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TIRE RECYCLING QUALITY OUT - STARTS WITH - QUALITY IN

TIRE RECYCLING QUALITY OUT - STARTS WITH - QUALITY IN. 2018 THETIRE Expo Michael Graveman. OUTLINE SYSTEM DESIGN, 1 - 2 - 3 - 4 STAGES? PORTABLE OR STATIONARY KNOWING YOUR MARKET PERIPHERAL COMPONENTS, WHAT AND WHY? MATERIAL HANDLING METAL SEPARATION AND RECOVERY FIBER SEPARATION

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TIRE RECYCLING QUALITY OUT - STARTS WITH - QUALITY IN

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  1. TIRE RECYCLING QUALITY OUT - STARTS WITH - QUALITY IN 2018 THETIRE Expo Michael Graveman

  2. OUTLINE • SYSTEM DESIGN, 1 - 2 - 3 - 4 STAGES? • PORTABLE OR STATIONARY • KNOWING YOUR MARKET • PERIPHERAL COMPONENTS, WHAT AND WHY? • MATERIAL HANDLING • METAL SEPARATION AND RECOVERY • FIBER SEPARATION • DE-STONING • PACKAGING • MAINTENANCE, NOT OPTIONAL • PREVENTATIVE • PRIMARY MACHINERY • PERIPHERAL COMPONENTS • HOUSEKEEPING • SAFETY

  3. MOBILE / PORTABLE?

  4. OR PERMANENT!

  5. DO YOUR CUSTOMERS NEED … TIRE CHIPS… …OR FINE POWDER

  6. PLAYGROUND AND SPORTS FIELD MATERIALS LANDSCAPE, AND PREMIUM TDF MATERIALS STAGE 3 PACKAGING STAGE 2 STAGE 4 TDF MATERIAL & CIVIL ENGINEERING STAGE 1 PAVING, MOLDED PRODUCTS, COMPOSITES

  7. SOMETHINGS JUST HAPPEN, QUALITY IS NOT ONE OF THEM! • PERIPHERAL COMPONENTS • CONVEYOR SYSTEMS • BELTS, SCREWS, OR AIR CONVEYORS? • MAGNETS • DRUMS, BELTS, PLATE, WHICH TYPE AND WHY? • SCREENERS • OSCILLATING, VIBRATING WHY AND WHERE • DENSITY SEPARATORS • WHAT ARE THEY AND WHY DO YOU NEED THEM? • FIBER SEPARATION • HOW MANY AND WHERE? • PACKAGING, WHAT FORM? • QUALITY IS THE RESULT OF HARD WORK AND ATTENTION TO DETAIL

  8. WHAT IS THE MAIN PROCESS TO PRODUCE QUALITY? COMMITMENT!

  9. PROCESSES REQUIRED TO MAKE A QUALITY PRODUCT METAL SEPARATION AIR SYSTEM TYPICAL BELT MAGNET MOST COSTLY CONVEYING METHOD PACKAGING FIBER SEPARATION & DE-STONING

  10. MATERIAL HANDLING SO, WHY DO YOU USE... • BELT CONVEYORS - TO MOVE LARGER MATERIAL OR MATERIAL WITH AN ELEVATED TEMPERATURE • SCREW CONVEYORS, ELEVATORS - TO MOVE SIZED MATERIAL WHERE YOU WANT TO CONTROL DUST, OR NEED TO CHANGE ELEVATION QUICKLY • PNEUMATIC SYSTEMS- TO MOVE MATERIAL WHERE THE AIR FLOW ASSISTS THE PROCESS MACHINERY FOR COOLING; AVOID USING AIR SYSTEMS ONCE THE CRUMB IS MADE VERY SMALL DUE TO PRODUCT LOSSES. NO PLACE TO SKIP MAINTENANCE; MORE PLANT DOWNTIME OCCURS DUE TO PERIPHERAL SYSTEM PROBLEMS THAN TO PRIMARY MACHINERY! -WHAT’S THE MESSAGE- TAKE AS MUCH CARE WITH AN INEXPENSIVE CONVEYOR AS YOU WOULD SHREDDER.

