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Salvadori MT REX Demonstrates the Economic Benefit of Waste Tyre Recycling in the Mining Industry

Ewan Scott
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Salvadori MT REX Demonstrates the Economic Benefit of Waste Tyre Recycling in the Mining Industry

Our planet has over 6,000 operating surface mines working around the clock to provide the raw materials that fuel our globe’s economic development. These mines have been operating for an average of 23 years, and 20% have been working for greater than 40 years. To operate efficiently, these surface mines utilise a wide range of equipment, such as dumpers, loaders, and other wheeled vehicles.

Salvadori Introduces New Machinery for Mines

A sample of 1,300 of the mines revealed a staggering 38,000 mining trucks in operation. This massive fleet of trucks is equipped with extra-large tyres, up to a 63” rim, which weigh up to 6 tons, and have an outside diameter of 4.1 metres. A mining dumper is typically configured with 6 wheels to tackle the demanding operating conditions, and each of these tyres has an operating life of 5 to 10 months. Once these tyres can no longer be repaired or retreaded, they require disposal. Some quick maths yields an estimated annual consumption of one million mining truck tyres, which equates to 5 million tons of material to be managed. Extending this analysis to the wide-ranging fleet of mining vehicles results in a mind-numbing eco-liability for today and future generations.

In order to address the issue Salvadori has introduced MT-REX™, a new patent-pending OTR tyre downsizing system. The MT-REX delivers considerable benefits to mines and mine service companies. Consisting of a single integrated piece of equipment, the MT-REX is both compact and mobile as well as requiring only one operator. The machine also offers a particularly fast processing time, being capable of downsizing a 63” tyre in less than one hour and consumes up to 50% less energy than an excavator equipped with a shear.

Downsizing is the first step in recycling a waste tyre, whereby the tyre is cut into multiple sections that can be processed by a traditional shredding line. Salvadori MT-REX is the world’s first fully-integrated OTR tyre downsizing machine. Following downsizing, the shredding process takes place. In the shredding step, the waste tyres are separated into components: steel, textiles and granular rubber. The third and final step is converting granular rubber into coloured and moulded products with other Salvadori equipment. These three steps of downsizing, shredding, and conversion close the loop of the circular economy and enable the transformation of waste to value.

Salvadori MT-REX is the first fully automated system capable of managing tyres up to 63” rim diameter and provides a continuous flow of clean and standardised sized tyre chunks. MT-REX can be operated by a single operator by means of a forklift … no overhead crane is necessary. Whole OTR tyres are loaded in the front-end, and pre-determined sized tyre chunks roll down the MT-REX conveyor belt.

The MT-REX completes four downsizing jobs in a single piece of equipment:

Loading

A forklift places the end-of life OTR tyre in the cradle. This cradle can safely accommodate smaller tyres with a 1.8 metre outside diameter (OD) to a large tyre’s 4.1 metre OD. In other words, virtually any OTR tyre can be loaded.

The cradle’s opening and closing movement is performed by oil hydraulic cylinders. In order to safely load the tyre, proximity sensors help the forklift operator position the OTR tyre.

Positioning

This positioning unit makes 3 movements:

– The unit’s mandrel probes the inside of the tyre and pivots 90 degrees. This places the tyre on a horizontal plane.

– The unit moves horizontally to automatically position tyres with different diameters at different distances from the cutting unit.

– Finally, the unit raises the tyre to the pre-programmed height.

These three movements place the tyre in the most-efficient cutting location based on each tyre’s unique geometry.

Then during the cutting operation, after each cut is performed, the tyre is automatically rotated by a prescribed number of degrees to prepare for the next cut.

This unit is moved by oil hydraulic cylinders. Depending on the tyre size, the positioning unit is fitted with a mandrel designed to keep the tyre in place during the cutting operation.

Three mandrels are available for varying rim dimensions;

– Small ranges from 33-35-39″ rims

– Medium ranges from 45-49-51″ rims

– Large ranges from 57-63″ rims

If future tyres exceeding 63” rim are developed, MT-REX’s™ configuration can be expanded.

Cutting

The cutting unit performs tyre downsizing with a uniquely designed 1.5 metre length blade profile operated by high pressure double effect oil hydraulic cylinders.

