FI130597B

FI130597B - A mobile recycling apparatus and a method of recycling

Info

Publication number: FI130597B
Application number: FI20206318A
Authority: FI
Inventors: Hannu Aurinko
Original assignee: Laatuinsinoeoerit Oy
Priority date: 2020-12-17
Filing date: 2020-12-17
Publication date: 2023-12-04
Also published as: WO2022129687A1; FI20206318A1

Abstract

The present invention relates to a modular, mobile recycling apparatus for recycling tires, such as dumper tires. The mobile recycling apparatus comprises an induction shock module (101) and a cutting module (102), and it may further comprise one or more recycling processing modules (103) for further processing portions of the tire processed by the induction shock module and/or the cutting module. Modules are separate from each other, so that one or more of said modules are transportable by a vehicle (110) to a site and couplable at the site to each other to form the mobile recycling apparatus having a desired configuration.

Description

A mobile recycling apparatus and a method of recycling

Field

The present invention relates to a method and a system product related to recycling. More particularly, the invention relates to a modular, mobile recycling apparatus particularly suitable for recycling tires on a site.

Background

Industrial sides, especially mining sites use heavy vehicles for transferring heavy loads. For example, so called dumpers, which have very large and heavy rubber tires. Tires wear out during use, and they are replaced regularly.

Currently, there are no practical solutions for recycling dumper scale tires. A dumper tire or equivalent may have a diameter up to over three meters, and it is heavy, up to several hundreds of kilograms. A common practice is to cut and/or shred the worn-out tires to smaller pieces using a tire cutter or a tire shredder, so that the remaining material is more suitable for being transported by truck.

The tire cutter or tire shredder requires great power and consumes a lot of energy. Cutting and/or shredding the tires results to mixed tire waste comprising rubber, pieces of metal, typically steel, among others. Different types of rubber, even expensive special rubber, become mixed tire waste. Separating metal and rubber from the mixed tire waste is in practice impossible, at least from o 20 economical point of view.

QA

Dumper tires, unlike car tires, are not designed for high speeds. Therefore, they

N usually dont have liners or casing, which car tires typically have. Thus, sides of - the tires are typically pure rubber, except for bead wires at or near the inner : circumference. A dumper tire may be provided with a belt under the tread. 3 25 Description of the related art

N Patent EP3017927 A1 discloses a mobile tire processing unit comprising a grinder that grinds tire pieces or full tires and disunites components following the grinding. Various separation units are provided that enable separating pure rubber. Problem of this prior art is that although allegedly pure rubber can be retained, metal portion is not properly separated. Furthermore, purity of the obtained rubber may not be good enough for reuse in manufacturing of high- quality products.

Utility model DE8908875 U1 discloses a machine for processing scrap tires. The entire tire is rotated by motor drive and steel parts of the tire are heated using a high frequency coil until rubber melts near the steel. Mechanical knives and hooks are used to separate the rubber from the steel.

Summary

An object is to provide a method and apparatus so as to solve the problem of recycling tires, in particular large dumper tires, so that valuable raw materials can be economically separated for reuse. The objects of the present invention are achieved with a method according to the characterizing portion of claim 1. The objects of the present invention are further achieved with an apparatus according to the characterizing portion of claim 6.

The preferred embodiments of the invention are disclosed in the dependent claims.

N

& According to a first aspect, a method for recycling tires by a modular, mobile en 20 recycling apparatus is provided. The method comprises a) removing at least one = bead wire from a previously unprocessed, whole tire. This is performed by heating

E the at least one bead wire by induction shock, for breaking down bonding between

N the at least one bead wire and rubber, after said heating, cooling the tire, and o separating each one of the at least one bead wire from the whole tire, wherein

S 25 said separating is performed mechanically or magnetically. The method s comprises, b) after removal of the at least one bead wires, cutting off rubber side walls of the tire using by a water jet cutting device, a sand pressure cutting device or an air pressure cutting device for obtaining cut-off rubber side walls and an annular tire tread portion.

According to a second aspect, the method further comprises c) further recycling processing portions of the tire obtained from step a) or b). The further recycling processing comprises at least one of cutting the annular tire tread portion for producing a mat, and/or shredding and/or granulating and/or pin milling the cut- off rubber side walls for producing recyclable rubber granules or powder.

According to a third aspect, before performing steps a), b) and/or c), the method comprises transporting one or more modules configured to perform any one of said steps to a site by a vehicle, and coupling the modules at the site to each other to form the mobile recycling apparatus having a desired configuration.

