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Sumitomo Rubber Introduces Rubberway

Ewan Scott
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Sumitomo Rubber Introduces Rubberway

Sustainability has always been more than a mere phrase for Sumitomo Rubber Industries (SRI) as it opts to use Rubberway

In an ongoing move towards more sustainable sourcing practices, the company has introduced the environmental and social risk assessment tool, Rubberway.

The global demand for natural rubber has necessitated a responsible approach to the procurement of its raw materials. With concerns such as deforestation stemming from farm expansion, as well as labour and human rights issues, SRI recognises the urgency of proactively addressing these challenges.

Taking a lead in sustainable natural rubber sourcing is Sumitomo Rubber Singapore Pte. Ltd. By introducing Rubberway, SRI hopes the technology will revolutionise the way it sources natural rubber – strengthening its commitment to sustainable practices by flagging risks for mitigation, at each level of the upstream supply chain. It also allows SRI to ensure it is procuring from areas compliant with GPSNR (Global Platform for Sustainable Natural Rubber) standards.

Rubberway works by leveraging statistical analysis from a wealth of data – gathered via questionnaires from each level of the supply chain, such as processing factories, intermediaries, smallholders and large plantations. The results are then used to evaluate the environmental and social implications associated with natural rubber production. The assessment covers – but is not limited to – deforestation, water resource management, forced labour and child labour in 10 natural rubber-producing countries.

Furthermore, the tool aligns with SRI’s long-term sustainability policy, ‘Driving Our Future Challenge 2050’, which seeks to enhance traceability and support smallholders during the purchase of raw materials, in accordance with the Sustainable Natural Rubber Policy.

This commitment is further exemplified by ongoing initiatives within SRI which emphasise collaboration amongst all stakeholders – including those within the supply chain – with a vision of fostering a sustainable natural rubber community.

Zeppelin Contracted to Expand ReOil Plant

Ewan Scott
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Zeppelin Contracted to Expand ReOil Plant

Zeppelin Systems and ReOil are to build a first-class tyre recycling plant in Poland

Zeppelin Systems has been a reliable plant engineering partner for the rubber and tyre industry for decades. On the path to a sustainable future for plant engineering, the company launched the Zeppelin Sustainable Tire Alliance in March 2023 to cooperate with international partners on shaping the future of tyre production and tyre recycling in a more environmentally friendly manner. One of the members of this technology alliance is the Polish company ReOil, which built Europe’s largest pyrolysis plant for the recycling of old tyres in 2015. Since then, ReOil has recycled around 20,000 tons of old tires annually. Zeppelin Systems was awarded the engineering contract for the construction of a second ReOil pyrolysis plant. Construction is scheduled to start in February 2024. After the completion of the gigantic plant, around 60,000 tons of old tyres are to be returned to the sustainable circular economy every year.

ReOil, said to be Europe’s largest pyrolysis plant operator, works in the field of raw material recycling. The company uses continuous pyrolysis to break down rubber from old tyres into gas, oil and recovered Carbon Black (rCB).

ReOil’s proposed new plant in Poland to be built by Zeppelin Systems

The recycled materials obtained are reused, for example, in the manufacture of textiles, new tyres, rubber components, plastics, steel or aviation fuel.

After commissioning in 2015 and initial test runs, ReOil has recycled around 70,000 tons of old tyres since 2020 to date. Since 2020, the plant has been operating in a process-stable and profitable manner.

With the construction of the new pyrolysis plant, the company has tripled its annual recycling capacity to around 60,000 tons per year. A first-class plant covering an area of around 27 acres, brought to life by technology and engineering solutions from Zeppelin Systems. 

Zeppelin Systems had previously supplied the basic engineering for the new plant in 2019, and the company has now been rewarded with the completion contract due to the high level of customer satisfaction.

As the main responsible engineering partner, Zeppelin Systems delivers turnkey solutions all from one source: from plant technology to process engineering and final plant planning. “A flagship project for Zeppelin Systems with a signalling effect. Only a few companies can implement such complex and extensive projects virtually anywhere in the world,” says Dr. Markus Vöge, CEO of Zeppelin Systems GmbH, adding; “The aim is to offer process solutions in the future that can be provided as part of license models. For example, theELT pyrolysis plant as a turnkey product from Zeppelin Systems.”