  11. SPECIFICALLY “WHAT MAINTENANCE IS REQUIRED?” FOR PRIMARY MACHINERY, FOLLOW MANUFACTURER’S GUIDELINES AT A MINIMUM • GREASE CONVEYOR BEARINGS • KEEP BELTS TRACKED PROPERLY • CHECK BELT SPLICES & REPAIR THEM SO A $300 REPAIR SAVES A $4,000 BELT • KEEP SAFETY GUARDS IN PLACE • KEEP THE DRIVE SYSTEM CLEAN AND FREE OF CONTAMINATION - IT IS THE SAME REASON OUR CARS ARE EQUIPPED WITH AIR FILTERS • CHECK SAFETY SYSTEMS REGULARLY, ESPECIALLY TEMPERATURE! • CHECK AIRLOCK WIPERS ON AIR SYSTEMS • KEEP DUCTING JOINTS TIGHT; REPAIR PIPE LEAKS MURPHY SAYS “ A $179 BEARING WILL STOP A MULTI MILLION DOLLAR PLANT AT THE MOST INOPPORTUNE TIME”

  12. A MAGNET IS A MAGNET IS A MAGNET! WRONG!!!! BELT MAGNETS • PERMANENT - APPLY THEM WHERE MATERIAL IS GENERALLY LARGER THAN 1/2” AND WHERE ABSOLUTE STEEL FREE IS NOT NECESSARY, PARTICULARLY EFFECTIVE FOR INITIAL SEPARATION PROCESS DRUM MAGNETS • CERAMIC OR RARE EARTH - APPLY THEM WHEN MATERIAL IS GENERALLY SMALLER THAN 1”. USE MULTIPLE RARE EARTH WHEN THE EXPENSE IS REQUIRED TO MAKE CONSUMER GRADE MATERIAL PLATE MAGNETS • USE AS LAST RESORT! - THEY ARE CHEAPER TO INSTALL BUT ARE ONLY AS RELIABLE AS THE OPERATOR CLEANING THEM. SO HOW STEEL FREE IS YOUR CRUMB RUBBER? 99% 99.9% 99.95%

  13. CRUMB RUBBER THAT IS 99% STEEL FREE FUEL QUALITY MATERIAL!! • HAS 20 POUNDS OF STEEL IN ONE TON, • 99.9% HAS 1 KG OF STEEL IN ONE TON, • AND 99.95% HAS .5 KG OF • STEEL IN ONE TON OF CRUMB. • THAT IS .5 KG OF WIRE!!! • FOR CONSUMER MARKETS YOU MUST • BE MUCH CLEANER THAN 99.99%! • AT “4 - 9’S” YOU STILL HAVE ALMOST • 100G OF STEEL IN 1 TON OF RUBBER!!!

  14. WHAT MAINTENANCE IS REQUIRED? WELL, MUCH LIKE THE MATERIAL HANDLING SYSTEMS, • KEEP MAGNETS & NEARBY SURFACES CLEAN OF WIRE • GREASE SHAFT BEARINGS • KEEP BELTS TRACKED ON BELT MAGNETS • CHECK BELT SPLICES ON BELT MAGNETS, EVEN VULCANIZED SPLICES • KEEP SAFETY GUARDS IN PLACE • KEEP THE DRIVE SYSTEM CLEAN AND FREE OF CONTAMINATION • CHECK SAFETY SYSTEMS REGULARLY

  15. TIRE WIRE – THE HIDDEN “ASSET” CONVERTING AN EXPENSE INTO REVENUE!

  16. STEEL CLEANING SYSTEMS – NO LONGER OPTIONAL

  17. A PLANT PROCESSING 1 MILLION TIRES SHOULD PRODUCE 1,600 TONS OF WIRE…AT TODAYS STEEL PRICES THIS REPRESENTS REVENUE OF MORE THAN $300,000 FROM WHAT WAS ONCE A $50,000 EXPENSE FOR DISPOSAL!

  18. FIBER, FIBER, AND MORE FIBER THE VILLAIN OF ALL TIRE PROCESSORS!!! SO WHY ALL THE FUSS OVER FIBER SEPARATION? IF YOU PROCESS RADIAL TRUCK TIRES THERE IS VERY LITTLE CONCERN WITH FIBER CONTENT. PHOTO ON THE LEFT BUT, IF YOU ADD PASSENGER TIRES TO THE MIX!!!!

