An overview on waste rubber recycling by microwave devulcanization

This review deals with waste rubber recycling by devulcanization treatment using microwave method. In fact, vulcanized rubbers have been extensively used in various fields due to their superior performances. Subsequently, the massive use of such materials, especially in the automotive industry, has generated a substantial amount of wastes which are not easily to be degraded due to the three-dimensional network formed by the vulcanization process. One of the optimal solutions for the successful recycling of rubber is devulcanization, i.e., the process in which the sulfur bonds in the vulcanized material are selectively broken. Currently, to achieve rubber devulcanization, the microwave treatment has been proposed as a promising alternative process due to its precise manipulation of process variables. Furthermore, the microwave process is easily to be coupled with effects of other elements such as chemical and swelling agents. In this work, different microwave devulcanization methods are reviewed, the utilization of the corresponding devulcanized materials has also been discussed. The reviewed contents are believed to be of great interest to academics and industries since they represent a great challenge from scientific, economic and environmental points of view.

4R of rubber waste management: current and outlook

Excessive accumulation of rubber waste necessitates the need to revisit the effectiveness of the existing rubber waste management system. This review provides an overview of the legislative frameworks, techniques, challenges, and trends of rubber waste management in various countries. The 4R (reduce, reuse, recycle and recover) framework applied in waste management system in some countries appears to be viable for the processing of rubber waste. Certain countries especially some of the European Union (EU) members have implemented extended producer responsibility (EPR) system to manage the collection of rubber waste, particularly used tires. The processing of rubber waste in each level of the 4R hierarchy was then discussed, with detailed elaboration on the most practiced 'R', recycling which encompasses the direct recycling of products, as well as material recycling via physical and/or chemical means. The challenges faced in the implementation of rubber waste management system in different countries were highlighted and recommendations for a more sustainable rubber consumption were provided at the end of this review.

Organic chemical devulcanization of rubber vulcanizates in supercritical carbon dioxide and associated less eco-unfriendly approaches: A review

There is a growing need to recover raw materials from waste due to increasing environmental concerns and the widely adopted transition to circular economy. For waste tyres, it is necessary to continuously develop methods and processes that can devulcanize rubber vulcanizates into rubber products with qualities and properties that can closely match those of the virgin rubber. Currently, the most common, due to its efficiency and perceived eco-friendliness in recovering raw rubber from waste rubbers, such as tyres, is devulcanization in supercritical carbon dioxide (scCO₂) using commercial and typical devulcanizing agents. The scCO₂ has been generally accepted as an attractive alternative to the traditional liquid-based devulcanization media because of the resultant devulcanized rubber has relatively better quality than other processes. For instance, when scCO₂ is employed to recover rubber from waste tyres (e.g. truck tyres) and the recovered rubber is blended with virgin natural rubber (NR) in various compositions, the curing and mechanical properties of the blends closely match those of virgin NR. The atmospheric toxicity and cost of the commonly used devulcanization materials like chemical agents, oils and solvents have enabled a shift towards utilization of greener (mainly organic) and readily available devulcanization chemical components. This literature review paper discusses the approaches, which have less negative impact on the environment, in chemical devulcanization of rubber vulcanizates. A special focus has been on thermo-chemical devulcanization of waste tyres in scCO₂ using common organic devulcanizing agents.

Effects of Posttreatments on the Storage Stability of Reclaimed Rubber

Reclaimed rubber should be considered a source of new material with an economic impact, so the recycling of waste rubber is especially important. In this paper, sulfur-cured waste tire rubber powder is successfully devulcanized in a normal-pressure continuous regeneration system under the application of an activator and aromatic oil. Then, the reclaimed rubber was subjected to further mechanical shearing using a two-roll mill, rubber extruder, and rubber strainer. The effects of the storage time at room temperature on the properties and structure of reclaimed rubber were examined by sol fraction measurement, Mooney viscosity measurement, crosslink density measurement, tensile property testing, and Rubber Process Analyzer (RPA) measurement. The results under the test conditions indicated that different postprocessing operations were not making much difference to the properties of the reclaimed rubber. But the effect of storage time is more significant; the Mooney viscosity value increased from 65 to 90 when the storage period increases to 60 days, the sol fraction decreased, and the crosslink and density storage modulus also increased with increasing storage time due to the slow recombination and aggregation of the molecular fragments with free radicals happening in the reclaimed rubber during the storage.