Guido Veit, Vice President Sales, Plastic and Rubber at Zeppelin Systems GmbH, adds; “ReOil’s engineering contract is the first project as part of the Zeppelin Sustainable Tire Alliance. This makes us proud and demonstrates the strength of the alliance. In addition, we will continue to work hard to bring additional processes to technological maturity and strengthen the network in terms of the circular economy.”

ReOil Managing Director Paweł Mikuśkiewicz is also delighted with the very successful partnership between Zeppelin Systems and ReOil; “We knew that this major project could only be planned and built with the help of an experienced and internationally active plant engineering partner. That is why we chose Zeppelin Systems, and we really appreciate our long-standing, trusting business relationship.”

 

Entyr Receives Australian Award

Ewan Scott
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Entyr Receives Australian Award

Environmental technology company, Entyr Limited, received the Innovation Award for its world-leading thermal conversion process for end-of-life tyres at the national Waste Innovation and Recycling Awards held in Melbourne on the 25th October

Over the past two years, Australian-based Entyr Ltd has been transitioning its internationally patented thermal conversion process from research and development to full commercialisation, creating high-quality tyre-derived products which are changing the future of the environment, waste tyre disposal, and road safety.

“As a pioneering Australian company, receiving this recognition from our industry peers means so very much.  To know that our commitment to solving the global waste tyre problem is acknowledged and that the industry backs a complete circular solution, strengthens our resolve to achieve full commercialisation and take our technology to the world,” said Entyr Ltd Co-founder, Mr Andrew Drennan accepting the award on behalf of the company.

Entyr Limited was awarded the Innovation Award for its low-emissions thermal baking conversion process for end-of-life tyres. The process avoids the burning of toxic waste and is controlled within an atmospherically sealed vessel with no chemical intervention.  Repurposing almost 100 per cent of an end-of-life tyre, the innovative processing transforms tyres into commercially valuable products of recovered carbon black, tyre derived fuel oil, steel and gas, replacing the need for virgin resources in manufacturing, primarily tested and used in asphalt mixes.

“I would like to thank all the sponsors of the awards, particularly Veolia, who sponsored this Innovation Award.  I would also like to thank the Inside Waste and Waste Management Review teams who consistently support the waste and recycling industry as we move towards complete circular solutions for waste,” said Drennan.

The TRAC Rubber Recycling Symposium 2023

Ewan Scott
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The TRAC Rubber Recycling Symposium 2023

After a break caused by the pandemic, the TRAC Rubber Recycling Symposium returned to its biennial cycle with a conference held in Nova Scotia this October

The Rubber Recycling Symposium was opened by the President and CEO of TRAC, Carol Hochu, who highlighted that everyone attending is on a journey to sustainability. The focus of this year’s event was then about sustainability as much as simply recycling.

The event was hosted by Divert NS (Nova Scotia). Stacy Breau, CEO of Divert NS, spoke about the success of the stewardship scheme in Nova Scotia, with a recovery rate of 88.5 per cent. Much of the recovered material is used as aggregate in road construction and engineering projects, with the balance going into tyre-derived fuel. Breau said that Divert NS aimed to transition from recycling to a refusal to waste materials.

Stewardship and Extended Producer Responsibility were a focus on the first day. The initial panel focused on the Canadian solutions, each province having a stewardship scheme tuned to its geographical needs – what works in Ontario is not the same as might be required in Saskatchewan or The Yukon. This was followed by presentations from three very different approaches to tyre management – Fredrick Ardefors spoke about the Swedish model, where SDAB has complete control of the market. Lina Goodman highlighted the challenges in Australia, where there is a voluntary stewardship scheme, and John Sheerin discussed the USA, where there is a free market.

The panel being introduced for the Global EPR discussion -l-r Lina Goodman, John Sheerin, Fredrick Ardefors and Carol Hochu

Of course, in these dynamic times, legislation had to be discussed; the two key topics here were the issues around replacing 6PPD, which has been proven to be harmful to the environment, and the European ban on crumb rubber infill – Speakers here were Jamie McNutt from the USTMA and Alex Van Gelgeren from the ETRMA.