According to a fourth aspect, the step of heating the at least one bead wire by induction shock comprises adjusting diameter of a plurality of induction coils arranged at regular angle intervals along a circumference to match with a diameter of the portion of the tire with the at least one bead wire, and heating the at least one bead wire by the induction coils while simultaneously rotating the tire and/or the induction coils about the tire's center by the angle interval between the induction coils for heating the entire circumference of the at least one bead wire. o 20 According to a fifth aspect, the step of heating the at least one bead wire by

S induction shock comprises applying at least one circular induction coil with a s diameter matching with a diameter of the portion of the tire with the at least one = bead wire by selecting at least one circular induction coil with a suitable diameter = and/or adjusting diameter of the at least one circular induction coil, and 2 25 simultaneously heating the entire circumference of the at least one bead wire by 3 the at least one circular induction coil.

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According to a sixth aspect, the step of cooling the tire is performed by water jet cooling, air jet cooling or liguid nitrogen cooling.

According to a first apparatus aspect, a modular, mobile recycling apparatus for recycling tires, such as dumper tires, is provided. The mobile recycling apparatus comprises a) an induction shock module and b) a cutting module. The induction shock module comprises an induction unit comprising a plurality of induction coils configured to heat at least one bead wire of a whole tire by induction shock for breaking down bonding between the at least one bead wire and rubber, a cooling unit configured to cool the tire after said heating, and a separation unit configured to separate the at least one bead wire from the whole tire. Said separating is performed mechanically or magnetically. The cutting module configured to cut off rubber sides of the tire by a water jet cutting device, a sand pressure cutting device or an air pressure cutting device after removal of the bead wire, to obtain cut-off rubber sides and an annular tire tread portion.

According to a second apparatus aspect, the mobile recycling apparatus further comprises at least one recycling processing module configured to further process portions of the tire obtained from processing the tire by the induction shock module and/or the cutting module. The at least one recycling processing module comprising at least one of a mat cutting unit and and a rubber processing unit.

The mat cutting unit is a mechanical cutting unit or a water jet cutting unit configured to cut a remaining annular tire tread portion for producing a mat. The o rubber processing unit is configured to shred and/or granulate and/or pin mill the

O cut-off rubber sides of the tire for producing recyclable rubber granules or

N powder.

N

= According to a third apparatus aspect, the induction shock module, the cutting © 25 module and the recycling processing modules are separate from each other, so & that one or more of said modules are transportable by a vehicle to a site and ä couplable at the site to each other to form the mobile recycling apparatus having a desired configuration.

According to a fourth apparatus aspect, the induction unit comprises a plurality of induction coils arranged at regular angle intervals along a circumference.

Diameter of the circumference of the induction coils is configured to be adjusted 5 to match with a diameter of a diameter of the portion of the tire with the at least one bead wire and wherein the induction unit comprises a rotation unit configured to rotate the tire and/or the induction coils about the tire's center over the angle interval of the induction coil during said heating the at least one bead wire for heating the entire circumference of the at least one bead wire.

According to a fifth apparatus aspect, the induction unit comprises at least one circular induction coil. Diameter of the at least one circular induction coil is selectable and/or is configured to be adjusted to match with a diameter of the portion of the tire with the at least one bead wire. The at least one circular induction coil is configured to simultaneously heat the entire circumference of the at least one bead wire.

According to a sixth apparatus aspect, the cooling unit is configured to cool the tire by water jet cooling, air jet cooling or liguid nitrogen cooling.

The present invention is based on the idea of providing a modular tire recycling apparatus that can be transported to a site for processing tires. The modular o 20 apparatus comprises a module for removing first the metal bead wire from the

N whole tire utilizing induction heating, before the tire is cut or shredded, so that

N rubber material of the sides of the tire and valuable metal of the bead wire can = be recycled separately. The rubber from the sides of the tire is cut off to obtain

E high-guality recycled rubber. For minimizing amount of toxic and/or harmful 2 25 compounds produced due to the induction heating, and for enhancing bead wire 3 separation, the tire is cooled quickly after the heating.

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N

The present invention has the advantage that valuable materials comprised in the waste tires can be processed on site into valuable, pure raw materials, in particular steel and rubber. The tire tread portions, which typically comprise also other materials than rubber, may be utilized for example as blasting mat.

Modularity makes the apparatus versatile, so that it may be adjusted to serve a variety of needs in a variety of conditions. New modules with different, specialized functionalities may be introduced for handling different types of recyclable materials.

In comparison to traditional methods, in which the tire is first crushed or shredded before separating rubber and steel, amount of energy required by the induction heating and subsequent removal of the bead wires requires less power and consumes less energy than crushing or shredding a tire with the bead wires due to huge power required to crush the steel of the bead wires. Also, need for maintenance of wearing parts of the apparatus is reduced.

