Preliminary Investigation on Auto-Thermal Extrusion of Ground Tire Rubber

Management of ground tire rubber waste by incorporation into polyurethane-based composite foams

Rapid economic growth implicated the developing multiple industry sectors, including the automotive branch, increasing waste generation since recycling and utilization methods have not been established simultaneously. A very severe threat is the generation of enormous amounts of post-consumer tires considered burdensome waste, e.g., due to the substantial emissions of volatile organic compounds (VOCs). Therefore, it is essential to develop novel, environmentally friendly methods for their utilization, which would hinder their environmental impacts. One of the most promising approaches is shredding, resulting in the generation of ground tire rubber (GTR), which can be introduced into polymeric materials as filler. The presented work is related to the thermomechanical treatment of GTR in a twin-screw extruder with zinc borate, whose incorporation is aimed to enhance shear forces within the extruder barrel. Modified GTR was introduced into flexible polyurethane (PU) foams, and the impact of modification parameters on the cellular structure, static and dynamic mechanical performance, thermal stability, as well as thermal insulation, and acoustic properties was investigated. Emissions of VOCs from applied fillers and prepared composites were monitored and evaluated. Depending on the treatment parameters, beneficial changes in foams' cellular structure were noted, which enhanced their thermal insulation performance, mechanical strength, and thermal stability. It was proven that the proposed method of GTR thermomechanical treatment assisted by zinc borate particles might benefit the performance of flexible PU foamed composites and hinder VOC emissions, which could broaden the application range of GTR and provide novel ways for its efficient utilization.

Insights into the Structural and Dielectric Behavior of Composites Produced from EPDM Waste Processed through a Devulcanization Method and SBR

Ethylene propylene diene monomer (EPDM) is one of the most used polymers in the world. It is an elastomer, which means that the existing cross-linking between the main chains of the polymer created during the vulcanization process makes its recycling difficult. In this paper, a possible solution to this issue is studied. The devulcanization of EPDM is achieved by a thermomechanical process followed by microwave irradiation. These combined treatments suppress the cross-linking, yielding a material (EPDMd) that can be successfully blended to form composites. A common elastomer, styrene butadiene rubber (SBR), has been selected as the matrix. The new SBR/EPDMd composites can be useful as elastomeric dielectric materials and can contribute to the recycling of the discarded EPDM. To provide a better understanding of their microstructure and its relationship with their micro- and macroscopic behavior, samples containing 20 and 40% of EPDMd have been tested by thermogravimetric and dielectric analysis, focusing on variables such as the thermal properties of the blends, permittivity, electric modulus, conductivity, and activation energies. The results show interesting changes linked to the presence of EPDMd in the SBR matrix, such as the displacement of the β dielectric relaxation toward higher frequencies. The correct integration between the two phases is confirmed by the absence of any Maxwell-Wagner-Sillars type relaxation in their dielectric behavior. The presence of additives in the EPDMd samples has an effect on the conductivity, mainly due to the conductive aluminum silicate present in the EPDMd, which acts toward increasing some key dielectric features like conductivity and permittivity and decreasing the insulation of the final SBR/EPDMd materials. The inclusion of EPDMd also affects the α relaxations (low frequencies) and suppresses the β relaxations (high frequencies). The samples showed a non-Debye dielectric behavior. In short, a compact and well-integrated material with a dielectric behavior is created, which exhibits interesting differences from the reference SBR matrix. Finally, it is concluded that the compounds tested are suitable for applications as electrical insulators.

Processing, Mechanical and Morphological Properties of GTR Modified by SBS Copolymers

In this work, ground tire rubber (GTR) was thermo-mechanically treated in the presence of styrene-butadiene-styrene (SBS) copolymers. During preliminary investigation, the effects of different SBS copolymer grades, the variable content of SBS copolymer on the Mooney viscosity, and the thermal and mechanical properties of modified GTR were determined. Subsequently, GTR modified by SBS copolymer and cross-linking agents (sulfur-based system and dicumyl peroxide) was characterized by assessment of rheological, physico-mechanical, and morphological properties. Rheological investigations showed that linear SBS copolymer, with the highest melt flow rate among studied SBS grades, was the most promising modifier of GTR, considering processing behavior. It was also observed that an SBS improves the thermal stability of the modified GTR. However, it was found that higher content of SBS copolymer (above 30 wt%) does not bring any effective changes and, for economic reasons, is inefficient. The results showed that samples based on GTR modified by SBS and dicumyl peroxide have better processability and slightly higher mechanical properties compared to samples cross-linked by a sulfur-based system. This is due to the affinity of dicumyl peroxide to the co-cross-linking of GTR and SBS phases.

