CONTROLLED FINE MILLING OF ELASTOMERS

BY ULTRA-HIGH
ULTRA HIGH PRESSURE (UHP) WATER
JET TECHNOLOGY
Competitive edge for traditional grinding chains

Backround

Material
M
i l recycling
li today
d faces
f
difficulties:
diffi l i
granulate purity after separation (textile, nylon metal, halobutyl contamination)
granulate chemical activity (limited usage as filler
filler))
Granulate size. (hard to achieve smaller than 1000)
High
Profile
Tread
Tyres

Safety
Surfaces

Granulates
Powders
TPEs

Molded
Products

Used
Tyres
Medium
M
di
Treads

SOURCING
AND SORTING
Carcasses for
Retread

POWDER &
GRANULATE
PRODUCTION

PRODUCTS
MANUFACTURING

Steel
ELT*) Scrap for
Shredding
Textile

*) ELT = End of Life Tyres

Special
Construction
Products

Mulch
Products

DISTRIBUTION
TRADING
MARKETING
SALES

What is JetMilled powder

Obtained from end of life truck tires through using ultra

hi h pressure water
high
Chemicallyy active,, with extreme high
g surface/mass ratio
Containing high concentration of isoprene
100% metal free

THE PRODUCT: A TYPICAL APPEARANCE

Conventional crumb

Metal particle contaminations,

yp
yp
plane,, chemically
y inactive surfaces
typically

UHP rubber powder

Pure material with large specific

surface

SEM photos by kind courtesy of the

Technical University of Budapest

THE PRODUCT: SUPERIOR MATERIAL PROPERTIES

Conventional crumb

UHP rubber powder

Result is a mixture off different

ff
rubber

Selective milling:
g separated
p
rubber

qualities and metal particles

stripping + intact steel cord
Metal separation requires extra equipment Guaranteed metal-free separation
andd energy. N
Non-magnetic particles
l remain
((one-step grinding
d andd separation))
in crumb
Mechanical ggrindingg usuallyy results surface
f No surface
f oxidation ((coking)
g)
oxidation (friction heat coking)
Typically plane particle surface
Large specific surface of product
particles
ti l

Why this product is novel?

Result of high chemical activity

High
g chemical activityy
With high isoprene content

Extreme product purity

(thread/side wall/halobutyl)

Unique morphology:
V fifine grain
Very
i size,
i
High surface/volume ratio

First time
abilityy for direct revulcanization,,
thus can be utilized
in manufacturing of new rubber
products, substituting
NR or synthetic
th ti
components

Why this product is novel?

100% metal free fine crumb (200-1000 microns)

According to the free roots on the nano structures caused by the ultra high pressure water, incomparable active
chemical bonding activity is obtained.
Component which can substitute Natural Rubber and Synthetic Rubber

Petrochemical
industry

Rubber industry

Tyre component
or retreading

Technical rubber
component

Special Rubber
component

Rubber Bitumen
component

Coating
component

Construction
rubber

Thermoplastic
Duroplastic
components

The technology achievements:

Won
W the
h bronze
b
medal
d l off the
h

European Environmental Press in 2008

(P ll
(Pollutech
h Lyon)
L )
The rubber bitumen developed based on our product is
patented,
d an ownedd bby MOL N
NyRt.
R (H
(Hungarian
i Oil andd
Gas company)
Pilot
Pil plant
l iin operation
i since
i 2011

UHP WATERJET TECHNOLOGY: A BRIEF REVIEW

Unique process for selective production of fine rubber powder from truck tires
One-step process at ambient temperature
Clean technology clean product
Closed-chain process, no harmful output
Beneficial
f
pproduct pproperties
p
No surface oxidation of particles
Chemicallyy active surface
f morphology
p gy with nanostructures
Extra large specific surface

UNMATCHED TIRE PROCESSING TECHNOLOGY

Resulting cost effective, highly selective separation

PLANT TECHNOLOGY

Water treatment unit and tire tread milling machine

PLANT TECHNOLOGY

Product drying and handling line

PERFECT EXTRACTION

Extracted truck tire treads:

Extreme
E
t
purity
it off material
t i l
separation

PROVEN MATERIAL SUPERIORITY

Outstanding revulcanization: properties remains within 5% of
the original even at 20% added UHP powder to the base mixture

Base elastomer:
General rubber mix of high NR-content
Built-in material:
300 UHP rubber powder of truck tire tread
Testing equipment: Ektron EKT-100H
EKT 100H

THE PRODUCT: NEW HORIZONS

Boundless application fields:
Clean,
Cl
amorphous
h
rubber
bb powder
d off hi
high
h specific
ifi surface
f

with active centers

Wide
Wid iindustrial
d t i l utilization
tili ti possibilities
ibiliti without
ith t activating
ti ti or

devulcanizing of the surface (no need for additional

mechanical chemical
mechanical,
chemical, or other treatment)
Ideal intelligent filling or row-material substituting, in

different systems.
systems Exceptional reactive compounding
properties
Base polymer
matrix

Reactive
R
ti
filler

NEW HORIZONS: WIDE-RANGE APPLICABILITY

Intelligent component for various polymer systems
proven by laboratory and industrial application tests
Rubber industry
industr

Reactive filling (dry regenerate) for various rubber-base systems

Homogenous vulcanized polymer matrix from most pre-vulcanizing mixtures

Plastics industry

Effective reactive compounding properties

Wide-range polymer compatibility for different TPEs even over 50% UHP rubber-powder load
Advantageous interfacial bonding properties with PP, LDPE/HDPE, PUR, PVC

Coatings and dye industry

Reservoirs and wire coatings

Dye and paint components
Insulators for construction industry

Rubber
R bb bi
bitumen

Active component for rubber asphalt road surface

Non-settling chemically stable rubber-bitumen produced by mechano-chemical dispergation with
improvedd wearing properties, weather
h resistance andd noise reduction
d

What is the cost of this product?

To produce 1kg JetMilled product requires 3,5 kwh

energy.
The cost of a plant that produce 1500 tons powder a

year cost 1,3M Euro

4 people can operate the plant in one shift.
The p
plant can fit in 600 sqm.
q
The compound price can range from0.9-1.1 euro/kg
Plant
Pl t size
i iis scalable
l bl to
t match
t h existing
i ti capacity.
it

Executiv summary

Technology
T h l
complementing
l
ti ttraditional
diti l grinding
i di capacities
iti
Premium
P i fifinished
i h d product,
d t fifine, clean,
l
active
ti crumbb
Investment
I
t
t andd production
d ti iis candidate
did t tto subsidy
b id ffrom

E i
Environement
t Protection
P t ti FFunds
d
Return
R t on iinvestment
t
t within
ithi 4 years