Brief description of the drawings

In the following the invention will be described in greater detail, in connection — with preferred embodiments, with reference to the attached drawings, in which

Figure 1 illustrates a modular, mobile recycling apparatus.

Figure 2 illustrates a cross-section of a tire.

Figure 3 illustrates operation of an induction shock module.

N Detailed description

N 20 The figure 1 shows schematically a modular, mobile recycling apparatus

N according to the invention. The modules (101, 102, 103) are mutually r independent units, designed to be transported by a vehicle (110). Modularity jami

N enables the mobile recycling apparatus to be transported to a site by one or more & vehicles (110), to adapt transport to various road facilities and transport vehicle

N 25 — types. Modularity enables also configurability of the mobile recycling apparatus.

N

Any module may be replaced by another module according to needs of each specific site and material to be processed by the mobile recycling apparatus.

Modules are preferably designed so that they can be seamlessly combined as a recycling processing line with any wanted configuration.

Modules (101, 102, 103) may be combined to form a seamless processing apparatus configuration. Combining may be performed before transport or after transport. Modularity allows each module (101, 102, 103) to have a size that can be more easily handled during transport as well as during setting up the mobile recycling apparatus for operation.

The figure 2 illustrates a cross-section of a tire (200), in particular a dumper tire.

In comparison to car tires designed for higher speeds, dumper tires are designed primarily for durability and lower speeds, which enables a simple tire structure.

The tire (200) comprises a tread portion (202) between two side portions (201).

The tread portion (202) may comprise a belt (220) running over the entire circumference of the tread portion. In the side portions (201), inner circumference of the tire (200) comprises bead wires (210). Distinctive from car tires, dumper tires typically dont comprise a lining covering the inner surface of the tire. The entire tire (200) is typically made of rubber, except for the bead wires (210), which are made of metal, typically steel, and the belt (220), which may be made of various materials typically used in belts, such as steel, fiberglass and/or rayon.

Due to the great size of dumper tires, it is uneconomical to transport them into a

N recycling plant for recycling, and they tend to end up being piled as mere waste.

N The modular, mobile recycling apparatus enables separating valuable raw

N materials, in particular rubber and steel, from e.g. the dumper tires for recycling = on site. 2 25 The figure 3 illustrates operation of an induction shock module (101) of the mobile 3 recycling apparatus. The induction shock module (101) is configured for heating

N the bead wires inductively, for breaking down bonding between the bead wires and rubber. As known from the literature, by heating the bead wires, force and energy required to remove bead wires from a tire can be reduced significantly, by 80%, 90%, 95%, 98% and in some cases virtually 100%. Rubber residues on the removed bead wires can also be reduced to less than 5%, preferable less than 2%, and most preferably less than 1%. In some case the rubber residues maybe essentially 0%. Low rubber residue causes the disassembled bead wires to be valuable, pure raw material for recycling.

The tire (200) is inserted to the induction shock module (101) as whole. The induction shock module comprises an induction unit that has a one or more induction coils (301) for heating the bead wires by induction shock for breaking down bonding between bead wire and rubber.

The induction coils (301) are preferably arranged circumferentially at regular angle intervals (a). In the figure 3, there are four induction coils (301) but any number of induction coils can be applied. Diameter of the circumference on which the induction coils (301) are arranged is adjustable to enable placing the induction coils (301) on the inner circumference of the tire (200) on which the bead wires (210) are located, to maximize effectivity of the induction heating. The induction unit may comprise a rotation unit which rotates the tire (200) about its center over the angle interval (a) of the induction coils during said induction heating for heating the entire circumference of the bead wires (210). In the figure 3, the rotation unit is represented by rotation elements (300) arranged circumferentially o so that they contact surface of the tire (200) for rotating it. Alternatively, the

S rotation unit may rotate the induction coils about the center of the tire. Any type

N of rotating means is applicable which is suitable for rotating the tire (200) and/or = the induction coils (301) about the tire's geometrical center over the predefined z 25 angle. © 0 An alternative to a plurality of induction coils and rotating action, one or more

N circular induction coil may be used. The one or more circular induction coils are - configured to simultaneously heat the entire circumference of the at least one bead wire. Diameter of the circular induction coils is selected and/or is configured to be adjusted to match with a diameter of the portion of the inner circumference of the tire with the at least one bead wire. The at least one circular induction coil may be made exchangeable to facilitate changing the diameter of the circular induction coil according to each tire to be processed. Diameter of the circular coil(s) may also be adjustable, so that one circular induction coil or one set of circular induction coils may cover a range of diameters to be applicable for induction heating of bead wires with different diameters within the range. A single circular induction coil may be sufficient, or more than one circular induction coils may be applied to heat bead wires on both sides of the tire simultaneously.

