Process-design for devulcanization of whole truck tire rubber
Vignesh Kumar Rajendran
Location
University of Twente
Link:
Abstract
Devulcanization, as the name says, is the reversion of the vulcanization process: this is the most ideal process for recycling of rubber. It is a cradle-to-cradle approach, as the devulcanized material has a high quality and a property profile close to the virgin material. In contrast to reclaimed rubber, which so far is the best recycled rubber product on the market, this material can be used in higher loadings in virgin rubber compounds; for reclaim, the quantity of recycled material is limited to a few percent in tire applications. The core of the devulcanization process is breakdown of the sulfur network while the polymer stays intact; thus, the devulcanized material resembles the original material in structure and properties. However, there are also limitations to this approach: the material has undergone degradation to a certain extent during its first service life, influencing the properties and performance of the material. This not necessarily is a negative influence; aging for instance is slower for the recycled material than for the virgin rubber. Besides, the starting material also determines the end product: e.g. contaminations of the granulate with non-rubber components will negatively influence the properties of the devulcanizate. Furthermore, as devulcanization is a chemical process requiring a certain temperature level and shearing forces, which are non selective concerning crosslink- and polymer breakdown, there will be a certain degree of polymer degradation as well in this process. The challenge is to shift this balance as far as possible to the side of crosslink scission, and this needs thorough fine-tuning of the devulcanization process. In the original definition, this project was focused on the design of a devulcanization process for passenger car tires, as Rumal, the industrial partner within this project, wants to extend their product portfolio to this type of recycled rubber in the highest possible quality. However, the first setup of the process and production line was done for truck tire granulate, the standard product from Rumal. This material is mainly based on natural rubber (NR), which is less critical in devulcanization than the synthetic rubbers contained in passenger car tires. Besides the type of feedstock, the main parameters in this context are type and concentration of devulcanization aid, process oil, time temperature profile, and shearing forces. The basis for the devulcanization process is a small-scale, batch-wise process, which was developed in an earlier project within the Elastomer Technology & Engineering group at the UT. This process has to be scaled up and transferred into a continuous extruder process, including the special design of the extruder and the process parameters.