There followed talks about sustainability in tyre manufacturing and market development opportunities for ELT – this latter topic being a perennial one that arises at every rubber recycling event – how do we increase demand for recycled rubber products?

The event closed with its now familiar CEO Panel, where CRM’s Barry Takalou, Emterra’s Emmie Leung and Pliteq’s Paul Downey gave their perspective on the markets, opportunities and challenges that the industry faces. They looked at how obstacles could be removed, and the industry could become part of the Circular Economy solution.

New Zealand Finally Gets Control of Tyres

Ewan Scott
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New Zealand Finally Gets Control of Tyres

New Zealand has struggled with the challenge of how to handle its used tyres for many years, now, it appears to be taking control of tyre management

In November 2021, Tyrewise, the New Zealand tyre stewardship operator get the green light, but two years later regulations are only just being put in place to control the import and sale of tyres in the country.

Regulations have now been approved that will change the way New Zealand manages the 6.5 million tyres that reach their end of life every year.  

Regulations under which tyres will be imported into and sold in New Zealand, and how these tyres are managed when they reach end of life is the final step that should enable the regulated product stewardship scheme, Tyrewise.

According to Mark Gilbert, Chair of Auto Stewardship New Zealand, the regulation will reduce the environmental, economic, and societal harm posed by end-of-life tyres that would otherwise be dumped, illegally stockpiled or landfilled.

Auto Stewardship New Zealand is the not-for-profit charitable trust which provides governance for the accredited product stewardship scheme, Tyrewise.

A key part of the regulation is replacing the existing ad hoc ‘environmental’ or disposal charges New Zealanders currently face when disposing of old tyres. The tyre stewardship fee will be charged on eligible tyres imported into the country, whether loose or attached to a vehicle.

“It is excellent news to have the regulation published,” says Gilbert. “It outlines how regulated product stewardship will work for the first time in New Zealand – enabling an entire industry to effectively manage their product from import to end-of-life.”

According to Gilbert, it has been well over 10 years since the Tyrewise project began and three years since the Declaration of Priority Product Notice 2020, which includes tyres. “The timeline will see the regulation come into effect from March next year.”

The regulation means that all participants in the tyre supply chain from the point of import to end-of-life must be registered with Tyrewise and will have to abide by a code of practice which will be audited by the scheme delivery manager. “This will reduce the chance of illegal stockpiling and tyre fires which impact negatively on our communities and turns a tyre from being wasted into an available resource.”

“This is what industry and the Ministry have been working towards since the beginning – a regulated scheme which provides a level playing field for stewarding end-of-life tyres,” Gilbert says.  “The replacement tyre stewardship fee, which has been set at $6.65 + GST for a standard passenger tyre, will be consistent across the country.”

The fee, specified in the regulation by tyre size and type, covers the cost of future stewardship of the tyre on which the fee is paid, says Gilbert.  “It shifts the cost burden of managing end-of-life tyres from disposal to the point of purchase, allowing Tyrewise to manage end-of-life tyres from collection to processing by providing free collection, ensuring tyres end up at registered processors where we can add value.”

According to Gilbert, old tyres are a valuable resource; “Only around 40 per cent of the tyres which reach their end-of-life in New Zealand are currently recycled or used in the creation of new products. Tyrewise will use part of the fee to further stimulate domestic markets to make innovative new products from tyres, creating jobs and keeping resources in use for as long as possible as part of a circular economy.”

This ability of Tyrewise to fund industry development from the collection fees is one of the key benefits of a Stewardship/ EPR scheme. New Zealand has a unique chance to show how well such a system can work as there is very limited grey importation possible – so Tyrewise should be able to have full oversight of the whole New Zealand market.

Tyrewise has set a target of 80 per cent of tyres processed by the fourth year of operation and over 90 per cent by the sixth year, Mark says.

Tyrewise will initially cover all air-filled and solid tyres for use on motorised vehicles for cars, trucks, buses, motorcycles, all-terrain vehicles, tractors, forklifts, aircraft and off-road vehicles.  Tyres for products like bicycles and non-motorised equipment such as prams, as well as coils for retreads will be brought into the scheme at a later date. Consultation with stakeholders on these scope two tyres is expected late 2024.

