Flotation Separation of Mixed Rubber Granules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The limited physical utilization of used tire material in the form of granules or powder is hindered by the incompatibility of butyl, chloro, or bromobutyl rubber with natural rubber, leading to adverse performance in tire mixtures due to their molecular structure, making it difficult to homogenize and utilize the regenerated material effectively.
Innovation Solution
The method employs flotation to separate granulated or powdered rubbers based on different rubber types by exploiting differences in surface wettability, allowing for the efficient separation of natural rubber from butyl or halobutyl rubber, thereby reducing the adverse effects and enabling the reuse of valuable rubber materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If granulated used tire material containing butyl/halobutyl rubber is added to fresh tire mixtures, then the quantity of rubber aggregate is increased, but the homogeneity and performance of the tire mixture deteriorates due to incompatibility with natural rubber
Solution Approach 1:
The invention extracts and removes butyl/halobutyl rubber components from granulated used tire material through a multi-step processing method involving devulcanization, washing, and separation. This extraction eliminates the incompatible rubber types while retaining natural rubber, thereby increasing the quantity of usable rubber aggregate without compromising mixture homogeneity
Solution Approach 2:
The invention changes the physical and chemical parameters of the granulated rubber material through devulcanization (breaking sulfur bonds), washing (removing contaminants), and drying. These parameter changes transform the material from an incompatible state to a compatible state, enabling higher quantities to be added to fresh tire mixtures while maintaining homogeneity
2Productivity
If whole tires are comminuted and ground to produce granulated rubber, then the productivity of rubber aggregate production is increased, but the quality of the rubber product deteriorates due to inclusion of inner liner mixture
Solution Approach 1:
The invention extracts and removes the inner liner mixture (butyl/halobutyl rubber) from the granulated tire material through devulcanization and washing processes. This extraction enables the production of purer rubber granules while maintaining high productivity, as the entire tire can still be comminuted and ground initially
Solution Approach 2:
The invention changes the chemical parameters of the rubber granules by breaking down sulfur crosslinks through devulcanization and removing contaminants through washing. These parameter changes improve the manufacturing precision and purity of the final rubber aggregate product while preserving the high productivity of whole-tire comminution
3Strength
If granulated tire particles are vulcanized for the second time in new tire mixtures, then the strength of the new tire is improved, but the dynamic performance deteriorates due to differences in strength/extension characteristics at the interface
Solution Approach 1:
The invention extracts and removes butyl/halobutyl rubber components that cause interface problems during vulcanization. By eliminating these incompatible rubber types, the invention enables better interfacial bonding between granulated particles and the fresh tire mixture, thereby improving dynamic performance while maintaining strength
Solution Approach 2:
The invention changes the physical and chemical parameters of the granulated rubber through devulcanization and washing, making it more compatible with natural rubber. This compatibility improvement ensures more uniform strength and extension characteristics at the interface during vulcanization, enhancing both strength and dynamic performance of the new tire
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enables the separation of rubber types, reducing the butyl/halobutyl rubber content, conserving natural rubber resources, and allowing for the regeneration of high-value granulated rubber for further use in tire production, thus enhancing the environmental sustainability and resource efficiency of rubber recycling.
Implementation Method 1
The method employs flotation to separate granulated or powdered rubbers based on different rubber types by exploiting differences in surface wettability
Data Source
AI summary
A method for processing rubber granules or rubber powders containing different types of rubber. Vehicle tires containing natural rubber in the tread and butyl rubber in the inner liner are granulated or ground to prepare rubber granules or rubber powders, which are processed in a flotation cell under stirring and with the addition of air. The natural rubber fraction of the rubber granules has a higher tendency to adsorb air bubbles and to rise in the flotation cell, while the butyl rubber fraction remains at the bottom. The rubber granules are separated into two or more rubber fractions with an increased amount of a specific rubber type in each fraction.