Mechanochemical Treatment in High-Shear Thermokinetic Mixer as an Alternative for Tire Recycling

This publication highlights the use of a high-speed thermokinetic mixer as an alternative to recycling ground tire rubber (GTR) using mechanochemical treatment. The GTR initially had a gelled fraction of 80% and presented a reduction of up to 50% of gel fraction in the most intensive condition (5145 rpm, n₂). The processing condition at the lowest speed (2564 rpm, n₁) resulted in greater selectivity in chain scission (K~1). However, in the most intense processing condition (10 min to n₂), more significant degradation was observed via random scission, reduction in the glass transition temperature, T_g (11 °C), increase in the soluble polymeric fraction, and a more significant reduction in the density of bonds occurs. The artificial neural network could describe and correlate the thermal degradation profile with the processing conditions and the physicochemical characteristics of the GTR. The n₂ velocity resulted in the formation of particles with a smoother and more continuous surface, which is related to the increase in the amount of soluble phase. The approach presented here represents an alternative to the mechanochemical treatment since it can reduce the crosslink density with selectivity and in short times (1–3 min).

Insights into Stoichiometry Adjustments Governing the Performance of Flexible Foamed Polyurethane/Ground Tire Rubber Composites

Polyurethanes (PU) are widely applied in the industry due to their tunable performance adjusted by changes in the isocyanate index—stoichiometric balance between isocyanate and hydroxyl groups. This balance is affected by the incorporation of modifiers of fillers into the PU matrix and is especially crucial for PU foams due to the additional role of isocyanates—foaming of the material. Despite the awareness of the issue underlined in research works, the contribution of additives into formulations is often omitted, adversely impacting foams’ performance. Herein, flexible foamed PU/ground tire rubber (GTR) composites containing 12 different types of modified GTR particles differing by hydroxyl value (LOH) (from 45.05 to 88.49 mg KOH/g) were prepared. The impact of GTR functionalities on the mechanical, thermomechanical, and thermal performance of composites prepared with and without considering the LOH of fillers was assessed. Formulation adjustments induced changes in tensile strength (92–218% of the initial value), elongation at break (78–100%), tensile toughness (100–185%), compressive strength (156–343%), and compressive toughness (166–310%) proportional to the shift of glass transition temperatures (3.4–12.3 °C) caused by the additional isocyanates’ reactions yielding structure stiffening. On the other hand, formulation adjustments reduced composites’ thermal degradation onset due to the inferior thermal stability of hard segments compared to soft segments. Generally, changes in the composites’ performance resulting from formulation adjustments were proportional to the hydroxyl values of GTR, justifying the applied approach.

Comprehensive Enhancement of Prepolymer-Based Flexible Polyurethane Foams' Performance by Introduction of Cost-Effective Waste-Based Ground Tire Rubber Particles

Material innovations in polyurethane (PU) foams should ideally combine performance enhancement, environmental impact limitation, and cost reduction. These goals can be achieved by applying recycled or waste-based materials without broader industrial applications, implicating their low price. Herein, from 5 to 20 parts by weight of ground tire rubber (GTR) particles originated from the recycling of postconsumer car tires were incorporated into a flexible foamed PU matrix as a cost-effective waste-based filler. A two-step prepolymer method of foams manufacturing was applied to maximize the potential of applied formulation changes. The impact of the GTR content on the foams' processing, chemical, and cellular structure, as well as static and dynamic mechanical properties, thermal stability, sound suppression ability, and thermal insulation performance, was investigated. The introduction of GTR caused a beneficial reduction in the average cell diameter, from 263.1 µm to 144.8-188.5 µm, implicating a 1.0-4.3% decrease in the thermal conductivity coefficient. Moreover, due to the excellent mechanical performance of the car tires-the primary application of GTR-the tensile performance of the foams was enhanced despite the disruption of the cellular structure resulting from the competitiveness between the hydroxyl groups of the applied polyols and on the surface of the GTR particles. The tensile strength and elongation at break were increased by 10 and 8% for 20 parts by weight GTR addition. Generally, the presented work indicates that GTR can be efficiently applied as a filler for flexible PU foams, which could simultaneously enhance their performance, reduce costs, and limit environmental impacts due to the application of waste-based material.

Recent Advances in Development of Waste-Based Polymer Materials: A Review

Limited petroleum sources, suitable law regulations, and higher awareness within society has caused sustainable development of manufacturing and recycling of polymer blends and composites to be gaining increasing attention. This work aims to report recent advances in the manufacturing of environmentally friendly and low-cost polymer materials based on post-production and post-consumer wastes. Sustainable development of three groups of materials: wood polymer composites, polyurethane foams, and rubber recycling products were comprehensively described. Special attention was focused on examples of industrially applicable technologies developed in Poland over the last five years. Moreover, current trends and limitations in the future “green” development of waste-based polymer materials were also discussed.

