Lines for processing the worn-out tyres & rubber waste

Lines for processing the worn-out tyres & rubber waste

1.1. Way of processing

Line for the worn tyres processing ЛПШ500 (LPSh500) is intended for mechanical mincing of the worn tyres aiming to get a rubber powder– modifier (with the dimensions of the powder particles up to 1.0mm) without the steel-wire or textile cords.

  • Those processes are laid into a base of the technology;

  • mechanical cropping (cutting mainly) of the tyre on the equipment for the bead-rings cutting out and on the equipment for the tyre cutting into bands;

  • crushing the bands in the rubber mincer ИШ into the pieces(chips) of the dimensions not more than 50 x50x50 mm;

  • milling the chips in the rubber crushing mill Др800-490/610 into fraction up to 5mm.;

  • initial division of the milled fraction into the rubber crumbs, metal wires and the textile fibers;

  • processing of the rubber crumbs in the rubber destructurizing machine МДР-400 up to the rubber powder-modifier-obtaining with the particles dimensions up to 1.0 mm by a method of the temperature–shifting comminution. In processing of the temperature– shifting comminution of the cropped tyre, the production of the highly active rubber powders with the well developed surfaces of the particles is obtained, that is very important during the secondary usage of the rubber powders as the additive asphaltic bituminous mixes as well to the production of the water or wet proofing and - rooting materials;

  • separating and filtration of the rubber powder -modifiers from the balances of the metal-wire and textile cords.

Equipment for the bead ring cutting–out from tyreEquipment for the tyre cutting into bandsRubber mincer ИШRubber destructurizing machine МДР-400

1.2.Composition of the production complex

Productiveness of the equipment is 500 kg/h (80 t/month) by the end product- the rubber powder–modifier.

Pos.
Denomination
Qn-ty. pcs.
Drive(s) power, kW
1
Equipment for the bead ring cutting–out from tyre
2
4+4
2
Equipment for the tyre cutting into bands
2
4+4
3
Rubber mincer ИШ
1
30
4
Rubber crushing mill Др800-490/610
1
75
5
Rubber destructurizing machine МДР-400
1
160
6
Conveyer magnetic separator
1
4
7
Conveyer
1
2
8
Conveyer
1
2
9
Conveyer vibroseparator
1
10
10
Conveyer
1
2
11
Conveyer
1
2
12
Vibrosieve
2
1.5
13
Pneumatic transport
2
4+4
14
Cyclon (separator)
1
 
15
Cyclon with bin
1
 
16
Drum magnetic separator
1
4

Totally:

Installed power – 320 Kw

Nominal power – 220 Kw

Servicing staff – 6 persons

Line for the worn tyres processing ЛПШ-500 (LPSh-500)

1.3. Peculiarities and advantages of these technologies

  • method of processing is mechanical fully, without usage of the criogenical and chemical technologies , and that allows to keep the high developed and active surface of the minced rubber powder;

  • processing of the worn tyres both with the metal-wire and with textile cords, as well processing of the tyres with the combined cords is possible;

  • mobile carrying-out of the equipment for the prime cropping of the tyres (the bead-cutting into the bands) and their use at the places of the tyres storage are possible;

  • high efficiency of the by-products cleaning depends on the line completing by the separators;

  • ruther low power consumption in comparison with the other technologies;

  • complex ( the line) may be used both in the industrial production for the reclamation and processing the tyres that have worked off their resourses and as the bitumen items;

  • line is modulated that is the possibility of the production capacities is possible for the sake of the finish completing the line by some single items of the equipments, and it is under the relatively low increase of the expenditures for the electric power.

2. Technical data

The technical data of the line ЛПШ-500 are the following:

Output by the end product, kg/h
500
Dispersion of the power, mm
up to 1
Maximum dimensions of the processed tyres, mm
1200 x 360
Installed power, not more , kW
320
Servicing staff, persons
6
Occupied working area, m2
400

The present equipment is intended for operation in the fire-dangerous zоne, class П-IIa as per ПУЭ-76.

The manufacture category is “B” as per “СНиП” II-90-81.

The climate version is УХЛ-4 as per ГОСТ 15150-59.

The equipment is designed in accordance with ДСТУ 2689-94 “Equipment for the polymeric materials processing” and “ОСТ 24.200.01-90 “The items of the polimer machine building“ and will be manufactured in accordance with ГОСТs, CCБТ (System of Standards in sphere of the environment protection and improvement of the nature resourses usage, the safety of labor, industrial engineering), that permits to carry out the international certification of the equipment, in particular, as per ISO 9001:2009.

The line equipments are accompanied with the service forms and records, including the instructions and technical manuals (The Request for proposal (RPF), The Certificate, The Service Instructions, The Program and Methods of the Tests, etc.,), which are enough for consultations with the supervision bodies to put the line into operation.

3. Fields of the final products use

The rubber crumb obtained as a result of the worn tyres processing have the numerous and perspective spheres for further practical usage under the effective organization of the marketing accompaniment shall, undoubtedly, provide the quick and stable its realization at the home and foreign markets, as well effective involving the compatiable articles into the highly remunerative manufacture:

  • the powder rubber with the particle dimensions up to 0.6 mm is used as additions (up to 50-70 %) during the manufacture of the rubber foot wears and other rubber – technical articles .At the same, time the properties of such rubbers(a strength, an elasticity) do not differ practically from the usual rubber properties produced of the crude raw rubber:

  • the power rubber with the particles dimensions up to 1.0 mm may be used in the manufacture of the composite roofing (the roll roofing and the rubber roofing slate),the rail tyre plates, the bituminous-rubber cements, vulcanized and non- vulcanized roll hydro- proofing materials;

  • the powder rubber having the particles dimensions from 0.5 up to 1.0 mm is used as the addition to modify the oil asphalt in the asphalt–concrete mixes, which are used in the automobile roads building, and such additions improve the road deformation and friction properties. Such additions permit to increase a strength of the road way covering, as well their impact resistance, frost resistance and resistance to the roadway cracking owing to the temperature differences. The volume of the minced rubber in such improved roadway coverings should be about 20% of the mineral materials mass, that is 60…70 tons per 1 km of the roadway;

  • the rubber crumbs with the parties dimensions from 1.0 up to 2.0 mm are used for the rubber regenerate preparation as well in the building materials industry for the rubber-bitumen binders in the aerodrome mastic, the foil-isol, the bituminous proofings, asphalt-concrete mixes, the sorbents production, etc.;

  • the rubber crumbs with the particles dimensions from 2.0 up to 5.0 mm are used in the modern football fields with the artificial grassy coverings and the floor coverings for the sporting structures, the athletic maneges, the pavement coverings, the sound- absorbing screens (panels, braids).It is used for the massive rubber plates production to the tram and railway crossings, excelling by the low level of the noise and the modern design; for the sporting grounds with the comfortable and secure coverings; for the cattle-breeding housings for life-stock.