The cutting depth and speed are customisable based upon tyre geometry, tread dimensions and other parameters. This enables operators to select the optimum size downsized tyre chunks while maximising cutting speed.

The cutting blades have been designed to be quickly and easily removed for maintenance and replacement.

Conveying

The downsized pieces are automatically removed by an electrically operated conveyor belt. This unit can be extended and connected to an external container or to the input feed of a traditional tyre shredding line.

The integrated conveyor keeps tyres from being contaminated by foreign objects such as rocks, which could adversely affect shredding equipment.

The MT-REX is pre-programmable by PLC and a touch screen HMI management system. The PLC allows the possibility of storing a sufficient number of programmes (recipes) for the processing of different types of tyres. In addition, the MT-REX can also be operated with a radio frequency remote.

Power to the MT-REX is supplied by 400V-50Hz-3 phases + neutral + grounding.

MT-REX is powered exclusively by electrical motors. Diesel fuel is only required if an electrical generator is used. The electrical power is an environmentally sustainable (no exhaust emissions), low-cost solution. Standard energy consumption is 40kWh, which translates to a few Euros per hour of electric energy to operate the MT-REX. Even if the electrical power is supplied by a diesel generator, the fuel consumption is less than 50% of an excavator equipped with a shear.

Safety is uncompromised with the MT-REX. Fixed guards surround the cutting area, with two side gates enabling maintenance operations. These maintenance gates have an electric safety lockout feature to prohibit access during operation. Additionally, optical safety barriers protect the loading site. The system is compliant to European Machinery Directive 2006/42/EC.

Optional internet-ready webcam connection is available to remotely diagnose the system and perform routine maintenance.

Despite its weight of nearly 42 tons and a footprint of 7 X 14 metres, MT-REX is modularly configured, making relocation to an alternative site easy in only two days (one day for disassembly and one day for re-assembly).

With a processing time of less than one hour for a 63” tyre, MT-REX continuously operated can downsize more than 7,000 tyres per year and consistently feeds more than 35,000 tons per year of clean and regularly cut pieces to a traditional shredding line. All of this can be completed with only one operator who is safely located behind the gates.

Comparing the MT-REX to alternatives makes economic and safety decisions easy. For example, an excavator with a shear will burn over 210,000 litres of fuel per year and require additional equipment to move the highly irregular downsized rubber to the following process. This operation must be staffed by multiple people per shift, all who are in close proximity to the downsizing process involving multi-ton tyres.

Spain Uses Low Temperature Rubber Modified Bitumen

Ewan Scott
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Spain Uses Low Temperature Rubber Modified Bitumen

During September, roadworks were carried out to improve the road safety on the A-92 passing through Puerto de la Mora in the Province of Granada between Kilometres 256 and 269. This stretch is a priority enclave for the Andalusian Community and one of the fundamental motorway transport routes, because it channels huge quantities of traffic.

How Crumb Rubber Has Made the Difference on Road A92

These quantities normally exceed more than 18,000 vehicles, of which more than 2,600 are trucks, connecting western Andalucia with the province of Almeria and the zone of Levante. Thus, the renovation of the road surface is expected to enhance road safety and the effectiveness of the winter road management plan in this area, as it is one of the most dangerous areas in the province, because it goes through a mountain pass with an altitude above 1,300 metres,

The works included putting down a new layer of tarmac, because the old road surface had deteriorated due to the increased levels of traffic, as well as extreme weather conditions.

During the winter, there are continuous snowfalls, while in summer the road is exposed to many hours of solar radiation and increased temperatures. To be able to face up to these challenges, a micro surface of 3 centimetres thickness was chosen, made by a mix similar to BBTM 11B with a discontinuous mineral skeleton, which provides roughness and good performance if it rains, manufactured with a modified bitumen from ground tyres, which makes it possible to increase the resistance to surface deterioration and reduce the impact of the thermal degradation. This thus increases the service life, comfort and safety of the tarmac.

Furthermore, they carried out improvements on several stretches in which a technology that makes it possible to reduce the manufacturing temperature of these mixtures by 30-35 degrees was used, contributing to a reduction in the emissions of pollutants and the consumption of fuels associated with the production of these materials.

