Also known as Activated Rubber Powder (ARP) or Micronized Rubber Powder (MRP). The rubber industry has been researching the devulcanization of rubber for many years. The main difficulty in recycling rubber has been de vulcanizing the rubber without compromising its desirable properties. The process of devulcanization involves treating rubber in granular form with heat and/or softening agents in order to restore its elastic qualities, in order to enable the rubber to be reused. Several experimental processes have achieved varying degrees of success in the laboratory, but have been less successful when scaled up to commercial production levels.
Whereas SARPCO has developed De-vulcanized rubber powder as different processes result in different levels of devulcanization: for example, the use of a very fine granulate and a process that produces surface devulcanization will yield a product with some of the desired qualities of non recycled rubber.
The rubber recycling process begins with the collection and shredding of discarded tires. This reduces the rubber to a granular material, and all the steel and reinforcing fibers are removed. After a secondary grinding, the resulting rubber powder is ready for product remanufacture. However, the manufacturing applications that can utilize this inert material are restricted to those which do not require its vulcanization.
In the rubber recycling process, devulcanization begins with the delinking of the sulfur molecules from the rubber molecules, thereby facilitating the formation of new cross-linkages. SARPCO De-vulcanization rubber powder produce a new polymer with consistent properties that are close to those of natural and synthetic rubber, and at a significantly lower potential cost.
De-vulcanization is classified as fine, dry, powdered elastomeric activated rubber powder in which a significant proportion of particles are less than 100 µm and free of foreign particulates (metal, fiber, etc.). De-vulcanization particle size distributions typically range from 180 µm to 10 µm. Narrower distributions can be achieved depending on the classification technology.
De-vulcanization is typically most often made from end-of-life tire material
De-vulcanization is a free flowing, black rubber powder that disperses into a multitude of systems and applications. Due to its micron size, De-vulcanization can be incorporated into multiple polymers, and provides a smooth surface appearance on finished products. In some cases, in order to improve compatibility with host materials, the De-vulcanization is given a chemical treatment to activate, or “make functional” the surface of the powder particles.
De-vulcanization represents an evolution over previous post-manufactured rubber technologies. The most basic rubber processing technology converts end-of-life tire and post-industrial rubber material into rubber chips that are typically one inch or larger in size. These chips are then used in tire-derived fuel and civil engineering projects. A advance generation processing technology converts end-of-life tire and rubber material into crumb rubber, typically comprises chips between one inch and 30 mesh in size, with the associated fiber and steel mostly removed. This material is used in asphalt, as garden mulch and in playgrounds.
De-vulcanization is a micron-size material that is produced in various sizes, including 80 mesh and down to 300 mesh. De-vulcanization is virtually metal and fiber-free, enabling its use in a wide range of advanced products.
De-vulcanization is used as a compound extender to offset the use of natural rubber and synthetic polymers as well as act as a process aid in material production. In some cases, De-vulcanization can reduce formulation costs, because it replaces commodity-priced natural rubber. According to some estimates, De-vulcanization powder can offers up to 50 percent cost savings over virgin raw materials.
De-vulcanization also can improve the sustainability, and in some cases the performance, of the compounds in which it is used. For example, the smaller particle sizes of De-vulcanization are known to increase the impact strength of certain plastic compositions. However, in all applications the particle size and loading levels depend on the target application.Due to its size and composition, De-vulcanization can be incorporated into more advanced and higher-value applications than crumb rubber. Industries incorporating De-vulcanization into their products include tire, automotive, construction, industrial components and consumer products. It is also can be used as a additive in tires, plastics, asphalt, rubber sealants. De-vulcanization can also be incorporated into prime or recycled grade polypropylene (PP) high-density polyethylene (HDPE) and nylons.
Additionally, the incorporation of SARPCO de vulcanized powder in thermoplastic elastomers (TPE) and thermo plastic vulcanizates (TPV) makes it a feasible ingredient for automotive and building & construction applications. Currently, the SARPCO is leading producer of de vulcanized powder , which utilizes a high speed mill process and with this facility SARPCO would be able to produce annual more than 1500 tons of de vulcanized powder. De vulcanized powder produced by SARPCO has set high benchmarks for performance in a range of applications with customers and third-party research institutions, including several studies on increased asphalt performance. De Vulcanized rubber powder made by SARPCO company is well applicable in several areas.
It can be used for the production of rubber compounds, for the manufacture of thermoplastic elastomers mixtures and as an ingredient for the manufacture of asphalt surfaces of roads and motorways. From De Vulcanized rubber powder following products can be made rubber pipes, rubber hoses, conveyor belts, also in the production of rubber parts for the automotive industry.SARPCO De Vulcanized rubber powder can reduce significantly input material rubber quantity in the final rubber manufacturing and significant reduction of financial costs.
SARPCO De Vulcanized rubber powder can be used in a variety of ways. There is no limitation to its use if it is prudently incorporated with new rubber, or used on its own appropriately compounded in less demanding areas. It has already proven its worth and versatility in such products or areas as.
1. Auto mats, mechanical goods and flaps, and floor coverings
2. Inner tubes
3. Tyres and retreaded tyres
4. Hoses and beltings
5. Rubber surfacing material, especially asphalt rubber materials used for roads, airport runways, highways and roofing
6. Sealants, adhesives and tape insulating materials
7. Shoe soles and rubber footwear
8. Electrical plugs and battery boxes
: - The price of The De Vulcanized rubber powder is low relative to that of Natural Rubber
: - The mixing time required for De Vulcanized rubber powder is less than that for new rubber. This is due to the mechanical and chemical breakdown that it has gone through during the De Vulcanized process
: - The Power consumed in mixing De Vulcanized rubber powder is less than, that consumed in mixing of new rubber : - De Vulcanized rubber powder imparts faster processing during extrusion and calendaring than new rubber. The De Vulcanized rubber powder is smooth flowing during pressing or calendaring
: - Being a consumer of De Vulcanized rubber powder, you are contributing to a "Friendly Environment" as this is green field product