Sustainable mobility: The route of tires through the circular economy model

Until nowadays, the concept of the 3Rs (Reduce, Reuse, Recycle) has tried to develop responsible consumption habits. Nonetheless, the rise of ecological thinking has generated the appearance of four new Rs in addition to these basic 3Rs; the currently 7Rs (Reduce, Reuse, Recycle, Redesign, Renew, Repair and Recover) which refer to the actions necessary to achieve the change towards a circular economy (CE) model. This model aims at extending the lifetime of the resources through their rational and efficient use to generate value repeatedly, reducing costs and waste. In this review, we examine the route followed by tires from the CE perspective, analyzing end-of-life strategies that aim to improve the circular flow of tire rubber materials. We discuss the most relevant studies on the "7Rs" concepts applied to tires, comparing different scientific approaches, as well as their industrial and commercial implementation. We also illustrate the drawbacks and feasibility of each of the R-hierarchy strategies. From the early stages of production to the post-consumption step, the path that tires trail within this CE model evidences the commitment and efforts towards the development of effective management schemes for achieving a real sustainable mobility.

Thermomechanical Devulcanisation of Ethylene Propylene Diene Monomer (EPDM) Rubber and Its Subsequent Reintegration into Virgin Rubber

Rubber waste remains a challenge for material science because its covalently cross-linked structure hinders the establishment of the circular economy of rubber. Devulcanisation may provide a solution, as it converts rubber vulcanisates back into their original, uncured state. Devulcanised rubber may be revulcanised or incorporated into virgin rubber, thus waste is utilized and the use of primary resources is reduced at the same time. In this paper, we treated sulphur-cured EPDM (ethylene propylene diene monomer) rubber on a two-roll mill at various temperatures and frictions. We determined the effectiveness of devulcanisation via Horikx’s analysis, which suggested that low devulcanisation temperatures would result in a 50% decrease in cross-link density with minimal polymer degradation. The devulcanisate was recycled via two methods: (a) revulcanisation with extra curing agents, and (b) mixing it with various amounts of the original rubber mixture, preparing rubber samples with 25, 50, 75, and 100 wt% recycled content. Tensile tests revealed that the samples’ elastic properties were severely compromised at 75 and 100 wt% devulcanisate contents. However, tensile strength decreased only by 15% and 20% for revulcanisates containing 25% and 50% recycled rubber, respectively.

EFFECTS OF CROSSLINK BOND TYPE OF IIR-BASED WASTE RUBBER POWDER ON THE EPDM-ASSISTED DEVULCANIZATION REACTION

Isobutylene–isoprene rubber (IIR)–based waste rubber powder (WRP) present in WRP/ethylene–propylene–diene monomer (EPDM) blends was devulcanized through a stress-induced reaction by increasing the screw rotation speed in the presence of subcritical ethanol. The effects of crosslink bond type (which was cured using phenolic resin, sulphur, or zinc oxide) of WRP and the screw rotation speed on devulcanization were investigated. The results showed that the Mooney viscosity and gel content of the devulcanized blends (DWRP/EPDM) decreased with an increase in the screw rotation speed, and the optimal screw rotation speed maximized the molecular weight (Mη) of sols and enhanced the mechanical properties of the revulcanized material. The optimal screw rotation speed for the phenolic resin-cured WRP1 and zinc oxide-cured WRP3 was 500 r min−1 and that for sulphur-cured WRP2 was 300 r min−1. At the optimal screw rotation speed, crosslink bonds severely fractured, and the main chain structure remained relatively intact. The 1H-NMR spectra of the sol in the devulcanized blends (DWRP/EPDM) confirmed that the content of the alpha and double-bond protons of sols are the highest at the optimal screw rotation speed, and many promoting agent (480) molecules penetrate and participate in devulcanization. Scanning electron microscopy images indicated that the size of the unfused gel particles in the mixed-revulcanized materials of IIR/(DWRP1/EPDM), IIR/(DWRP2/EPDM), and BIIR/(DWRP3/EPDM) was the smallest at the optimal screw rotation speed.