These projects have been realised inside a research project entitled ‘Study of Binders and Modified Asphalt compounds with Ground Tyres in Severe Climates’, that aims to principally develop new high-performing, more sustainable bituminous materials.

The project is the offspring of a collaboration between the Department for Development and Housing for the Regional Government of Andalucia, the construction company Pérez Jiménez and the Construction Engineering Laboratory from the University of Granada.

It is one of the most important interventions carried out to date, in Europe, with manufactured mixes from ground tyres. It is the first time that they have used low-temperature rubber mixtures on the construction of 13 kilometres of motorway with increased volumes of traffic and severe climates, in which they have recycled approximately 160 tonnes of rubber crumb. This is equivalent to more than 32,000 tyres at the end of its useful life.

Segurvital – The Innovative Motorist Protection System from Recycled Tyre Rubber

Ewan Scott
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Segurvital – The Innovative Motorist Protection System from Recycled Tyre Rubber

Last October, an innovative protection system on the motorways of La Rioja, Spain, was installed that utilises recycled rubber crumb from end of use tyres.  It relates to a new design of motorway barrier that protects motorists and cyclists from serious injuries in the case of an accident. The motorway barrier, named Segurvital, has been developed by the Spanish Company Inoxmar Entreacerox S.L. This system connects directly to the conventional motorway barriers in order to avoid exposure to dangerous securing posts, and it is composed through a series of recycled rubber rollers that absorb the blow to the victim.

Segurvital Looking to Passenger Safety

Segurvital is accredited with the maximum safety parameters (UNE 135900-12:2008): by avoiding the situation where the victim is thrown from the road, reducing the seriousness of the accident by absorbing a large part of the impact, avoiding amputations and spinal damage.

This pioneering protection system for motorists has been installed along a 160-metre stretch of the motorway in La Rioja (LR-254) that is used frequently by bicycles and motorbikes and will be extended up to 1 kilometer. The development has been carried out over 4 months and has been financed by the European Union and the Riojan government. The latter, after assessment of its operation and a reception by the group of motorists will study the system at other points. Following the management of the DGT, it will carry out a dissemination of the results with the purpose of making it applicable to the rest of the road owners.

Tyre Baler Opens a New Chapter for Derby Recycler

Ewan Scott
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Tyre Baler Opens a New Chapter for Derby Recycler

Derby (UK) based tyre recycler, Metallon has recently overhauled its tyre recycling operation.

New Tyre Baler for Metallon

With the help of Cheltenham based, QCR Recycling Equipment, Metallon has purchased a QCR Tyre Baler to improve the process of handling waste car tyres.

A tyre baler is an essential piece of equipment for tyre recyclers nowadays and the QCR Tyre Baler is the recyclers’ choice, with over 40 machines being used in the UK.

The highest throughput on the market, a wider chamber, more depth and a superior 85 tonne compaction force makes it an easy choice for recyclers. QCR’s Tyre Baler maximises both efficiency on loading and transportation. One simple switch can alter the size of the bales and a double row of Hardox retention fingers ensure maximum bale weights and speedier loading. This impressive tyre baler can achieve a 15-20 per cent increase in bale weights over other competition, increasing payloads but reducing labour, loading and wire costs. Other unique features include hydraulic heavy duty door clamps and a 300lt oil reservoir for constant cooling.

Piles of loose tyres are a sight of the past in the yard. All tyres are baled and stacked to await transportation. Loose tyres are voluminous and therefore take up a lot of room. They are also a trip hazard and there is always the risk of falling tyres.

The QCR Tyre Baler’s high throughput rate allows for 4-6 bales of around 110 car tyres per bale to be made every hour. It therefore only takes a matter of hours for Metallon to have a 40ʼ trailer stacked with 30 tyre bales ready for transportation. Double stacking is authorised when tyres are compacted, maximising the space a 40ʼ trailer can carry. This results in the reduction of transport space by up to 60 per cent. The QCR Tyre Baler is also helping to reduce floor space by up to 80 per cent.

“We chose QCR after considering several equipment options and we are very pleased with the QCR Tyre Baler. It has a larger aperture than most tyre balers, which allows for a higher throughput. QCR’s engineers helped us maximise our productivity, loading and tying the bales. I would highly recommend both the QCR Tyre Baler and their high quality services.” Bill Legg, Managing Director of Metallon (Derby) Ltd.