The term matching diameter of the induction coil(s) and the bead wire refers to an arrangement in which a range of diameters on which the induction coil(s) effectively operate includes the diameter of the respective bead wires.

During the induction heating phase, various gases may be released, which may comprise harmful volatile organic compounds (VOC) and polycyclic aromatic hydrocarbon (PAH) compounds. The induction shock unit (101) preferably comprises ventilation and filtering means, which collect and handle any gases released during the induction heating so that they are not released in the environment. Ventilation gases may be handled for example by an active coal filter.

After the induction heating has been performed, the tire (200) is cooled down.

N Preferably, the cooling is performed actively to speed up the cooling process. For

N example, water jet cooling or air jet cooling may be applied. Water jet cooling

N can achieve wanted cooling more guickly than air jet cooling. For further = enhancing and speeding up the cooling process, liquid nitrogen may be used for

N 25 cooling the tire. The cooling reduces amount of volatile organic compounds (VOC) & and polycyclic aromatic hydrocarbon (PAH) compounds released to environment

O

S during the process. In addition, cooling to very cold temperatures may change characteristics of the rubber, for example by making it more brittle, so that the subseguent step of removing the bead wires can be performed both easier and more energy efficiently. This decreases energy consumption of the bead wire removal phase and reduces need for maintenance of wearing parts of the apparatus.

After the tire has been cooled, the bead wires are separated from the tire structure. The induction shock module preferably comprises a separation unit that separates the bead wires from the whole tire. Separation may be performed mechanically, for example by hook(s), gripper(s) or clamp(s), or separation may be performed magnetically. If magnetic separation is used, one or more electrical magnets are preferably used, so that magnetic force can be easily controlled.

After processing the tire in the induction shock module, the valuable bead wires have been removed, and are ready to be recycled. Due to induction heating, rubber residues on the bead wires are negligible.

After removal of the bead wires, the tire may further be processed in a cutting module (102). The cutting module (102) is configured to cut off rubber sides (201) of the tire, separating them from the tread portion (202). The cutting module may comprise a water jet cutting device, a sand pressure cutting device or an air pressure cutting device. After removing the rubber sides (201), an annular tire tread portion remains, which may comprise foreign material as the belt (220), in addition to rubber. o 20 When dumper type tires are processed, the sides (201) comprise, after removal

S of the bead wires, only rubber material. Thus, the cut-off sides (201) also

N comprise only rubber material, which may be used for recycling.

N

= The mobile recycling apparatus may further comprise at least one recycling

N processing module (103). The recycling processing module (103) processes 2 25 portions of the tire obtained from processing the tire by the induction shock

N module and/or the cutting module. For example, the recycling processing module - (103) may comprise a mat cutting unit, which cuts the remaining annular tire tread portion (220) for producing a mat. The mat cutting unit may be a mechanical cutting unit or a water jet cutting unit. Mats obtained from by cutting the annular tread portion (220) may be used for example as explosion mats.

The recycling processing module (103) may comprise a rubber processing unit, which shreds and/or granulates and/or pin mills the cut-off rubber sides of the tire for producing rubber granules or powder.

It is apparent to a person skilled in the art that as technology advanced, the basic idea of the invention can be implemented in various ways. The invention and its embodiments are therefore not restricted to the above examples, but they may vary within the scope of the claims.

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Claims

1. A method for recycling tires by a modular, mobile recycling apparatus, the method comprising a) removing at least one bead wire (210) from a previously unprocessed, whole tire by - heating the at least one bead wire (210) by induction shock, for breaking down bonding between the at least one bead wire and rubber; - after said heating, cooling the tire; and - separating each one of the at least one bead wire (210) from the whole tire, wherein said separating is performed mechanically or magnetically; and, b) after removal of the at least one bead wires (210), cutting off rubber side walls (201) of the tire using by a water jet cutting device, a sand pressure cutting device or an air pressure cutting device for obtaining cut-off rubber side walls (201) and an annular tire tread portion (202), characterized in that before performing steps a) and b), the method comprises: - transporting one or more modules (101, 102, 103) configured N to perform any one of said steps to a site by a vehicle (110); N and 3 - coupling the modules (101, 102, 103) at the site to each other N to form the mobile recycling apparatus having a desired E 25 configuration. ©

O 2. The method for recycling tires according to claim 1, the method further S comprising c) further recycling processing portions of the tire obtained from step a) or b), wherein the further recycling processing comprises at least one of: - cutting the annular tire tread portion (202) for producing a mat, and/or - shredding and/or granulating and/or pin milling the cut-off rubber side walls (201) for producing recyclable rubber granules or powder, and characterized in that before performing steps a), b) and/or €), the method comprises said steps of transporting and coupling.