Current progress in waste tire rubber devulcanization

Vulcanized rubber, due to its superior mechanical properties, has long been used in various industries, especially automotive. The rubber industry has evolved and expanded over the years to meet the increasing global demands for tires. Today tires consist of about 19% natural rubber and 24% synthetic rubber, while plastic polymer and metal, filler and additives make up the rest. Over 1.6 billion new tires are produced annually and around 1 billion waste tires are generated. Tires are extensively designed with several complex processes to make them virtually indestructible. Since tire rubber does not decompose easily, their disposal at the end of service life creates a monumental environmental impact. However, waste tire rubber (WTR) consist of valuable rubber hydrocarbon, making its recovery or regeneration highly desirable. The conventional recovery method of WTR tends to produce undesirable products due to the destruction of the polymeric chain and exponentially degenerates the vulcanizates' physical properties. Since then, multiple devulcanization processes were introduced to effectively and selectively cleave vulcanizate's crosslinks while retaining the polymeric networks. Different devulcanization methods such as chemical, mechanical, irradiation, biological and their combinations that have been explored until now are reviewed here. Besides, an overview of the latest development of devulcanization by ionic liquids and deep eutectic solvents are also described. While such devulcanization technique provides new sustainability pathway(s) for WTR, the generated devulcanizate also possesses comparable physical properties to that of virgin products. This further opens the possibility of novel circular economic opportunities worldwide.

Devulcanization of natural rubber industry waste in supercritical carbon dioxide combined with diphenyl disulfide

The elimination of rubber wastes without affecting the environment is one of the most important challenges of the 21st century waste management. Accordingly, the present work is focused on the recycling of natural rubber (NR) industry waste by means of devulcanization in supercritical carbon dioxide (scCO₂) atmosphere. With that aim, a novel device allowing to perform rubber devulcanization was developed. It consists of a triaxial compression reactor integrated into a dynamic hydraulic universal testing machine with a heating chamber. NR industry waste was devulcanized in the mentioned device at different temperatures, in scCO₂ by using diphenyl disulfide (DD) as devulcanizing reagent. The devulcanization degree and quality of the treated materials were evaluated by the swelling test combined with the Horikx theory. It was appeared that a successful devulcanization, with almost no degradation, was obtained, and the devulcanization degree reached maximum value of ~90%. Thermogravimetric tests and scanning electron microscopy (SEM) images strengthened these results. Finally, it was concluded that the developed device is appropriate to perform rubber recycling, which contributes to the progress in the environmental protection.

Waste Tyres Pyrolysis for Obtaining Limonene

This review deals with the technologies of limonene production from waste tyre pyrolysis. Thermal decomposition is attractive for tackling the waste tyre disposal problem, as it enables both: energy to be recovered and limonene to be obtained. This material management recycling of tyres is environmentally more beneficial than the burning of all valuable products, including limonene. Given this recoverability of materials from waste tyres, a comprehensive evaluation was carried out to show the main effect of process conditions (heating rate, temperature, pressure, carrier gas flow rate, and type of volatile residence and process times) for different pyrolytic methods and types of apparatus on the yield of limonene. All the results cited are given in the context of the pyrolysis method and the type of reactor, as well as the experimental conditions in order to avoid contradictions between different researchers. It is shown that secondary and side reactions are very sensitive to interaction with the above-mentioned variables. The yields of all pyrolytic products are also given, as background for limonene, the main product reported in this study.