AkzoNobel and Black Bear Team-up to Make Powder Coatings

Ewan Scott
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AkzoNobel and Black Bear Team-up to Make Powder Coatings

Tyres that have reached the end of the road are being harvested for recovered carbon black rCB and used to produce powder coatings in a new cooperation between AkzoNobel and Dutch company Black Bear.

rCB to be Used as Powder Coatings

The Cradle-to-Cradle certified rCB supplied by Black Bear – which is obtained from end-of-life tyres – is being used as pigment in the eco-premium products developed by AkzoNobel’s Powder Coatings business. With this cooperation AkzoNobel not only uses carbon black, traditionally obtained from fossil fuels, with a vastly lower CO2 footprint, but also helps to solve the global waste tyre problem.

“This partnership is a great example of how the supply chain can contribute to CO2 savings,” said André Veneman, AkzoNobel’s Director of Sustainability. “We encourage more suppliers to work with us and collectively contribute to develop more sustainable product solutions.”

Added CEO of Black Bear, Martijn Lopes Cardozo: “We are proud to have partnered with AkzoNobel, who are clearly recognised as the leader in sustainable paints and coatings.”

Powder coatings are an inherently sustainable product as they contain no volatile organic compounds (VOCs) and produce virtually no waste. The majority of products supplied through AkzoNobel’s market-leading Interpon brand also qualify as eco-premium.

“We are pleased to have partnered with an innovative company like Black Bear,” said Klaas Kruithof, AkzoNobel’s Chief Technology Officer for Paints and Coatings. “We selected their product based on technical performance and environmental footprint, in line with our own Planet Possible agenda of doing more with less.”

In addition to announcing the agreement, the two companies will also work together to find additional applications for Black Bear’s certified rCB.

Sustainable Materials Group Seminar – Broadening Horizons

Ewan Scott
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Sustainable Materials Group Seminar – Broadening Horizons

The second annual Artis Special Materials Group (SMG) event will take place in London on the 17th January at the Institute of Materials, Minerals, and Mining.

Important Seminar for ARTIS

This seminar brings together those who are keen to develop new markets for recycled tyre materials and puts experts in a range of fields from research, product development, and technology through to finance and marketing together for this unique opportunity in London.

The SMG will take the opportunity to share some of the activities that it has been undertaking to support rubber sustainability. They say that the group is pleased that the topic of recovered carbon black is already receiving additional attention. Now, they wish to use the SMG to ‘broaden horizons’ to see what else can be done, as a group, to develop and support other renewable materials in order to make industry more responsible.

Phenix Technologies Joins Special Materials Group

Ewan Scott
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Phenix Technologies Joins Special Materials Group

French company Phenix Technologies has joined the Special Materials Group (SMG) promoted by UK based research operation Artis, according to shareholder Jean Paul Bouysset.

Good Fit for Phenix Technologies

Phenix Technologies has been developing some new techniques to produce devulcanised rubbers and has had some considerable success with its technology. Phenix also operates a test and research laboratory in France and is keen to partner with like-minded operations to seek solutions to handling end-of-life tyre rubber in an efficient and environmentally friendly manner.

Liberty Tire Recycling Acts to Strengthen Balance Sheet

Ewan Scott
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Liberty Tire Recycling Acts to Strengthen Balance Sheet

Liberty Tire Recycling Holdco, LLC and its subsidiaries have entered into a privately negotiated agreement with holders of more than 96 per cent of the Company’s Second Lien Secured Notes and 80 per cent of the Company’s common equity designed to substantially deleverage the company’s balance sheet, reduce interest expense, and better position the company to capitalise on attractive organic and inorganic growth opportunities.

New Financial Changes Explained

In connection with this transaction, the company expects that Carlyle Strategic Partners, an investment fund managed by The Carlyle Group, will become the company’s majority equity sponsor and will partner with Liberty to provide additional strategic resources to support the company’s continued success. The Transaction contemplates:

  • A refinancing of the company’s existing Term Loan which will reduce interest expenses and extend the maturity date.
  • An exchange offer, launched yesterday, for all of the company’s Second Lien Senior Secured Notes, which the company expects will substantially reduce the principal amount and interest rate, and extend the maturity of its notes.