  19. YOU WILL ASK; WHAT HAPPENED TO MY CRUMB RUBBER? FIBER REPRESENTS ONLY 5-7% BY WEIGHT BUT NEARLY 50% BY VOLUME AFTER GRANULATING

  20. CLEANING UP THE CRUMB RUBBER IS A CHALLENGE FIBER SEPARATION IS NOT ACHIEVED WITH A SINGLE MACHINE, • AIR SYSTEMS AND FILTERS • WIND SHEAR / ELUTRIATORS - LOOK SIMILAR TO CYCLONES • ORBITAL SCREENERS - FOR SPALLING ACTION • GRAVITY TABLE SEPARATORS A HIGH QUALITY SYSTEM WILL COLLECT FIBER AT A MINIMUM OF 8 LOCATIONS IN A 4 STAGE PLANT AFTER THE FIBER IS OUT, DON’T OVERLOOK THESTONES, LEAD PARTICLES, BRASS PARTICLES, AND OTHER CONTAMINANTS DENSITY SEPARTORS ARE REQUIRED TO PRODUCE CLEAN CRUMB FOR MOLDED PRODUCT AND PAVING APPLICATIONS IF YOU ARE NOT DE-STONING YOU ARE NOT MAKING CLEAN RUBBER POWDER!

  21. WHAT MAINTENANCE IS REQUIRED? • KEEP FANS SYSTEMS AND FILTERS CLEAN • KEEP SCREENS CLEAN AND FREE OF WIRE • REPEAT AFTER ME “GREASE BEARINGS” “GREASE BEARINGS” “GREASE BEARINGS” • KEEP SAFETY GUARDS IN PLACE • KEEP THE DRIVE SYSTEMS CLEAN AND FREE OF CONTAMINATION • CHECK SAFETY SYSTEMS REGULARLY, ESPECIALLY SPARK DETECTION SYSTEMS IN DUCTING • CHECK AIRLOCK WIPERS ON AIR SYSTEMS • KEEP DUCTING JOINTS TIGHT; REPAIR PIPE LEAKS

  22. THE PRODUCT IS CLEAN, NOW WHAT? WHAT PACKAGE FORM DOES YOUR CLIENT REQUIRE? TODAY’S MARKET REQUIRES FLEXIBILITY, WHETHER YOU PACKAGE IN 10KG PLASTIC BAGS OR 20 TON TRUCKS, KNOW WHAT THE CLIENT NEEDS! AN ASPHALT CONTRACTOR WILL NOT WANT 10KG BAGS AND A TIRE MANUFACTURER WILL NOT WANT 1 TON SUPER SACKS TAKE TEST SAMPLES REGULARLY, 2 OR 3 TIMES PER HOUR AND DOCUMENT THE RESULTS. BEYOND QUALITY ASSURANCES YOU CAN OBSERVE MACHINERY WEAR OR A SCREEN FAILURE.

  23. TO REPEAT - MAINTENANCE IS NO PLACE FOR COMPLACENCY WHY? WELL, YOU WANT TO... • OPERATE THE MACHINERY WITH LESS STRESS AND WITHIN MANUFACTURER’S GUIDELINES • ACHIEVE MAXIMUM PRODUCTION • PRODUCE HIGHER QUALITY MATERIALS • KEEP OPERATING COSTS REDUCED WHY NOT? • YOU PREFER CATASTROPHIC FAILURES TO ROUTINE MAINTENANCE • INDIFFERENT TO PRODUCT QUALITY, I ASSURE YOU, CUSTOMERS WILL VIEW THIS DIFFERENTLY • BOTTOM LINE IS OF NO CONCERN - HOPEFULLY WE DON’T HAVE ANYONE WITH THIS MINDSET HERE.

  24. SO WHETHER YOU ARE OPERATING 5 TON ROLLS... … OR 150 GRAM KNIVES IGNORE THESE AND YOU ARE CERTAIN TO FAIL!

  25. LAST BUT BY NO MEANS LEAST HOUSEKEEPING AND SAFETY THE TWO MOST NOTED TERMS FOLLOWING A PLANT ACCIDENT OR OPERATOR INJURY ARE… “LACK OF” AS IN, LACK OF HOUSKEEPING CONTRIBUTED TO A FIRE… OR LACK OF PLANT SAFETY CONTRIBUTED TO AN OPERATOR INJURY... THERE IS NOT A GREAT DEAL TO DWELL ON WITH REGARD TO HOUSEKEEPING AND PLANT SAFETY OTHER THAN TO BE CERTAIN IT TOPS YOUR AGENDA EVERY SINGLE DAY! EMERGENCY PLAN? PLANT INSPECTIONS? TO PACKAGE THIS, “WHERE DOES HIGH QUALITY CRUMB RUBBER COME FROM?”, A CLEAN, SAFE, AND WELL MAINTAINED TIRE RECYCLING FACILITY

  26. THANK YOU Mike Graveman Granutech Saturn Systems Grand Prairie, Texas 972 313 3003 mgraveman@granutech.com

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