Devulcanization Technologies for Recycling of Tire-Derived Rubber: A Review

In general, composite materials are difficult to recycle. Tires belong to this class of materials. On top, one of their main constitutents, vulcanized rubber, is as elastomer, which cannot be remolten and hence is particularly challenging to put to a new use. Today, the main end-of-life routes of tires and other rubber products are landfilling, incineration in e.g., cement plants, and grinding to a fine powder, generating huge quantities and indicating a lack of sustainable recycling of this valuable material. True feedstock recycling is not feasible for complex mixtures such as tires, but devulcanization can be done to reactivate the cross-linked polymer for material recycling in novel rubber products. Devulcanization, i.e., the breaking up of sulfur bonds by chemical, thermophysical, or biological means, is a promising route that has been investigated for more than 50 years. This review article presents an update on the state-of-the art in rubber devulcanization. The article addresses established devulcanization technologies and novel processes described in the scientific and patent literatures. On the one hand, tires have become high-tech products, where the simultaneous improvement of wet traction, rolling resistance, and abrasion resistance (the so-called "magic triangle") is hard to achieve. On the other hand, recycling and sustainable end-of-life uses are becoming more and more important. It is expected that the public discussion of environmental impacts of thermoplastics will soon spill over to thermosets and elastomers. Therefore, the industry needs to develop and market solutions proactively. Every year, approximately 40 million tons of tires are discarded. Through the devulcanization of end-of-life tires (ELT), it is possible to produce new raw materials with good mechanical properties and a superior environmental footprint over virgin products. The devulcanization process has become an interesting technology that is able to support the circular economy concept.

Integrating Sacrificial Bonds into Dynamic Covalent Networks toward Mechanically Robust and Malleable Elastomers

Vitrimers are a class of covalently cross-linked polymers that have drawn great attention due to their fascinating properties such as malleability and reprocessability. The state of art approach to improve their mechanical properties is the addition of fillers, which, however, greatly restricts the chain mobility and impedes network topology rearrangement, thereby deteriorating the dynamic properties of vitrimer composites. Here, we demonstrate that the integration of sacrificial bonds into a vitrimeric network can remarkably enhance the overall mechanical properties while facilitating network rearrangement. Specifically, commercially available epoxidized natural rubber is covalently cross-linked with sebacic acid and simultaneously grafted with N-acetylglycine (NAg) through the chemical reaction between epoxy and carboxyl groups, generating exchangeable β-hydroxyl esters and introducing amide functionalities into the networks. The hydrogen bonds arising from amide functionalities act in a sacrificial and reversible manner, that is, preferentially break prior to the covalent framework and undergo reversible breaking and reforming to dissipate mechanical energy under external load, which leads to a rarely achieved combination of high strength, modulus, and toughness. The topology rearrangement of the cross-linked networks can be accomplished through transesterification reactions at high temperatures, which is accelerated with the increase of grafting NAg amount due to the dissociation of transient hydrogen bonds and increase of the ester concentration in the system.

Vegetable derived-oil facilitating carbon black migration from waste tire rubbers and its reinforcement effect

Three dimensional chemically cross-linked polymer networks present a great challenge for recycling and reutilization of waste tire rubber. In this work, the covalently cross-linked networks of ground tire rubber (GTR) were degraded heterogeneously under 150 °C due to the synergistic effects of the soybean oil and controlled oxidation. The degradation mechanism was discussed using Horikx theory and Fourier transformation infrared spectroscopy (FTIR). The results showed that the structural evolution of sol and gel parts, which indicated that the sols consisted of degraded GTR chains with low molecular weight, while the gels were mainly composed of bound rubber coated carbon black, which are separated from the cross-linked network of GTR in a high degradation degree. The degraded GTR compound demonstrated an excellent reinforcing effect on solution styrene-butadiene rubber (SSBR), due to the presence of core-shell structured carbon black. This work provide an efficient and economic approach to degrade GTR and transform it into useful products.

