For a very long time, the governments of many developed countries have been putting the environmental situation on the agenda. modern cities. Every year, hundreds of thousands of waste polymers are thrown into landfills, thereby polluting the environment. But many organic substances, in particular those that have become unusable car tires, can be reused. By purchasing new or used equipment for processing rubber tires, everyone has the opportunity to build not only a profitable, but also an extremely useful business. It is a mistake to believe that every processing enterprise is something large-scale and requires large investments. Not at all - having a clear plan, you can meet a minimum of funds, while organizing an effective, profitable stable income shop.
Our business assessment:
Starting investments – from 6,000,000 rubles.
Market saturation is low.
The difficulty of starting a business is 7/10.
Opening a mini plant for processing car tires in Russia is not very difficult; the main thing is to know which way to approach the implementation of the planned project. As in any other market segment, there are nuances here that are extremely important to pay attention to. And the initial task of anyone who has seriously decided to organize their own business is to draw up a business plan for processing car tires, which would reflect the important stages of launching a production enterprise.
We can distinguish 2 areas of business - processing raw materials into crumbs and into liquid fuel. Each of these options is good and profitable in its own way. The only difference here is the size of the starting investment and the technological process.
Why is recycling old tires profitable?
Tire recycling as a business has become so interesting to investors and entrepreneurs not even because of the usefulness of the idea itself, but because of the positive aspects that can be noted when talking about this direction.
Why is it profitable to recycle used tires?
- Available raw materials. Material for further processing will be supplied to the workshop either at a very low price or completely free of charge.
- Simplicity of technology. Despite the fact that obtaining fuel from tires, from the point of view of physical and chemical processes, is a rather complex process, modern equipment makes technological scheme extremely simple.
- Huge market. With established sales channels, finished processed products will be immediately shipped to customers.
- Environmental friendliness. It would seem that recycling old car tires should be a very dirty process, but no - in the end, only the final product and some associated components that are not hazardous to human health are obtained. The only harmful factor is the increased noise level.
- Opportunity to receive preferential business conditions. The state today encourages innovators in every possible way and provides businessmen with subsidies and loans with “pleasant” interest rates.
But recycling of used tires is characterized by more than just positive aspects– there are also negative ones. For example, it will be very difficult to find regular wholesale customers. Therefore, in order to avoid equipment downtime, you should launch an advertising campaign at the business planning stage and begin producing products immediately “for a ready buyer.”
The business idea for recycling used tires is very promising, and all the difficulties that arise when preparing to launch a workshop are completely solvable.
Recycling tires into crumbs: what is needed for this?
Having decided to choose this line of business, the entrepreneur must solve the primary problem - buy equipment for processing tires into crumbs. There are a lot of machines on the market that can perform the task - grind tires into powder and crumbs of various sizes.
This business development scenario is especially good due to its simple technology and huge market.
Production line for processing tires into crumb rubber
Each line operates using a specific technology:
- Removing the seat ring and metal from the tire.
- Cutting tires into strips of a certain width.
- Removing the second seat ring.
- Cutting the tape into blanks.
- Grinding of tapes to obtain crumbs or powder.
- Cleaning up the crumbs.
- Removing textile cord.
- Warehousing of the finished product.
There is another way to grind worn tires - cryogenic technology. It consists of freezing the raw material and further crushing it. And despite the extremely high efficiency of the method, it is not used in our country, since the equipment for carrying out the process is prohibitively expensive - about 30,000,000 rubles.
The equipment presented on the market differs from each other in many respects - configuration, power, degree of automation. But the “average” line for processing tires into crumb rubber consists of the following list of machines and devices:
- Seal ring cutter.
- Seat ring squeezer.
- Tire cutter into strips and blanks.
- Abrasion machine.
- Vibrating sieve.
- Seperators.
- Transporters.
It will be quite problematic to independently assemble such a line from separate machines; it is much more practical to buy a ready-made one. But here the priority for a novice entrepreneur will be the issue of cost, since the price of equipment for processing tires into crumbs is quite high. Even the simplest device with minimal power (up to 100 kg/h) will cost an entrepreneur no less than 1,500,000 rubles. And the cost of more productive (up to 1000 kg/h) lines is much higher - 3000000-10000000 rubles. The following brands of equipment are popular among entrepreneurs: ATR 500, RDK 500, EcoStep 500, Eldan lines.
