The European industrial sector is currently experiencing a revolution driven by the European Green Deal and the Circular Economy Action Plan. With the increased pressure of resource scarcity, industries are moving away from the old linear business model of take, make and dispose and are adopting a new approach of closed loop production, where all products are recycled back into the manufacturing supply chain at the end of their life cycle. Within the waste management industry, the treatment of end of life tyres (ELTs) is of upmost importance as millions of tonnes of waste tyres would otherwise be sent to landfill or used as fuel in incinerators. However, the market is shifting rapidly to exploit the value of recovered raw materials within tyres. Within the tyre sector, the demand for European supply of recovered carbon black and pyrolysis oil is increasing as manufacturers seek to reduce their carbon footprint and address supply chain risks. There is therefore a great opportunity for localised waste processing, whereby waste is treated close to source, reducing greenhouse gas emissions through the avoidance of unnecessary transport, and adding value to the local economy.
The thermal waste treatment plant operated by this company is subject to European Union legislation and the more stringent rules laid down by the Flemish Region (waste tire to oil) relating to waste management in Belgium. The Flemish Regulation regarding Environmental Permits (VLAREM) dictates maximum levels for emissions into the atmosphere, discharge of waste water and noise levels. All projects require an Environmental Impact Assessment (EIA) and the application of the Best Available Techniques (BAT). The company had difficulty in finding a cost effective solution for a small scale tyre recycling plant of the scale of their business. However the strict environmental legislation in Belgium also has a number of benefits. High quality recycled products that have been certified to the correct environmental standards can gain early entry into the premium European market place.
A recent landmark project in waste tire to oil identified a market gap in the handling of heavy-duty truck and tractor tyres by a private waste management firm. Instead of exporting these large volumes of waste, the firm decided to invest in a small scale tyre recycling plant with a processing capacity designed to meet local needs. The facility is situated within an industrial park from which logistics companies can deliver scrap tyres. This example illustrates that cost effective recycling is feasible and profitable by applying a decentralised approach to waste recycling and processing. The project offers an attractive alternative to the often failing business model of large centralised tyre recycling plants.
Technical Fit: Why Batch Pyrolysis Systems Suit Small Enterprises
Technology choice for small operations is crucial to their long-term success. Batch pyrolysis plants have become the favourite choice for many European small companies and shops. There is considerable versatility with batch plants, which can process various amounts and types of waste rubber with minimal prep or shredding requirements prior to heating. As with continuous pyrolysis, the heating cycle is easily controlled to yield optimum rubber oil and carbon black yields. Most importantly, the reactors are in modules so that, unlike continuous plants and their expensive main processing line, the plant can easily be expanded with additional reactors as the local supply of feedstock increases. Thus, the initial capital investment is minimised while robust processing performance is maintained.
Using a small scale tyre recycling plant to achieve energy self-sufficiency. The pyrolysis process is used to process waste tyres into three main products: pyrolysis oil, steel wire and carbon black. Pyrolysis oil obtained as a result of tyre recycling process has high calorific value and can be used for heating the tyres in the plant or even for sale on market to other industries as a replacement for heavy fuel oil. The owner of the Belgian plant uses part of obtained oil for heating of pyrolysis reactors and thus achieves self-sufficiency in energy. He does not need natural gas or electricity for this anymore. This approach makes very good business sense as it saves operational costs and also takes the variable price of oil off the table. Achieving energy self-sufficiency from waste is a cornerstone of the Circular Economy.
The waste tire to oil project is profitable and environmentally sustainable. Economically, it has turned what was a cost of waste management for tyres into a positive revenue stream for the project by selling steel and carbon black to foundries and plastic manufacturers respectively. From an environmental perspective, many thousands of tonnes of tyres that would have been burnt in incinerators have been diverted from the landfill site and the carbon locked away in a solid form not emitting any carbon. The local community also benefit through reduced heavy goods vehicle traffic through moving the content of tyres from long distance haulage to local haulage. This case study illustrates how the right technical solution and understanding of the regulatory environment can allow small recycling projects to play a major role in the pursuit of a sustainable, carbon neutral future in Europe.