Tyre importers now have until 1 March 2024 to prepare for the first phase of the regulation to come into effect, with the second phase in effect from 1 September 2024.  For more information on the regulation visit www.tyrewise.co.nz.

Fornnax Unveils its Biggest High-Capacity Secondary Shredder at IFAT 2023

Satnam Singh
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Fornnax Unveils its Biggest High-Capacity Secondary Shredder at IFAT 2023

Fornnax benefits from the introduction of EPR in India, as the scheme drives improvements in recycling

The introduction of Extended Producer Responsibility (EPR) and recycling gaining wider acceptability in India gives a much-required impetus to domestic machinery producers to invest in innovation, technology and high-capacity machinery. The Indian government’s proactive role in framing policies that push and promote recycling boosts the evolving sector.

India’s fastest-growing recycling machinery manufacturer, Fornnax Technology, organised the global launch of its high-capacity shredder R-4000 HD at a leading trade fair for water, sewage, solid waste and recycling IFAT India 2023, held between October 17th -19th, 2023, at Bombay Exhibition Centre, Mumbai.

“The new model is an upgraded variant of standard version R-4000. The upgraded variant offers 30 per cent more power, functions with higher RPM and high motor power,” explained Jignesh Kundariya, Managing Director, Fornnax Technology Pvt Ltd, during a post-launch interaction at IFAT.

Fornnax unveiled the world’s biggest secondary shredder, R-4000 HD, on the inaugural day of the event, weighing 40,000 kg with a height and length of 4,860 mm and 6330 mm, respectively. The line has tyre recycling applications, steel cleaning, electronic and electrical waste, etc, and functions on a single 430 HP/320 KW motor. The newly launched equipment has one of the biggest rotors available, weighing 12.5 metric tons.

The powerful shredder has features like an IoT condition monitoring system, which includes auto greasing, controlled temperature, and vibration control and is placed on a wide and stable base frame structure.

Critical components with international warranty

Fornnax was the only recycling machinery producer showcasing this type of machine at the IFAT show. “The objective is to target both global and domestic markets from the new model. The variant is fitted with critical parts sourced from the international market.”

The critical components like motor, gearbox and bearing housing are all sourced from international companies of proven reputation and offered with a two-year warranty to provide overseas service and replacement globally.

“It is a global model to cater to the international audience and the growing domestic market.”

According to the Ahmedabad-based company, in the domestic market, the model targets companies aspiring for higher production levels with reduced manpower and electricity costs.

Investment in R&D up by 300%

The new product is compatible with global standards, which results from investing in R&D. “We have increased the team size by almost 300% in the last couple of years. We recruited the best of talent to introduce innovative product lines to compete with the best of the market.”

Although the machine came out of the production line about six months back, it was immediately sold to Rathi Rubber, which has a site near Chennai.

The operational success of the line gave the go-ahead for regular production and the machine’s official launch. Interestingly, the displayed model is also sold and is going to Tinna Rubber’s upcoming site near Mumbai in Maharashtra for installation.

Orders flowing from domestic & international market

The Fornnax order book is full for the newly unveiled shredder. Currently, it has orders for six installations in the domestic market and one order overseas market from Serbia. “We will soon hire more people to meet the delivery schedule,” said Kundariya.

It has just sold a complete tyre recycling line to Tinna Rubber, comprising a primary shredder, secondary shredder and granulator with 10 tons per hour capacity.

Improving brand visibility leads to European companies seeking JV

With back-to-back participation at global shows, the Fornnax brand has started gaining ground in the domestic and international recycling industry. “Fornnax has been increasingly recognised as an Indian recycling machinery brand with a strong and widening product portfolio. The continuous branding leads to foreign companies approaching us for exploring JV possibilities, specifically from Europe.”  According to Kundariya . “It has already expanded its footprints in Kuwait, Oman, Australia, Singapore & European markets.”

The company has allocated a sizeable budget for participating in international exhibitions annually to build its brand globally. It will exhibit at 14 global shows this year.

