The year 2020 has been a year like no other. The pandemic has brought everyone on the same platform. We all have been a mute witness to the rage of Nature and the apocalypse it can create. The question which persists in my mind is ‘Have we really learnt any lessons from the same?’ Are we going to treat Mother Earth better and build a sustainable planet for our future generation?

On a brighter note, most economies are showing signs of phenomenal recovery. The automobile sector looks to be one of the biggest beneficiaries. Vehicular traffic on the road and the number of new vehicle registrations are a big indicator of the same. In fact, an Indian two-wheeler manufacturer broke its own export record in December 2020. Our belief has proved true again. The human race has endured many such pandemics throughout the years of evolution and evolved better, stronger, smarter.

Processing ELTs

Indogreen Enviro has been involved in the process of ELTs (End of life Tyres) for about a decade.

We have been witnessing the growth of the tyre recycling industry. From the 1970-2000, the majority of organised ELT recycling was about making ‘Devulcanised rubber reclaim sheets.’ These sheets are used in a wide range of applications like tyre re-treads, bicycle tyres, conveyor belts, rubber compounds to name a few.

From 2000 onwards the market started changing due to the introduction of radial tyres. The radial tyres had high tensile steel in them and now could not be grinded directly like the nylon tyres. They need new technology Shredders, Raspers, Granulators to make it ready for grinding. This decade saw many high technology shredding and granulation plants coming up across the country. This included India’s largest and fully automated 100 Mt/annum plant till date Vapi, Gujarat. These granulation plants created a new market for ELT granules-based playground tiles and mats. The CRMB(Crumb Rubber Modified Bitumen) also gained acceptance in large national road construction projects.

Batch type pyrolysis plants

From 2005 onwards, there was a new tyre recycling technology introduced to the Indian market - ‘Batch type pyrolysis plants.’ These plants were initially imported from China. Though profitable, they were extremely unstable, environmentally non-compliant and unsafe for operation. Due to their profitability ,By the year 2019,India had more than 1000 batch type-pyrolysis plants installed. The combined tyre requirement per day for these plants was about 10,000 Mt/day. That would mean a requirement of 10,00,000 passenger car tyres every day, to give a perspective. This monster had a huge appetite that could not be met with tyres from India. So these pyrolysis companies started looking for imported tyres with a perpetual supply possibility from round the globe.

There was only one challenge. The pyrolysis plants are not allowed to import tyres. The shredding companies were allowed to import with a license from DGFT. The batch type pyrolysis companies started buying container loads of tyres from the shredding companies. India started importing about 900,000 MT annually making it the largest importer of ELT in the world until July 2019.The Public Interest Litigation filed against the ‘Batch type pyrolysis plants’ put the brakes on these transactions. The government was forced to take cognisance of the humungous nature of the impending matter at hand.

This is the India story, but could be a similar story for any country from Asia where the Scrap Tyre disposal policy is not yet framed or implemented. I am taking the stance of the agitator than just being a mute spectator. There is so much that can be done than what is being done today.

Scrap tyre disposal policy

There is a strong buzz about ‘Circular Economy’ in Europe and the US. Large tyre companies and chemical giants are investing in various tyre technologies to bring the derivatives from the tyres to be reused in manufacturing new tyres. In India, we don’t even have a national scrap tyre disposal policy. Most local tyre companies are still waiting for an ‘EPR’ to start thinking of sustainable disposal. 

In fact, we as a country need ‘Circular economy.’ The responsibly recycled ELT can create high quality reclaim rubber, High calorific value oil with possibility on further hydro treatment to distil commercial grade diesel & petrol, commercial grade carbon black for manufacturing pigments, etc, liberated fibre to make thermoplastics, liberated gases that can be further processed, this can go on and on. There is so much of interest from large companies to set up plants to process this waste but they hesitate because of the lack of a government framework to support the huge capital investment required.

Despite all odds, some companies from India have done some amazing work in developing innovative ELT recycling technologies. A fine example would be Radhe Renewable Energy Development Ltd, Rajkot. They conceived, developed and now operate the ‘World Largest 100 MT Per Day Single Reactor Continuous Pyrolysis Plant ‘ for the last 8 years in Bhilwara, Rajasthan. No other company from around the globe can boast of this feat.In fact some of the large global giants who were looking for a commercial scale large continuous plant could not believe that such a plant and technology existed, that too from a non-descript town from India. This company now supplies ASTM grade Carbon Black and High Calorie fuel to Indian tyre industry beginning the ‘Circular Economy.’

Another interesting Company is Hotfut Sports, an award-winning sports infrastructure development and management company that has been one of the largest consumers of turf technology and synthetic turf products across its various formats. These products have a primary infill requirement of SBR rubber. HotFut has consciously been adapting its procurement process to ensure all SBR and infill / shock-pad requirements are sourced responsibly using recycled ELT’s / rubber scrap making all their facilities more environmentally friendly. They have structured solutions for forward thinking tyre companies wanting to pro-actively process their ELT with a win -win proposition. Many major tyre companies have found their solution very sustainable as well as profitable.

Last year, Internet was abuzz about this start up ‘Blink Green’ from Pune, India. They used ELT for making attractive ladies’ footwear and purses. They have found the utility of this wonderful waste and now is utilising her designing skill and the expertise of the cobble community to churn out beautiful, durable items for the domestic and global market.

These kinds of stories are emerging from all across the continent Imagine the power of scalability of these kind of products with the right kind of financial and marketing support.

I look forward to the day (soon) when we have the ‘Scrap tyre disposal policy’ is finally rolled out and the top tyre companies wait for the EPR policy is over. With a sizeable contribution coming out of their respective CSR budgets and ATMA’s able guidance, a national body to look at new & innovative sustainable disposal practices for ELT could be established. This would be a giant first step taken in the Asian subcontinent towards sustainable recycling of this incredible waste and thus setting a precedence for other countries to follow.