“We believe these transactions will provide Liberty with increased financial flexibility to execute on our strategic growth plans and position the company to continue to provide our customers with industry-leading service levels,” said Thomas Womble, chief executive officer. “We greatly appreciate the continued support of our valued customers, suppliers, and partners who are critical to our success now and in the future.  I also want to thank our extraordinary employees, who have been vital to our success in continuing to be the premier provider of tyre recycling services in North America. We look forward to enhancing our relationships and many more years of continued partnership and success with all our important stakeholders.”

Ron Carlson, chief financial officer, said: “We expect that these transactions will allow us to continue to make significant capital investments in our plants and equipment, capitalise on new market opportunities, negotiate better vendor terms, and significantly grow the business both organically and through acquisitions.”

These transactions are subject to a number of terms and conditions and are expected to be completed by the end of the year, however there can be no assurances they will be completed or completed on the terms described in this release.

Saskatchewan Tyre Issues Grow

Ewan Scott
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0
Saskatchewan Tyre Issues Grow

Since the Saskatchewan Environment Ministry intervened in Tyre Stewardship operations in the Canadian province, rural residents in the sparsely populated state have begun to see tyre dumps growing.

Situation in Saskatchewan Worsens Once Again

“Honestly, it is an eyesore,” said Leslie Clark, a councillor for the municipality of Parkdale, surrounding the hamlet of Glaslyn in northwest Saskatchewan.

The Black Gold Rush program offered by the Saskatchewan Scrap Tire Corporation gave landowners the opportunity to recycle tyres for free.

When the program came to a halt in June, 227 municipalities in Saskatchewan had benefited from it. The remaining 69, near Regina and in the northwest, are still waiting.

“This isn’t just happening in our RM. This is happening across the province,” Clark said.

Although most tyre retailers offer recycling for a small fee, Clark said it’s not easy for everyone to haul several dozen tyres.

She estimates that in the RM of Parkdale alone, more than 250 farmers are stuck with up to 50 tyres each on their property.

The Saskatchewan Association of Rural Municipalities addressed the issue during its mid-term convention in November.

The organisation agreed to press the government to reinstate the program with the Tire Stewardship of Saskatchewan — a not-for-profit organization established after the Black Gold Rush program was put on hold.

The government said there are still options for people with scrap tyres. The Tire Stewardship offers the Return to Retailer Program. Saskatchewan residents can return up to 10 tyres daily to certain tyre retailers across the province.

Additionally, the Tire Stewardship is developing a program to manage legacy stockpiles of tyres.

Namibia’s Ohorongo Cement to use TDF

Ewan Scott
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0
Namibia’s Ohorongo Cement to use TDF

Namibian cement company, Ohorongo Cement, is to consider using tyre-derived fuel (TDF) at its Sargberg plant in association with Metallurgical Research and Consulting CC (METRECO). TDF would be the fourth alternative fuel used at Sargberg, after the implementation of wood chips, charcoal fines, and refuse-derived fuels (RDF).

New Energy Potential for Ohorongo Cement

“The Sargberg plant is equipped to combust TDF with minimal risk to the environment, while utilising the energy reservoir contained in scrap tyres,” said Camillo Shalli of METRECO.

“With gas temperatures of up to 2000°C, the cement manufacturing process guarantees a complete combustion and destruction of all toxic substances, resulting in no harmful emissions and will not compromise the product quality,” added Hans-Wilhelm Schütte, Managing Director of Ohorongo Cement.

METRECO will be responsible for collecting and processing the scrap tyres to produce a TDF that can be used by Ohorongo Cement as a substitute for coal. The partnership aims to “halt the practice of stockpiling, landfilling, and uncontrolled tyre burning as a waste disposal method in Namibia,” continued Shalli.

In addition to the environmental benefits of using waste tyres as a fuel in cement manufacturing – rather than allowing them to be landfilled or illegally dumped – there are benefits in terms of job creation, as well as in reducing CO2 emissions from the cement manufacturing process. There is also an economic benefit in terms of reducing Namibia’s trade balance.

(source:World Cement)

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