Meanwhile, with orders flowing from domestic and international markets, Fornnax is now targeting INR 1 billion annual turnover and is considering going public, expecting to be listed in the next 3-4 years.

Silage Black Hole for Tyres Addressed in France

Ewan Scott
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Silage Black Hole for Tyres Addressed in France

Agricultural operations legitimately use tyres as silage clamps, but what happens when they are no longer needed?

Rightly, or wrongly, farmers have the capacity to dispose of waste where it cannot be seen. They have the equipment and the space to dig a hole, bury waste and cover it up. Most conscientious farmers will, of course, not do that, but what can they do with their old tyres?

France has a solution. One that addresses the issue of cost of disposal for the farmers. In 2019, Ensivalor was established with a view to dealing with this agricultural tyre problem.  It has been collecting around 15,000 tonnes of tyres per year, but this has come at a cost to the farmers.

Now, a Decree passed in March 2023 will see that change. This decree expanded the responsibility of the tyre producers, requiring them to recover agricultural tyres, from 1st Jan 2024, this will include tyres used for silage clamps. These will be taken back for recycling, free of charge.

The target for Ensivalor for the collection of silage tyres in 2024 has been set at 30,000 tonnes, increasing by 10,000 tonnes per year to an expected peak of 70,000 tonnes in 2028.

The collection will be coordinated by trade bodies and unions, with contracts made with Ensivalor to handle the collection and disposal.

Mexican Authorities Clampdown on Tyre Use in Brick Kilns

Ewan Scott
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Mexican Authorities Clampdown on Tyre Use in Brick Kilns

Brick kilns have become the focus of a clean-up ordered by the City of San Luis Potosi to reduce pollution in the area

The worst offending brick kilns have seen the tyres they use for fuel confiscated. The City Council hope to recover some 5 million tyres through its tyre collection programme.

Some 30 per cent of the arisings have already been removed from brick kilns and tyre operations across the city according to city mayor Enrique Galindo Ceballos, who also assured that they hope that by 2024, which will be one year after starting this programme, they will be able to reach the annual goal of 5 million tyres collected.

 “I think it’s going very well. We set an annual goal of five million tyres. The truth is that it is a very good alternative to remove this type of material from the environment.” He added that it is brick kilns that use this material the most, and this is where they have found the most tyres. However, the mayor clarified that, this year, a project has been defined to have dedicated locations for burning operations, where car tyres will be able to be used for fuel.

The tyres that have been collected will go through a conventional mechanical tyre recycling process to recover the steel and rubber. However Galindo Ceballos did not specify particularly what end uses the recovered rubber might be put towards.

Source: El Sol de San Luis

Cabot Corporation Gains ISCC PLUS Certification

Ewan Scott
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Cabot Corporation Gains ISCC PLUS Certification

Cabot Corporation is driving continuous improvement in the sustainability agenda with the ambition to expand certifications throughout its global network

Cabot Corporation recently announced it has achieved International Sustainability and Carbon Certification (ISCC) PLUS certification at six of its facilities. Cabot currently has more ISCC PLUS-certified sites than any carbon black manufacturer and has ambitions to expand certification throughout its global network. Sites currently certified include three reinforcing carbon facilities in Europe and the Americas as well as two masterbatch and compounding facilities in Europe and the Company’s Europe, Middle East and Africa regional headquarters. Achieving ISCC PLUS certification furthers Cabot’s commitment to advancing circularity and traceability, helping its customers achieve their sustainability goals by delivering sustainable solutions at a global scale.

Across the globe, companies have announced ambitious sustainability goals to support the transition to a more circular, net-zero economy. Products manufactured at Cabot’s ISCC PLUS-certified facilities adhere to ISCC PLUS requirements by leveraging circular value chains and certified feedstocks in the product manufacturing process.

Cabot recently launched its EVOLVE® Sustainable Solutions technology platform, which is designed to deliver products that offer sustainable content with reliable performance at an industrial scale. Cabot currently offers two ISCC PLUS certified products powered by EVOLVE® Sustainable Solutions, VULCAN® 7H-C circular reinforcing carbon and STERLING® SO-RC110 circular reinforcing carbon. These products are produced via a mass balance approach designed to trace the flow of materials through a complex value chain.