To equip a “young” workshop, it is hardly worth buying an expensive, high-performance tire processing machine. To start a business, an average power (200-500 kg/h) will be quite sufficient - this way, the equipment will not be idle in the absence of raw materials or customers.
When organizing a tire recycling enterprise, many entrepreneurs are faced with the problem of finding premises. The fact is that the line, despite the absence of harmful emissions into the atmosphere, is very noisy. And therefore, the supervisory authorities have quite strict requirements for the location of the enterprise - away from residential areas.
Recycling tires into liquid fuel: what is needed for this?
The entire technology based on pyrolysis is carried out automatically, and the process is divided into the following stages:
- Sorting of raw materials received into the workshop.
- "Cutting" tires.
- The crushed raw materials decompose in the reactor under the influence of high temperatures.
After all the technological stages, the output is several semi-finished products - gas, steel cord, liquid fuel.
Each product obtained during the processing process finds its own application. The gas is reused during subsequent cycles, thereby saving on fuel. And steel cord and diesel are sent for storage with subsequent shipment to customers.
Processing by pyrolysis is carried out using special lines, the standard equipment of which is as follows:
- food storage containers,
- pyrolysis unit,
- conveyors,
- separators for cleaning steel cord.
Pyrolysis line for processing tires and rubber goods
And the most expensive equipment of all is the pyrolysis plant. This is what the entrepreneur pays for when he equips a workshop for converting tires into diesel fuel.
The price of a line for processing car tires to produce diesel oil, depending on productivity, may be different. On average, to purchase a high-quality line with a capacity of up to 5 tons per day and its commissioning, a minimum of 5,000,000 rubles will be required.
There are few ways to save on equipping a workshop - either get equipment from China or buy used machines.
A powerful pyrolysis plant for tire recycling can operate in continuous mode, showing the following output for final products:
- For fuel – 2 t/day.
- For steel cord – 0.5 t/day.
- For gas – 1 t/day.
Provided the line is fully loaded, the yield of liquid fuel will be 40% of the weight of the original rubber raw material.
Considering that the standard line is quite large in size, some difficulties may arise when choosing a suitable room.
Where to get raw materials?
Tire processing technology allows the use of raw materials of any degree of wear. But these tires still need to be obtained somewhere. And in the absence of well-established supply channels, a beginner in this business may encounter certain problems.
What are the possible options here?
- Buying tires from auto repair shops, services, and private owners.
- Collecting tires from landfills.
- Organization of collection points for waste tires from the population.
- Removal of used tires from the territory of enterprises.
It turns out that the processing of used rubber tires can be carried out both from free raw materials and from purchased ones. Moreover, there is much more free material - hundreds of kilograms of raw materials can be collected daily from the city landfill alone. But this is not enough for uninterrupted operation equipment, so buying tires for recycling also has a place. The raw materials are inexpensive - many companies, realizing that a certain type of enterprise is today interested in worn-out tires, began to ask for a certain amount for them, albeit purely symbolic. And accepting used tires for recycling for a small compensation from the private population will not only stock up on raw materials, but also attract the attention of city residents to the environmental situation.
Problems of marketing crumb rubber and liquid fuel
As in any other line of business, it is important to establish distribution channels as quickly as possible. And the priority, of course, is wholesale customers.
In fact, there are a lot of consumers of the resulting products. Crumb rubber is actively used in many industrial sectors - construction, automotive and even textiles. And the resulting fuel oil will be taken to production workshops, where recycled technical oil can be used as fuel.
And if you have already found reliable sales channels, know who benefits from selling the resulting products, and have established your own stable enterprise, share your experience of processing tires into crumbs with newcomers who plan to develop in the same direction.
How much can a business earn?
Practice has already shown that mechanical and pyrolysis processing of tires and rubber goods, when done correctly, brings a stable profit.
When calculating expected income, you need to estimate how much initial investment will be required. To organize a “medium” workshop in mandatory will have to provide:
- purchase of equipment and its commissioning,
- preparing the premises for production,
- preparation of the raw material base,
- hiring.
The monetary minimum that you need to focus on when opening a workshop is 6,000,000 rubles.
