in which the rubber mass is ground into a fine powder. At this stage of tire processing, additional cleaning of crumbs from textiles and metal is also carried out using a gravity separator. After that, the crushed rubber crumb is divided into fractions and packed in polyethylene bags of 20 kg or in big bags (soft containers) with a carrying capacity of up to 1000 kg.

Today, there are a sufficient number of manufacturers of this equipment on the Russian market.

Chemical processing method

With the chemical method of processing, automobile tires are subjected to pyrolysis. With this processing method, the thermal decomposition of rubber into its constituent elements occurs. Tires are pre-crushed into a homogeneous mass and sent to an oven, where they decompose at a temperature of 500 - 800 ° C. This procedure lasts 10 - 20 minutes. In the process of thermal decomposition of rubber, about 50% hydrogen and 26% methane are formed, as well as solid pyrolysis products, which are then used in wastewater treatment at wastewater treatment plants in Russia.

There is also an effective, but expensive physico-chemical method of processing tires into crumb rubber - cryogenic grinding of car tires. Crushing of rubber is carried out in a special cooling chamber at extremely low temperatures (up to - 120 ° C). A refrigerant (liquid nitrogen) is supplied to this chamber, cooling to ultra-low temperatures. In conditions of strong cooling, the rubber acquires a glassy state. Crushing of rubber occurs when struck with a special hammer. After grinding, textiles and metal are removed from crumb rubber.

In modern times, there are many mini-factories for the processing of tires. The business plan for recycling car tires is quite simple. Its implementation will require modern tire recycling equipment, warehouse equipment, fuel tanks, tools and overalls for workers, as well as equipment installation costs. It is necessary to register an enterprise and a license that will allow you to engage in this type of activity. Starting this business will require significant start-up capital.

vtorothodi.ru

scheme for creating a homemade grinder for PET

Polymer materials have become very firmly established in our lives and now they can be found in any industry.

But due to the fact that these materials do not decompose naturally, they cause serious damage to nature.

A positive feature is the possibility of their recycling.

To do this, the plastic is first prepared and brought to the state necessary for this, it is crushed. To do this, special devices were invented - crushers (shredders, machine tools, shredders) for plastic. You can make such a crusher with your own hands.

Varieties of choppers

In total, there are three types of such devices, which differ in the possibility of processing a particular polymer material.

They are divided into options:

The design looks like V-blades on scissors and is suitable for shredding plastics such as acrylic, film and nylon.
A type that is used primarily in plastics factories and recycling plants.

By design, they are of several types: hammer, cone or jaw crushers. They are used for processing large-sized plastic products, like a window profile.

The most common option has a rotary design and is used for processing thin-walled plastics like bottles, foam.

The plastic shredder will allow its owner to contribute to the environment and even earn money. For domestic purposes, a rotary version of the crusher is usually used. Its design consists of a rotor on which the knives are securely attached.

Crusher Mesh

After switching on (and it can work both from a liquid-fuel engine and from a conventional electric motor), the axis with knives begins to rotate and, as a result, under fast and strong blows, the raw materials that have got inside such a device are crushed.

At the bottom of the body for grinding there is a grate, which has a certain mesh size. It is determined depending on what diameter the fraction should ultimately have.

The raw material in the device is processed until it reaches the desired size and exits through this sieve.

Specialist note: the quality of the metal of the knives used should be used as strong as possible. It is best to use high-quality hardened steel so that the blades wear out less quickly and the sharpness of the knives lasts longer.

Materials and tools

To assemble such a device at home, you will need certain skills in working with a welding machine.

The total plastic shredder consists of such elements as:

circular saws. The optimal number is approximately 20 pieces.

Since this is the basis of the entire apparatus, they should be selected only with high-quality and various tooth configurations, which will allow better grinding of waste;

as a drive, it is best to use an electric version of the engine. The reason is a wider choice and the ability to use not only outdoors, but also indoors;
axis for fastening saws;
to create a frame and frame, you will also need a metal profile;
various elements for fastening;
a hopper through which the material will be fed for processing and a protective cover;
to connect the rotor you will need a special belt, as well as a pulley and several bearings.

Incorrect choice of crusher saws can lead to an imbalance on the axis, due to which the structure will vibrate strongly and wear out faster.

Process of creation

Schematic diagram of plastic crusher

After preparing everything necessary for work, you can begin the manufacturing stage:

First, a cutting block is made by putting circular saws on a pre-prepared axis. In order to leave the necessary space between such impromptu knives, it is worth using nuts.
Next, we mount the structure on the pulley and ensure free rotation due to the bearings.
Now we make a rectangular frame and a support frame from prepared metal materials.
The next step is to weld the height-adjusted legs, also using welding.
Further, the frame is covered with a steel sheet, for this we weld it to the frame. We make a hole of the required size in it and mount the engine at the correct distance from the cutting elements. The protective cover and material supply container are necessary for safety and work efficiency.
After creating the frame, we begin the last stage of assembling the plastic crusher. To do this, a so-called protective cover and a bunker are put on the knives, through which the raw material will be fed. During the installation of the casing, it is worthwhile to provide a hole in it for connecting the axis to the pulley.
The final touch is the connection of the cutting block to the motor shaft using a belt for this. Everything, the design is ready.

