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.

Ecolomondo Corporation, a leading Canadian innovator in sustainable scrap tyre recycling technology, has announced that its new milling line at Hawkesbury facility has achieved a major milestone during recent testing by reaching a throughput of approximately 2,700 lbs per hour of recovered carbon black (rCB). This result surpasses the company’s projected target of 2,200 lbs per hour.

When the new milling line is completely operational, it should be able to process 2,200 pounds of rCB per hour and provide a particle size distribution of 96 percent between 10 and 15 microns. It is anticipated that the plant would process more than 1.5 million scrap tyres annually, recovering 1,350 MT of process gas while producing 4,500 MT of recovered carbon black, 5,400 MT of oil and 2,250 MT of steel.

The company expects the commercial production of rCB to start by the end of May 2025. After being contacted, offtake clients told the company that they were eagerly expecting a larger supply of steel, oil and rCB, said the company. Depending on end-product market pricing, the company's yearly income from the sale of these sustainable goods plus tipping fees of USD 145 per metric tonne is expected to reach USD 12.1 million, with an estimated EBITDA of 45 to 50 percent, added the company statement.

Jean-François Labbé, Interim CEO, Ecolomondo Corporation, said, “This is a major achievement that brings the Hawkesbury facility closer to full production and commercialisation.”

Global speciality chemicals company Orion S.A. has launched a new bio-circular carbon black called ECOLAR 50 POWDER to provide coatings manufacturers with a new solution for more sustainable coatings.

ECOLAR 50 POWDER, which is entirely based on bio-circular feedstock, has coloristic qualities that are on par with those of ordinary speciality carbon blacks and includes 100 percent biogenic raw material according to 14C analysis. The coloristic qualities of ECOLAR 50 POWDER, a low to medium colour furnace black, offer moderate tinting strength and medium jetness in mass tone applications. ECOLAR 50 POWDER offers equivalent coloristic performance for full-tone and tinting applications, as well as comparable wetting and dispersion characteristics to conventionally manufactured low-colour furnace blacks.

ECOLAR 50 POWDER outperformed other common specialist carbon blacks in achieving medium jetness in a solvent-borne alkyd/melamine stoving enamel system. It created a similar neutral undertone as well. When tested in a water-borne 1K PU coating system, ECOLAR 50 POWDER created a more neutral undertone and jetness that was on par with other regular speciality carbon blacks.

Tilo Lindner, Vice President Global Marketing – Speciality Carbon Black, Orion, said, “We’re leading the way in advancing carbon black to meet increasing industry demands for sustainable products. ECOLAR 50 POWDER enables coatings formulators to develop truly sustainable products in all kinds of coatings applications.”

LD Carbon has inaugurated Korea’s first and largest waste tyre pyrolysis plant in Dangjin, South Korea.

Located in the Dangjin Hapdeok General Industrial Complex, the plant is expected to begin full-scale operation next month. The plant is spread over 29,800 square metres and features two factory buildings and five silos. The plant has an annual capacity to process 50 kilotonnes per annum (ktpa) of tyre chips derived from end-of-life tyres (ELTs).

At the location, LD Carbon uses a two-step pyrolysis process, first turning ELTs into solid char and pyrolysis oil. After that, the business uses a secondary pyrolysis process to further compress the char and create recovered carbon black (rCB). It is anticipated that the Dangjin facility would generate 20 ktpa of rCB and 24 ktpa of pyrolysis oil, which is a substantial increase above the combined output of 7 ktpa at its current pilot plant in Gimcheon. When compared to traditional carbon black, the rCB generated by the technique is said to lower carbon emissions by up to 32 ktpa.

The company is planning to build plants overseas and intends to join the Asian market soon. It has also struck a 10-year offtake deal with SK Incheon Petrochem for its pyrolysis oil.

Speciality chemicals company LANXESS India organised its first exclusive Solutions Day event in Mumbai today to showcase its diversified and sustainable product portfolio to customers and other key stakeholders.

The event was organised to promote the idea of ‘One LANXESS’, where its business units – namely Advanced Industrial Intermediates, Flavors & Fragrances, Inorganic Pigments, Liquid Purification Technologies, Lubricant Additives Business, Material Protection Products, Polymer Additives, Rhein Chemie and Saltigo – displayed their distinctive products and solutions at the event. It provided an opportunity to highlight the cross-business synergies that characterise LANXESS' integrated approach and to present the company's cutting-edge solutions designed for a variety of industrial applications.

Three main business sectors, namely Advanced Industrial Intermediates, Speciality Additives and Consumer Protection Products, are currently the emphasis of LANXESS's strategy shift from a polymers to speciality chemicals company. In order to improve the value provided to clients, the event sought to promote cooperation and creativity across these various business divisions. In order to promote knowledge exchange, discover possible areas for collaboration and capitalise on the capabilities of each business unit to propel overall development and success, the day included interactive workshops, technical presentations and networking opportunities.

Namitesh Roy Choudhury, Vice Chairman & Managing Director, LANXESS India, said “Our goal with Solutions Day is to strengthen our existing partnerships and explore future collaborations that support sustainable industry growth. Through this event, we want to highlight LANXESS’ integrated offerings to all our stakeholders and address the global industrial challenges through the combined power of sustainable chemistry, innovation and responsible business.”