The price of a mini plant will pay off the faster the sooner reliable sales channels are found. To calculate profits, the following figures are taken: the wholesale price for crumbs is from 15,000 rubles/t, the wholesale price of processed diesel is from 6,000 rubles/t.
The idea of recycling tires into fuel is dictated by the realities of our time. The car park is growing every year. Accordingly, the amount of consumables for their maintenance increases, and as a result, used spare parts also increase, falling into the category of waste. According to statistics, the volume of used tires per year is about a million tons.
Storing old rubber requires large areas, so the issue of waste disposal is becoming increasingly important. The polymers from which tires are made do not decompose. The most obvious way to get rid of them is to burn them. Environmentalists are confident that this technology for processing rubber waste causes enormous harm to the environment. During the combustion of rubber, very toxic substances are released into the air: benzopyrene, dioxins, PCBs, furan.
Every used tire can find a second life. When burned, one ton of waste produces 700 kg of rubber and 720 kg of toxins and soot, unsuitable for anything. The polymers in old wheels remain virtually unchanged after several years of use. Therefore, simply burning tires is ineffective and not economically justified.
Recycling old tires is a fairly promising area to open. The process technology does not require investment in the purchase of raw materials. Used car tires are thrown away, since the system for processing such waste in Russia is not established.
Owners of tire workshops are forced to pay money in order to organize the removal of rubber waste to a landfill. Therefore, there will certainly be those willing to provide the owners of such an enterprise with raw materials, as well as buyers for the finished product.
Types of rubber waste disposal
Depending on the method of exposure, the following methods of tire disposal are distinguished:
- Physical.
- Chemical.
Obtaining crumb rubber
Physical involves mechanical grinding of raw materials to the state of crumbs. The resulting powder is used in the production of new tires. This method is quite popular. In addition to rubber, chemical fibers and small amounts of steel are obtained from old tires.
The processing process begins with cutting the raw materials into small pieces. Using a magnetic separator, the remaining metal cord is removed. The resulting mass is crushed to a crumb state.
Pyrolysis method
This technology is based on the decomposition of raw materials into components under the influence of temperatures without the participation of oxygen. The result of pyrolysis depends on the temperature at which waste disposal occurs. There is low and high temperature pyrolysis. The method has become widespread in Europe. Pyrolysis of tires is more environmentally friendly than burning and is economically interesting, as it allows you to obtain fuel from waste material.
As a result of pyrolysis recycling, the following products are obtained from old tires:
- Synthetic oil (the basis for the production of various petroleum products, including fuel).
- Carbon black. It is used as a dye for concrete, for the manufacture of conveyor belts, and for the manufacture of paving slabs.
- Metal cord (reused for the production of new tires or used for scrap).
- Thermolysis gas (used for tire recycling plants or mini-boilers to provide heat).
The most cost-effective method is tire retreading through vulcanization. This option is most relevant for large wheels. The product obtained by this method is several times cheaper than a new tire. It is most profitable to recycle passenger car tires using pyrolysis.
How the process of recycling and processing by pyrolysis is built
Chemical recycling of tires includes the following steps:
- Tires to be recycled are collected at a recycling point.
- Using a special machine, the tire is cut into pieces, separating the tread and beads.
- The prepared raw materials are loaded into a retort and heated to a temperature of 1000 - 1400°. The thermolysis gas released during waste processing is cooled and converted into pyrolysis oil.
- The retort is replaced with another one filled with the next batch of raw materials.
- The cord remaining after completion of the operation is screened out and sent for further processing.
- The same thing happens with the carbon formed during pyrolysis.
It should be noted that the gas released during the pyrolysis process is used to maintain combustion in the installation. Part of the waste enters the atmosphere, therefore, when constructing a processing plant, the location relative to the nearest residential and other facilities is taken into account.
Equipment for pyrolysis processing of tires
The production process using high-temperature conditions has many advantages:
- Pyrolysis technology is practically waste-free. The resulting products are reused in various industries.
- Pyrolysis is the least environmentally harmful method of waste disposal.
- Recycling tires in a special reactor does not require enormous energy consumption.
- The ability to use the resulting products to support the technological process itself.
The main component of pyrolysis technology is the installation itself. Its cost ranges from one to ten million rubles. The reactor is a unit with dimensions of 10X5X3.5 m. The pyrolysis installation is mounted in an open space, not indoors. Power consumption is 6 kW per hour, productivity is 5 tons per day. Of these, carbon-containing components make up 30%, fuel liquid – 40%, the rest – metal cord and gas.