3. The method according to any of claims 1 to 2, wherein the step of heating the at least one bead wire (210) by induction shock comprises: - adjusting diameter of a plurality of induction coils (301) arranged at regular angle intervals (a) along a circumference to match with a diameter of the portion of the tire with the at least one bead wire (210); and - heating the at least one bead wire (210) by the induction coils (301) while simultaneously rotating the tire and/or the induction coils (301) about the tire's center by the angle N interval (a) between the induction coils (301) for heating the 3 entire circumference of the at least one bead wire (210). = r 25 4. The method according to any of claims 1 to 2, wherein the step of E heating the at least one bead wire (210) by induction shock comprises: = - applying at least one circular induction coil with a diameter S matching with a diameter of the portion of the tire with the at & least one bead wire (210) by selecting at least one circular induction coil with a suitable diameter and/or adjusting diameter of the at least one circular induction coil; and

- simultaneously heating the entire circumference of the at least one bead wire (210) by the at least one circular induction coil.

5. The method according to any of claims 1 to 4, wherein the step of cooling the tire is performed by water jet cooling, air jet cooling or liquid nitrogen cooling.

6. A modular, mobile recycling apparatus for recycling tires, such as dumper tires, the mobile recycling apparatus comprising: a) an induction shock module (101) comprising - an induction unit comprising a plurality of induction coils (301) configured to heat at least one bead wire (210) of a whole tire by induction shock for breaking down bonding between the at least one bead wire (210) and rubber, - a cooling unit configured to cool the tire after said heating, and - a separation unit configured to separate the at least one bead wire (210) from the whole tire, wherein said separating is performed mechanically or magnetically; and b) a cutting module (102) configured to cut off rubber sides of the tire by a water jet cutting device, a sand pressure cutting device or an air pressure cutting device after removal of the bead wire (210), to N obtain cut-off rubber sides and an annular tire tread portion, N characterized in that the induction shock module (101) and the ? cutting module (102) are separate from each other, so that one or ° 25 more of said modules are transportable by a vehicle (110) to a site E and couplable at the site to each other to form the mobile recycling = apparatus having a desired configuration.

N 7. The modular, mobile recycling apparatus according to claim 6, further comprising at least one recycling processing module (103) configured to further process portions of the tire obtained from processing the tire by the induction shock module (101) and/or the cutting module (102), the at least one recycling processing module (103) comprising at least one of: - a mat cutting unit configured to cut a remaining annular tire tread portion for producing a mat, wherein the mat cutting unit isa mechanical cutting unit or a water jet cutting unit; and - a rubber processing unit configured to shred and/or granulate and/or pin mill the cut-off rubber sides of the tire for producing recyclable rubber granules or powder, characterized in that said recycling processing module (103) is separate from said induction shock module (101) and said cutting module (102), so that it is transportable by a vehicle (110) to the site and couplable at the site to other modules (101, 102, 103) to form the mobile recycling apparatus having the desired configuration.

8. The modular, mobile recycling apparatus according to any of claims 6 to 7, wherein the induction unit comprises a plurality of induction coils (301) arranged at regular angle intervals (a) along a circumference, N 20 wherein diameter of the circumference of the induction coils (301) is O configured to be adjusted to match with a diameter of the portion of the & tire with the at least one bead wire (210) and wherein the induction unit = comprises a rotation unit configured to rotate the tire and/or the I induction coils (301) about the tire's center over the angle interval (a) N 25 of the induction coils (301) during said heating the at least one bead o wire (210) for heating the entire circumference of the at least one bead S wire (210).

N

9. The modular, mobile recycling apparatus according to any of claims 6 to 7, wherein the induction unit comprises at least one circular induction coil, wherein diameter of the at least one circular induction coil is selectable and/or is configured to be adjusted to match with a diameter of the portion of the tire with the at least one bead wire (210), and wherein the at least one circular induction coil is configured to simultaneously heat the entire circumference of the at least one bead wire (210).

10. The modular, mobile recycling apparatus according to any of claims 6 to 9, wherein the cooling unit is configured to cool the tire by water jet cooling, air jet cooling or liquid nitrogen cooling. N N O N o <Q N I = 00 0 O O N O N