The main recommendation given by experts is the need to draw up a drawing of how the planned structure will look like before starting work. This will make it possible to avoid inaccuracies and inconsistencies in the dimensions of individual parts.

Having designed and assembled such a unit with your own hands, you can, knowing its entire design, easily make changes and refine it.

The shredded plastic will have the size that is laid down in the design capabilities of the unit itself.

When choosing a power unit, it is necessary to determine in advance how often the device will be used. If the work on it is rare and the loads are insignificant, then a low-power electric motor will suffice, but for active use, a more powerful option and with a large number of revolutions will already be required.

And in order not to have to collect the processed fractional material on the floor, it is advisable to provide a place under the saws for attaching a special container in which it will be collected.

Watch a video review of a quality do-it-yourself plastic crusher:

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Do-it-yourself plastic crusher for recycling

Polymeric materials have firmly entered modern life, and there is not a single industry where they are not used, from the production of containers to space technologies. Every year, about 180 million tons of various plastics are produced on the planet. Most of them cannot independently decompose into simple components and be disposed of on their own.

This brings irreparable damage to nature and can cause an ecological catastrophe. A positive feature of almost any polymer (plastic) is the possibility of recycling, so that old plastic things can get a “new life” as useful items. Recycled plastic is slightly inferior in terms of strength characteristics to the primary polymer, but with certain proportions, products made from recycled plastic practically do not differ from the original.

Varieties of choppers

Before being recycled, any plastic must be shredded. For this, there are special devices - crushers. Depending on the physical qualities of the polymer placed in them, the devices can be classified into several categories:

for shredding PVC film, nylon or acrylic. The design resembles large scissors with "V"-shaped blades;
for large plastic waste. Most often used in recycling plants or plastics factories. There are hammer, jaw or cone designs. With their help, window profiles and large parts and cases are crushed;
for PET bottles and thin-walled plastics. The most common version of the grinder, structurally called rotary.

The required type of apparatus can be purchased or made by yourself. This is a small household appliance from the third category. Do-it-yourself plastic crusher is quite easy to do and does not require serious knowledge and specialized tools, except for a welding machine.

Learn more about rotary shredder

The most common design is the impact crusher. It consists of a rotor on which the knives are fixedly fixed. Under the action of a driving force - from a diesel, gasoline engine or an electric motor, the axis with knives sets in motion and grinds the raw materials that have fallen under the knives with quick blows. Depending on the purpose, there are low-speed machines and high-speed units.

At the bottom of the working chamber, a sieve or grate with a certain mesh size is installed, depending on the required quality and diameter of the obtained fraction. Raw materials are cyclically processed by knives and gradually pass through a sieve.

Particular attention is paid to the quality of the metal from which the knives are made - it must be a good hardened steel, which prevents rapid wear and ensures that sharpening is maintained for a long time.

We make our own crusher

There are several of the most popular varieties of plastic shredders that are made at home. In order to assemble this device with your own hands, you will need a little patience and minimal skills. As a special tool, you only need a welding machine or a household inverter.

A do-it-yourself plastic crusher, the scheme of which will differ slightly depending on the skill level of the manufacturer and his imagination, has the following common elements:

drive unit. The most commonly used electric motor. Thanks to a large selection and affordable prices, you can choose the model of the required power. In addition, the electric drive crusher is quieter and can be used both outdoors and indoors;
circular saws. This will be the basis of our apparatus. It is necessary to select a sufficient number of them and a different configuration of teeth for better grinding of waste. The optimal number of saws on the axis is about 20;
the axis on which the saws will be attached;
metal profile or pipe for the manufacture of the support frame and frame of the crusher;
protective cover and feed hopper. They can be made independently at home from galvanized sheet metal with metal scissors, a hammer and a vice;
a pulley, two bearings and a special belt, with which an interaction is created between the electric motor and the rotor;
fasteners (nuts, washers and self-tapping screws for metal).

When all the necessary materials and tools are prepared, you can begin to manufacture the unit.

First of all, you need to build a cutting block. To do this, we put circular saws on the prepared axle. The diameter of the axle and the seat of the saw must match. There should be a minimum distance between improvised knives, which is provided by ordinary metal washers. At the ends of the saw should be well fixed with nuts. Then we install the axle on the pulley and use two bearings so that the structure rotates freely.