For preparatory work, you will need special scissors, which also consume electricity, and several crucibles for replacing retorts. The entire process must be carried out continuously. The fuel obtained through the pyrolysis process will require special containers for storage and transportation. Usually tanks are used for this.
Possible difficulties when opening a pyrolysis production
Despite the economic attractiveness, the organization of pyrolysis production can be fraught with some pitfalls. It is important to take some considerations into account before investing in equipment and people.
Features of the technology for working with any waste require placing equipment away from residential areas. The distance to the nearest houses must be at least 300 meters. But this does not guarantee you the absence of a negative reaction from residents. The ideal place would be an abandoned workshop of some enterprise. But its arrangement will also require time and money.
Environmentalists are very wary of processing methods such as pyrolysis. It is absolutely certain that the owner of the installation will be required to purchase cleaning equipment. Its cost is sometimes comparable to investment in core processes.
An entrepreneur must be prepared for questions and demands from regulatory authorities, fire inspectors and other authorities. Pyrolysis falls under the concept of “waste recycling”. Such activities require a special license.
Taking into account the above points, we can say that it is not profitable to recycle only old car tires. Experts agree that ideal option there will be production of some other raw materials. An example of such a product would be glass or.
Video: Recycling tires into fuel
Worn tires are almost not subject to natural decomposition, which means that sooner or later they should be disposed of. Tires cannot simply be burned - such “disposal” of even one ton of products is fraught with “enrichment” of the atmosphere with centners of soot and toxic gases. In addition, this is simply a pointless waste of resources, because thanks to modern technologies waste tires can be profitably recycled, for example, into fuel. Let's consider a case of opening a company specializing in the processing of tires into fuel oil.
Tire recycling as a business unique look activities, since virtually no costs for raw materials are required. Moreover, in many cities, municipal authorities even pay for the recycling of tires. As for the resulting fuel oil, this is a product that is constantly in demand.
Fuel oil (pyrolysis oil): scope, consumers.
As a result of the tire recycling process, a dark oily liquid is released (30-40% of total mass raw materials). This is the so called pyrolysis oil, his Chemical properties similar to the characteristics of fuel oil and heating oil. It can be used in industrial furnaces, heat generators, boilers. In addition, the pyrolysis liquid is processed to produce higher quality fuel oil, diesel fuel or gasoline.
Potential Buyers
- boiler rooms;
- industrial enterprises;
- owners of private houses.
Equipment
To open this business you will need the following tire processing equipment (basic):
Almost all pyrolysis plants present on the domestic market are of Russian or “post-Soviet” origin. Their cost varies from one million to ten million rubles.
For example, a mini-plant for processing tires "Potram-Car Tires-Classic", which not only cuts and processes car tires into pyrolysis oil, but also turns it into diesel and gasoline distillates, will cost from 7,500,000 rubles. This plant is capable of processing 15-20 tons of raw materials per day.
From the same manufacturer you can also purchase a conventional installation for producing pyrolysis fuel SHAH (from 2,000,000 rubles), with a capacity of 5 tons of raw materials per day.
The cost of hydraulic shears NS-400, capable of cutting both passenger and truck tires, is 300,000 rubles.
A fuel storage tank with a capacity of 10,000 liters will cost 220,000 rubles.
Example of production organization
Let's consider an enterprise that processes tires into fuel (fuel oil) using a SHAH pyrolysis plant with a capacity of 5 tons. According to its technical characteristics, up to 400 kg of pyrolysis liquid should be obtained from one ton of raw materials.
To start a business you will need an investment of 4.6 million rubles:
- Purchase of a pyrolysis unit “SHAH” - 3,000 thousand rubles.
- Hydraulic scissors - 300 thousand rubles.
- A tank with a capacity of 10 thousand liters - 220 thousand rubles.
- Tools, consumables - 280 thousand rubles.
- Delivery, installation, commissioning - 300 thousand rubles.
- Other expenses (coordination, connection to electrical networks) - 500 thousand rubles.
With an operating mode of 30 shifts per month and 100% equipment utilization, the installation produces 60 tons of products.