Orion Engineered Carbons, a specialty chemical company, started commercial sales in Italy from the first new reactor for carbon black production to be commissioned in the European Union in over 40 years. 

The new 25-kiloton line at the facility in Ravenna, in the northern region of Emilia-Romagna, produces both specialty and technical rubber carbon blacks, primarily for the European market, the company said in a release. 

Corning Painter, CEO, Orion, said, “The new line offers customers seeking long-term solutions a unique strategic opportunity to align with a dependable plant that has been operating for more than 60 years in Europe.” 

Additional investments at the plant include a new co-generation facility to convert waste heat into electricity, generating up to 120 MWh of electricity per year. Seventy percent of the electricity is supplied to the national grid, serving about 30,000 households. Orion is a net exporter of electricity in Europe and worldwide. (TT)  

Shin-Etsu Chemical, a leading chemical company, plans to invest $702 million in its silicone portfolio, a key component of its functional materials business segment.

This latest investment follows a plan announced in February 2022, worth $562 million, to meet the surging demand for advanced functional silicone products. However, due to the continuous growth in need, especially for eco-friendly options that align with the global goal of carbon neutrality, the company has decided to expand the applications of its silicone products. The company will also focus on enhancing the advanced functionality of its product lineup and further developing environmentally friendly silicones.

In alignment with its newly announced silicones investment plan, Shin-Etsu Chemical will make investments not only in its central production hub in Japan, the Gunma Complex in Gunma Prefecture, but also in its Naoetsu Plant in Niigata Prefecture, Takefu Plant in Fukui Prefecture, and the Group company plant in Thailand, where silicone monomer and polymer production is conducted. The company will also invest further in existing silicone plants across other Asian countries, the United States, and Hungary. Simultaneously, Shin-Etsu Chemical will accelerate efforts to achieve carbon neutrality by embracing greener manufacturing processes.

Klean Industries Inc has announced that its partner Pyrolysis Hellas SA has completed Phase II of the Detailed Feasibility Study to design and build a tyre pyrolysis plant in Greece. Greek Authorities gave permits to its final Phase, the company said in a release. The company, while terming it as a significant milestone for the PHS project, claimed that it was the first tyre pyrolysis and carbon upgrading project in Greece to receive full authorizations.

Klean Industries Inc has announced that its partner Pyrolysis Hellas SA has completed Phase II of the Detailed Feasibility Study to design and build a tyre pyrolysis plant in Greece. Greek Authorities gave permits to its final Phase, the company said in a release. The company, while terming it as a significant milestone for the PHS project, claimed that it was the first tyre pyrolysis and carbon upgrading project in Greece to receive full authorizations.

Klean Industries Inc has announced that its partner Pyrolysis Hellas SA has completed Phase II of the Detailed Feasibility Study to design and build a tyre pyrolysis plant in Greece. Greek Authorities gave permits to its final Phase, the company said in a release. The company, while terming it as a significant milestone for the PHS project, claimed that it was the first tyre pyrolysis and carbon upgrading project in Greece to receive full authorizations.Klean Industries Inc has announced that its partner Pyrolysis Hellas SA has completed Phase II of the Detailed Feasibility Study to design and build a tyre pyrolysis plant in Greece. Greek Authorities gave permits to its final Phase, the company said in a release. The company, while terming it as a significant milestone for the PHS project, claimed that it was the first tyre pyrolysis and carbon upgrading project in Greece to receive full authorizations.

Each year, over 1.5 billion tyres are sold worldwide, representing more than 26 million metric tonnes, and just as many tyres each year also fall into the category of end-of-life tyres providing a large and partially untapped potential for resource and material recovery. Today, most traditional ELT treatment processes are not circular and do not result in any production of raw materials that are suitable to be reused in the tyre manufacturing industry. Without such ELT solutions in the EU, more than half of the EU end-of-life tyres and secondhand tyres are landfilled or are exported as tyre derived fuels for use into furnaces as an industrial fuel. The PHS project intends to reverse these trends and create a vibrant addition to advancements being made in the tyre recycling sector, the release said.

The PHS project is co-owned by Karabas European Hellenic Recycling. Currently, KEHR collects and recycles all types of scrap vehicle tyres and recycles them through traditional methods by shredding tyres into rubber granules, rubber powder & shock-absorbent surfacing slabs.

PHS has partnered with Klean Industries to build a modern tyre recycling facility that encompasses a state-of-the-art scrap tyre pyrolysis plant to recycle 20,000 TPA of waste tyres into valuable chemical products.

PHS proposes to construct and operate the Waste Tyre Pyrolysis Plant in Moulkia, a seaside town near Skala, Greece. It is located at an existing industrial site that is owned by KEHR, the release added. (TT)

ResiCare, an adhesive manufacturing subsidiary of Michelin, has found commercial use in Allin's plywood manufacturing unit, R'PLY. Allin and Michelin have been in collaboration since 2018.

The company claims that R'Ply is the first responsible plywood made using certified Poplar wood and integrating a ResiCare resin that is kinder to human health as well as the environment. The R’Ply is a high-performance plywood which can be used for multiple applications, according to the company. The plywood can be used for boat-building or in the building trade and will be available at certain DIY stores soon.

Michelin had set up a mobile ResiCare production unit at its Olsztyn site in May 2021. The company hopes to replace more than 80 percent of the usual adhesive used in its tyre textile reinforcement with the new ResiCare adhesive, which is free from any substances of very high concern for health (SVHC), by 2025. The company further plans to set up mobile production units similar to the one in Europe and Asia in the coming months. (TT)