The next step is the manufacture of the supporting frame. We make a rectangular frame from a metal corner, profile or pipe by welding. Then we weld the legs of the required height to it. We cover the frame with a sheet of metal, which is welded to the frame. We cut a hole in the sheet equal to the size of the cutting block. We mount the engine at a short distance from the knives.

After the frame is ready, you can proceed to the final stage of assembling our device. To do this, we put a protective cover on the knives and install a hopper on top for supplying raw materials. A hole must be provided in the casing through which the axle will be connected to the pulley. Using a special belt, we connect the motor shaft and the cutting block. Our simplest plastic crusher design is ready.

People who have extensive experience in the manufacture of various units with their own hands recommend that they first draw up a drawing of the future design. In this way, you can avoid size mismatches or miss a node or part.

Before purchasing an engine, you should decide on its power and output speed. For infrequent use and at low loads, a compact electric motor of low power is sufficient. The more actively the crusher will be used, the more powerful and “resourceful” the motor should be.

Circular saws are better to choose light-alloy ones. They are slightly more expensive than standard products, but they retain their sharpness much better, which will save you from regularly and often removing the cutting block to sharpen saws. The design itself should be thought out in such a way that you can easily get to any of its nodes.

For greater convenience, you can make a special container where the processed raw materials will be located. The container is fixed directly under the saws of the crusher. If you need to receive recycled plastic of various sizes, you should take care of manufacturing and installing a special mesh or grid under the disks with the desired cell size.

Small Conclusions

A plastic crusher is a tool that will not only help fight environmental pollution, but also bring some income to the owner. Shredded plastic can be handed over by weight to recycling points and earn some money. In addition, depending on the design of the cutting unit and the power of the motor, the device can be used to grind leaves and branches - and this is already a serious help to any summer resident or owner of a private house.

The assembly of the unit is not particularly difficult, and thanks to your own developments, you can improve the design. Assembled independently, the crusher will not differ in any way from mass-produced grinders for household needs, and in terms of reliability it will surpass cheap Chinese counterparts. One of the options for what a plastic crusher can be - a video story is attached.

polymerinfo.com

We make a garden shredder with our own hands on circular saws

After spring tree pruning, most gardeners are faced with the problem of disposing of old branches. If you are a thrifty owner who is used to putting all the waste into action, then most likely you send all the branches to the compost heap. There, all this stuff rots and in 3-4 years you are guaranteed to receive an excellent organic fertilizer - compost. All this, of course, is wonderful, but too long. If you first chop the branches and leaves on them, then your compost will ripen in a season, or even in a couple of months. And here a garden shredder can come to your aid - a device that will turn the source material into chips or flour. The devices that are on sale are not cheap, so we suggest that you familiarize yourself with the instructions for making a garden shredder with your own hands.

We will make such a bandura ... let's go!

We will not convince you that a homemade shredder will be completely free. Naturally, some details will go into its manufacture, which will cost money. However, on average, a home-made unit will cost you 2 times cheaper than a ready-made chopper of a popular brand. Judge for yourself, for the chopper you will need:

Circular saws - 15-25 pieces
Motor - gasoline or electric
Stud (rod) M20, washers and nuts to it
Pulley (for example, from a VAZ generator) and a tight belt
Bearings
Metal pipes for the frame
Sheet Metal for Hopper
Plastic washers 14-24 pieces

Crushing of material in the garden shredder is carried out with the help of knives. In finished models, the knife is most often a metal disc with 2-3 cutting surfaces. A large amount of work quickly makes the teeth unusable and they have to be sharpened periodically - you see, this is not very convenient, and besides, it takes your time. If you decide to make a garden chopper with your own hands, then you can not repeat these design flaws, but assemble a reliable, high-performance and, most importantly, durable knife.

We suggest using carbide-tipped saw blades for this. It will take not one disk, but several to collect a system from them - a package. In ready-made garden shredders, the knife, as a rule, has a thickness of 3 cm, but we can pick up a package of any thickness - everything will depend on the number of saws purchased. On average, for a quality knife 6-10 cm thick, you will need 15-25 pieces. Each disc has many teeth, originally designed to cut through hard wood. Therefore, grass stems, leaves and branches for them will be the same as seeds. As a last resort, if the teeth on the saw become dull, there is nothing to stop you from going to the nearest tool store and getting a replacement for it.

Circular saws can be successfully used as chopper knives

However, the knife is not everything. In order to set it in motion, we need an engine. For fast chopping of branches in small volumes, it is easier to use an electric motor. Its use may seem somewhat inconvenient due to the cable and the need to connect to an outlet, but it works almost silently and does not emit exhaust gases. The walk-behind tractor has more power, so it is ideal for those cases when you need to crush coarse material often and for a long time.