The properties of the resulting pyrolysis oil correspond to heating oil. The average wholesale cost of this fuel is 9,500 rubles per ton ( price current as of 02/12/2013).
With this option, monthly revenue will be 570,000 rubles, the net profitability of the activity is 50%. The return on investment at 100% line load will be 16 months, and at 50% load 32 months.
It is difficult to imagine the modern world without cars. Their number is constantly growing, and at the same time the number of car tires that have become unusable is also increasing. Their disposal is problematic, since they are highly flammable and not subject to natural decomposition. Currently, only 20% of old tires are recycled. That's why this type activities are very relevant, especially for big cities, so this is a good and modern business idea.
Why recycle old tires? In addition to recycling environmentally dangerous products human life, this issue is relevant in the field of oil production. It is no secret that natural oil reserves are irreplaceable. And from 1 ton of tires, where the net weight of rubber is about 700 kg, you can produce 400 kg of finished raw materials. When processed, about 30-40% of the raw materials yield pyrolysis oil, used in boiler houses. By processing pyrolysis oil, we obtain high-quality fuel oil, diesel fuel, and gasoline.
A significant advantage of this business is that there are no expenses required to purchase raw materials. And in some cities, authorities also finance the recycling of car tires.
To organize this activity, it is necessary to find a suitable territory located at a sufficient distance from the residential sector (at least 300 m). On the territory it will be necessary to equip a warehouse for raw materials, a site for the preparation and processing of raw materials, and a warehouse for finished products.
Equipment will need to be purchased: a tire shredding unit (hydraulic shears), a reactor - pyrolysis unit, and tanks for the resulting products. The reactor is installed in an open area. It is possible to recycle about 5 tons of tires per day. During processing, gas is released on which the reactor operates. To work on it, two workers who have received special training will be required.
The cost of this installation varies depending on technical characteristics and varies from 1 to 10 million rubles. More expensive installations not only make it possible to obtain pyrolysis oil from recycled tires, but also process it further into diesel or gasoline distillate. The installations also differ in their processing capacity - 5-20 tons per day.
The average cost of opening this business is about 5 million rubles: purchase of a pyrolysis unit, hydraulic shears, 2 tanks per 10 thousand liters, other tools and materials, delivery and installation of equipment, and other associated costs.
When the equipment is fully loaded, the output is 60 tons of pyrolysis oil per month. The price on the wholesale market is 9.5 thousand rubles. per ton. With this volume, monthly revenue will be 570 thousand rubles. Business profitability – 50%. Provided the equipment is loaded to full capacity, the initial investment will pay off in 16 months.
When purchasing new car tires, drivers are often faced with the question: what to do with a “corroded” tire that is not suitable for further use. IN modern world Where the number of cars is steadily growing, tire recycling is acquiring enormous environmental and economic importance for all developed countries of the world, including Russia. The recycling problem is primarily due to the fact that used tires do not decompose and, as a result, are a source of long-term environmental pollution. Secondly, rubber is flammable and does not biodegrade. Thirdly, a huge number of rubber tires provide a convenient habitat for numerous rodents and insects, many of which are a source of dangerous infectious diseases. To avoid or prevent this, one option is to build a plant for recycling and processing tires into crumbs, from which new material can be made.
This article raises the question - what to do with used tires? To do this, it is necessary to compare tire recycling in Russia with other developed countries of the world, analyze the processing of tires into crumbs and fuel, and also analyze the possibilities of using new materials obtained from waste tires.
To solve these problems, you must first understand the following concepts:
Recycling implies the action of the verb “recycle”, use, application of something. Waste disposal.
Processing is a production process to which raw materials are subjected.
The rapid growth of the vehicle fleet observed in Russia over the past decade has become a natural reason for the aggravation of the problem of recycling used tires. If in most of the most developed countries of Europe and in the United States they have been familiar with this problem since the 70s of the last century, then in Russia it began to be fully felt only in the year 2000, when the level of motorization of the population reached quite noticeable volumes in the country. In Russia, the number of registered cars at the end of 2014 was 58.95 million units, which is 4.9% more than in 2013.
In developed countries, the recycling rate of used tires is close to 100%. According to the European Association for recycling tires in 2008, about 3.3 million tons of used car tires were generated in the EU countries. And only 6% of the total volume of waste was sent to landfill. In Japan in the same year, as a result of operation, 96 million pieces of worn tires were generated (1056 thousand tons). The processing level for the same period was 88.5%.