“As a leader in our industry, it is critical that we take actions as a company that progress our 2025 sustainability goals as well as ambition for a lower carbon future while ensuring our solutions also help our customers achieve their own sustainability objectives,” said Aatif Misbah, vice president and general manager, Sustainable Solutions. “The launch of our EVOLVE Sustainable Solutions technology platform is a testament to our commitment to collaborate with our suppliers to deliver innovative, sustainable solutions that incorporate decarbonization and circular economy strategies. Industry certifications, like ISCC PLUS, help solidify our commitments for our customers and offer the necessary chain of custody verification by third parties to ensure the integrity and performance of our global supply chain.”

Cabot’s EVOLVE Sustainable Solutions technology platform is currently focused on delivering sustainable reinforcing carbons that leverage circular value chains and materials recovered from end-of-life tyres, and/or renewable and bio-based materials, and/or processes that reduce GHG emissions. By obtaining ISCC PLUS certification at its masterbatch and compounding facilities, Cabot aims to help deliver the performance, quality and consistency that the plastics industry requires at scale for certified solutions.

Industry Tests Find No Free-Standing Nanotubes Released from Tyre Wear

Ewan Scott
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Industry Tests Find No Free-Standing Nanotubes Released from Tyre Wear

Tyre wear and brake dust particles now create more pollution in most cities than emissions. However, concerns have arisen about the issues those wear particles might create

UK-based Emissions Analytics state that their investigation shows that the microscopic particles from tyre wear can be airborne and most end up being deposited at the roadside, if not on the road.  Being airborne, there is potentially a risk to the environment, and to people.

At the Akron Rubber Development Laboratory (ARDL), a tyre with a tread enhanced with single wall carbon nanotubes was exposed to accelerated wear and handling simulation tests.

Analysis of captured airborne particles showed no free-standing nanotubes, and no aerosolised nanotubes were found in the air during simulation of the life cycle of tyres. This potentially unlocks the door to mass use of single wall carbon nanotubes that have tyre industry-acknowledged benefits: improved safety and durability, and reduced energy consumption and vehicle CO2 emissions.

Single-wall carbon nanotubes, also known as graphene nanotubes, offer unique benefits in comparison to standard tyre additives, such as silica and carbon black, leading to a growing number of projects for developing safer and more eco-friendly tyres. Possible release of nanoparticles into the air was of interest for the tyre industry, which is heavily focused on environmental aspects. OCSiAl, the world’s largest producer of single wall carbon nanotubes, took a lead in initiating wear simulation tests of a tyre enhanced with nanotubes.

The test was performed by ARDL at a Calspan facility in Cleveland, OH. “We have introduced TUBALL nanotubes produced by OCSiAl into tread to check the probability of nanoparticles exposure, as this tyre component experiences the main wear during the car’s motion. An independent laboratory captured any possible aerosol released and applied a specific quantification method relying on Raman spectroscopy for the detection of airborne particles. Only rubber particles with nanotubes embedded into the matrix were discovered. No free-standing TUBALL nanotubes were observed,” said Gunther Van Kerckhove, H&S Lead Manager at OCSiAl.

The performed test verifies the results shown by VITO, a leading independent European research and technology organisation, in 2017 during abrader tests on single-wall carbon nanotube-enhanced epoxy, polyethylene, and elastomer samples. Taber abrading tests revealed no free-standing or protruding nanotubes in those tests. The reason lies in single wall carbon nanotubes’ bonding strength and their unique morphology: ultra-flexible with a 3000:1 length-to-diameter ratio.

“Exposure monitoring studies with material samples are not sufficient for the tyre industry. We wanted to check the exposure of a real tyre with nanotubes during wear similar road conditions – to check the potential impact on human health and the environment. After confirming that no single wall carbon nanotubes are expelled during tyre usage, the next step will be to verify that there is no exposure during recycling of a tyre either,” said Jean-Nicolas Helt, Development and Support Leader for Elastomers at OCSiAl.

Single wall carbon nanotubes are currently the only market solution allowing the industry to achieve a long-awaited breakthrough in tyres: improved durability and safety on the road and reduced energy consumption, leading to cost savings and lower CO2 emissions to the environment.

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