1. Saws are assembled on an axis, the diameter of which is determined by the bore diameter of the discs (20mm). For this, a stud with an M20 thread is suitable. Accordingly, washers and nuts of the same diameter will be needed.

Saws assembled on the axis of the future chopper

If we install discs on a hairpin close to each other, then the knife will not work. And here's why: the width of the saw teeth is greater than the width of the blade itself, so when rotating, the teeth will cling to each other. To prevent this from happening, it is necessary to separate the disks a short distance. This is easy to do with homemade washers that you can cut out of thin plastic. Their number should be 1 piece less than the number of circular saws.

2. A pulley is put on the stud axle (from the VAZ generator or from the pump). To rotate the axis, two VAZ intermediate shaft bearings with an inner diameter of 20 mm are also used.

3. A frame is welded from profiled metal pipes, on which the walk-behind tractor bar is attached. The engine is mounted on the frame so that it can be moved relative to the circular saws. This is necessary to change the tension of the drive belt if necessary.

An axle with circular saws is attached to the frame

4. For ease of use, a thrust bar made of a metal profile is fixed on the frame, into which branches and stems will rest during crushing.

5. The cutting block must be fitted with a metal casing that is welded from sheet metal or cut from galvanized steel. For reliability, it is better to use the first option.

The casing is better to be made of sheet iron - it is more reliable!

6. Another hopper with a socket is attached from above to load the material to be crushed. There are no special requirements for this part, so most often it is made of flexible galvanized steel.

The receiving hopper is easy to make from galvanized steel

Unlike factory models, a homemade chopper does not require an overly careful attitude. It will become a universal helper in the household and will help not only to chop branches and other household waste, but also to crush fruits (apples, pears, plums), and along with the seeds. This is very convenient if you need to make jam, puree or homemade wine when the fruits are crushed to a paste.

Garden shredder in action

The circular saws that form the blade of the unit are capable of processing fairly large pieces of wood. Of course, we are not talking about logs, but branches with a diameter of 10 cm will be quite “too tough” for him. This home-made shredder compares favorably with the factory product, the body of which simply will not let large parts of the material through. Accordingly, you will significantly save your time, because you do not have to sort the branches by size and think about what to do with too large fragments. Also, it will not be necessary to monitor the moisture content of the material, while the purchased grinder requires adjusting the degree of dampness of the feedstock. The fact is that in most modern ready-made shredders, the electric motor is located at the bottom of the structure, so when processing wet stems, moisture will inevitably get into the engine, and this will lead to breakdown. In a homemade product, you are free to decide where to install the engine, in the version described above, it is located horizontally, on the same level as the knives.

It is also worth paying attention to the cost savings when using a homemade chopper. Firstly, manufacturing will initially be cheaper than buying a factory device, and secondly, a “home-made” will not need to purchase expensive parts in the event of a breakdown - all of its elements are not expensive.

Homemade garden shredder is able to crush even large branches, turning them into chips

In addition, a homemade garden shredder has a high performance. All waste loaded into the hopper will be pulled in by the circular saws and disappear at an incredible speed. Thus, a home-made device can be no worse than an expensive and modern garden tool. In a word, if the chopper is really needed, but there is no money to buy it, there is only one way out - to make it yourself!

Every year, thousands of tires go to landfills and landfills, despite the fact that for an enterprising person they are free resource from which crumb rubber can be produced.

If it was needed only once, you can buy it in the right amount from manufacturers.

But where can you get crumb rubber if you need it on an ongoing basis and in large quantities?

It is worth thinking about buying your own.

However full installation is not affordable for everyone, and not everyone will be profitable such an investment. The way out is to create equipment with your own hands, and use it to produce crumb rubber from tires at home.

If you need very little raw materials, you can do without equipment at all.

This will only require scissors and cutter.

The metal cord is first removed from the tire, then it is divided into ribbons and crushed into smaller fractions to the required size.

At this point, the process is considered complete.

Material for the design of paths, flower beds or a separate playground is ready to use.

But to get more raw materials or have an income from tire recycling at home, you need the right equipment.

Tire crusher construction

Three main methods of crumb production are used:

Tire crushing after cooling with liquid nitrogen to -190 degrees.
Obtaining crumbs on industrial equipment of a full cycle with the removal and subsequent grinding of rubber.
Recycling using universal crushers, which you can do yourself at home.

The first two methods require large investments. Third option available to everyone who has the ability and desire to make a crusher at home.

Required units can be make it yourself in the workshop or on the production site- where there are metal-cutting machines (turning, milling) and a welding machine for the manufacture of component parts.

If it is impossible to perform the machining of blanks on your own and you have to order them according to your drawings, the cost of tire recycling machines will still be several times cheaper than similar purchased units.

The main component of the tire recycling line is a shredder (rubber grinder). Let us consider in more detail the purpose of the nodes of this machine.