If we talk about the scale of such a phenomenon as tire waste in Russia, then, it is estimated that today the volume of discarded used tires is about 1 million 850 thousand tons per year. The estimated volume of mechanical recycling of tires in Russia does not exceed 2% of the total volume of annual tire waste, and the processing of tires into fuel using the pyrolysis method does not exceed 3%. Another 20% of worn tires are burned. The remaining volume goes to landfill. Moreover, by 2015, the volume of tire waste generated annually in Russia may reach more than 2 million tons per year.
One of the alternatives to burning car tires is the processing of used tires into crumbs or fuel ( pyrolysis). Moreover, tires contain a significant amount of “useful” components that can be reused.
The volume of the Russian crumb rubber market at the end of 2014 was 51.5 thousand tons, which is 28.4% more than in 2013. Thus, in 2014, crumb production increased by 15.8 thousand tons compared to 2013 (by 0.02%).
Pyrolysis plants
The processing of tires into fuel by pyrolysis, on the contrary, decreased in 2014 by 15 percent compared to 2013. This is associated with low profitability and low demand for fuel obtained by pyrolysis.
According to data for 2014, the largest volume of retail crumb production in Russia falls on: the Central Federal District - 12.8 thousand tons (64.06%); followed by the Volga Federal District - 3.2 thousand tons (17.24%); The Northwestern Federal District closes the top three - 1.9 thousand tons (10.16%).
In 2014, imports of crumb rubber increased sharply. At the end of 2014, 4.7 thousand tons of crumb rubber were imported into Russia, which is 27.2 times higher than the level previous year. The leader in supplies in 2014 in physical terms is Lithuania, accounting for 88.52% of imports. The volume of imports from Lithuania amounted to 4.16 thousand tons. Significantly smaller volumes of imports are occupied by China (5.87%, or 276.0 tons) and Greece (4.26%, or 200.4 tons). In 2014, imports of crumb rubber increased sharply. At the end of 2014, crumb rubber worth $1.66 million was imported into Russia, which is 11.1 times higher than the previous year.
In the Moscow region there are about 10 of the most famous enterprises producing crumb rubber. They have their own websites, warehouses and an established sales market, including their own facilities for the production of rubber tiles from crumbs. Prices for rubber tiles vary from 14 to 18 rubles per kg. Moreover, the price often depends on the fraction of crumb rubber. Packaging is carried out in bags, the size of which varies from 25 to 30 kg.
Recycling and recycling of used car tires is a necessary area of activity in the environmental component of our region. Since used car tires are stored at the places of their use (in motor transport, agricultural, industrial and other enterprises), and are also transported to landfills, landfills and other unauthorized disposal sites. The name of this type of waste has a detrimental effect on environment; Taking more than 100 years to decompose, discarded tires cause irreparable harm to the environment. When tires are burned, more than 250 kg of soot and more than 400 kg of toxic gases per ton are released into the atmosphere.
By processing car tires, we obtain crumb rubber, which is used in many industries and human activities. Main uses of crumb rubber - production of safety floor coverings. Crumb rubber is also used for the production of high-quality road surfaces (asphalt), for the construction of children's and sports grounds, and for the improvement of streets and courtyards.
Crumb rubber has wide and extensive applications in various fields. Many Russian enterprises experience the need for crumb rubber and its shortage.
The following products are produced from the resulting crumb rubber:
Reclaimed rubber (40%);
Production of new tires (as a filler up to 10-15%);
Crude rubber (30%);
Production of rubber parts for cars (up to 25%);
Foaming rubber (15%);
Production of rubber hoses (up to 40%);
Carpets for sports fields and football fields (90%);
Filled seamless rubber coatings (80%);
Shoe soles (up to 70%);
Lining for railway rails and railway fittings (70%);
Plumbing gaskets (25%);
Rubber roofing (up to 40%);
Asphalt additives (15-70 tons per 1 kilometer of pavement);
ERDM granules (100%);
Rubber paving stones (100%);
Tread tape for wheel restoration (up to 45%);
Gaskets and seals for doors and windows (up to 25%);
Mooring fenders (up to 70%);
Oil well plugging (70%), etc.
Recycling of used car tires