Covalently Cross-Linked Elastomers with Self-Healing and Malleable Abilities Enabled by Boronic Ester Bonds

Covalently cross-linked rubbers are renowned for their high elasticity that play an indispensable role in various applications including tires, seals, and medical implants. Development of self-healing and malleable rubbers is highly desirable as it allows for damage repair and reprocessability to extend the lifetime and alleviate environmental pollution. Herein, we propose a facile approach to prepare permanently cross-linked yet self-healing and recyclable diene-rubber by programming dynamic boronic ester linkages into the network. The network is synthesized through one-pot thermally initiated thiol-ene "click" reaction between a novel dithiol-containing boronic ester cross-linker and commonly used styrene-butadiene rubber without modifying the macromolecular structure. The resulted samples are covalently cross-linked and possess relatively high mechanical strength which can be readily tailored by varying boronic ester content. Owing to the transesterification of boronic ester bonds, the samples can alter network topologies, endowing the materials with self-healing ability and malleability.

Engineering of β-Hydroxyl Esters into Elastomer-Nanoparticle Interface toward Malleable, Robust, and Reprocessable Vitrimer Composites

Rubbers are strategically important due to their indispensable applications in the daily life and high-tech fields. For their real-world applications, the covalent cross-linking, reinforcement, and malleability of rubbers are three important issues because they are closely related to the elasticity, mechanical properties, and recycling of the rubber materials. Herein, we demonstrate a simple way to prepare covalently cross-linked yet recyclable and robust elastomeric vitrimer composites by incorporating exchangeable β-hydroxyl ester bonds into the elastomer-nanoparticle interface using epoxy group-functionalized silica (Esilica) as both cross-linker and reinforcement in carboxyl group-grafted styrene-butadiene rubber (CSBR). The Esilica-cross-linked CSBR composites exhibit promising mechanical properties due to the covalent linkages in the interface and fine silica dispersion in the matrix. In addition, the interface can undergo dynamic reshuffling via transesterification reactions to alter network topology at high temperatures, conferring the resulting composites the ability to be reshaped and recycled.

Liquefaction of ground tire rubber at low temperature

Low-temperature liquefaction has been investigated as a novel method for recycling ground tire rubber (GTR) into liquid using an environmentally benign process. The liquefaction was carried out at different temperatures (140, 160 and 180 °C) over variable time ranges (2-24 h) by blending the GTR with aromatic oil in a range from 0 to 100 parts per hundred rubber (phr). The liquefied GTR was separated into sol (the soluble fraction of rubber which can be extracted with toluene) and gel fractions (the solid fraction obtained after extraction) to evaluate the reclaiming efficiency. It was discovered that the percentage of the sol fraction increased with time, swelling ratio and temperature. Liquefied rubber was obtained with a high sol fraction (68.34 wt%) at 140 °C. Simultaneously, separation of nano-sized carbon black from the rubber networks occurred. The separation of carbon black from the network is the result of significant damage to the cross-linked-network that occurs throughout the liquefaction process. During liquefaction, a competitive reaction between main chain scission and cross-link bond breakage takes place.

Devulcanization of Scrap Tire Rubber with Supercritical CO2: A Study of the Effects of Process Parameters on the Properties of Devulcanized Rubber

A continuous extrusion devulcanization process has been developed by using supercritical CO2. Experiments have been carried out on an industrial scale twin screw extruder to study the effects of processing conditions on the properties of devulcanized rubber. Using a fractional factorial design in three levels, the effects of process temperature, screw speed, and feed rate on the sol fraction, degree of devulcanization, Mooney viscosity, and tensile properties of devulcanized rubber have been investigated. The significance of the effects of the processing conditions decreases in the following order: flow rate, screw speed, and process temperature. Similar trends are noted for different responses with the exception of tensile properties. The observed relationship between the sol fraction and the degree of crosslinking in the rubber samples before and after devulcanization points to a highly selective disruption of the sulfur crosslinks in the rubber network during devulcanization rather than a random network scission. Mooney viscosity has been found to be in excellent agreement with the network structure properties, sol fraction, and degree of devulcanization.