Ground Tire Rubber Modified by Elastomers via Low-Temperature Extrusion Process: Physico-Mechanical Properties and Volatile Organic Emission Assessment

In this paper, low-temperature extrusion of ground tire rubber was performed as a pro-ecological waste tires recycling method. During this process, ground tire rubber was modified with constant content of dicumyl peroxide and a variable amount of elastomer (in the range: 2.5–15 phr). During the studies, three types of elastomers were used: styrene-butadiene rubber, styrene-ethylene/butylene-styrene grafted with maleic anhydride and ethylene-octene copolymer. Energy consumption measurements, curing characteristics, physico-mechanical properties and volatile organic compounds emitted from modified reclaimed GTR were determined. The VOCs emission profile was investigated using a passive sampling technique, miniature emission chambers system and static headspace analysis and subsequently quantitative or qualitative analysis by gas chromatography. The VOCs analysis showed that in the studied conditions the most emitted volatile compounds are dicumyl peroxide decomposition by-products, such as: α-methylstyrene, acetophenone, α-cumyl alcohol, methyl cumyl ether, while the detection level of benzothiazole (devulcanization “marker”) was very low. Moreover, it was found that the mechanical properties of the obtained materials significantly improved with a higher content of styrene-butadiene rubber and styrene-ethylene/butylene-styrene grafted with maleic anhydride while the opposite trend was observed for ethylene-octene copolymer content.

Processing, Performance Properties, and Storage Stability of Ground Tire Rubber Modified by Dicumyl Peroxide and Ethylene-Vinyl Acetate Copolymers

In this paper, ground tire rubber was modified with dicumyl peroxide and a variable content (in the range of 0–15 phr) of ethylene-vinyl acetate copolymers characterized by different vinyl acetate contents (in the range of 18–39 wt.%). Modification of ground tire rubber was performed via an auto-thermal extrusion process in which heat was generated during internal shearing of the material inside the extruder barrel. The processing, performance properties, and storage stability of modified reclaimed ground tire rubber were evaluated based on specific mechanical energy, infrared camera images, an oscillating disc rheometer, tensile tests, equilibrium swelling, gas chromatography combined with a flame ionization detector, and gas chromatography with mass spectrometry. It was found that the developed formulas of modified GTR allowed the preparation of materials characterized by tensile strengths in the range of 2.6–9.3 MPa and elongation at break in the range of 78–225%. Moreover, the prepared materials showed good storage stability for at least three months and satisfied processability with commercial rubbers (natural rubber, styrene-butadiene rubber).

Ground Tire Rubber Filled Flexible Polyurethane Foam-Effect of Waste Rubber Treatment on Composite Performance

The application range of flexible polyurethane (PU) foams is comprehensive because of their versatility and flexibility in adjusting structure and performance. In addition to the investigations associated with further broadening of their potential properties, researchers are looking for new raw materials, beneficially originated from renewable resources or recycling. A great example of such a material is ground tire rubber (GTR)—the product of the material recycling of post-consumer car tires. To fully exploit the benefits of this material, it should be modified to enhance the interfacial interactions between PU and GTR. In the presented work, GTR particles were thermo-mechanically modified with the addition of fresh and waste rapeseed oil in the reactive extrusion process. The introduction of modified GTR particles into a flexible PU matrix caused a beneficial 17–28% decrease in average cell diameters. Such an effect caused an even 5% drop in thermal conductivity coefficient values, enhancing thermal insulation performance. The application of waste oil resulted in the superior mechanical performance of composites compared to the fresh one and thermo-mechanical modification without oils. The compressive and tensile performance of composites filled with waste oil-modified GTR was almost the same as for the unfilled foam. Moreover, the introduction of ground tire rubber particles enhanced the thermal stability of neat polyurethane foam.

Ground Tire Rubber Modified by Ethylene-Vinyl Acetate Copolymer: Processing, Physico-Mechanical Properties, Volatile Organic Compounds Emission and Recycling Possibility

Ground tire rubber (GTR) was reclaimed and modified with 10 phr of ethylene-vinyl acetate copolymer via low-temperature extrusion process. Processing, physico-mechanical properties, volatile organic compounds emission, and recycling possibility were investigated. In order to better understand the impact of used modifiers, their efficiency was compared with trans-polyoctenamer, which is an additive that is commercially dedicated to waste rubber recycling. The results showed that a relatively small amount of ethylene-vinyl acetate copolymer improves the mechanical properties of modified reclaimed GTR and also allows further recycling by multiple processing without the deterioration of performance after three cycles.

Waste Rubber Pyrolysis: Product Yields and Limonene Concentration

Tires, conveyor belts, floor mats, and shoe soles form a main-stream of rubber waste. The amount of these used materials continuously increases due to development of the rubber market. Therefore, pro-ecological utilization (i.e., energy recycling instead of burning) and recovering valuable and recyclable materials becomes an urgent necessity. In this regard, this work was devoted to the chemical recycling of selected used rubber products, and it especially explores the possibility of limonene production. Different types of waste rubber were characterized and pyrolyzed at microgram and laboratory scales, and the results were compared. Additionally, the pyrolysis of tires, the most significant stream of rubber waste, was also conducted in a semi-technical scale reactor. The effectiveness of limonene formation in the liquid fractions obtained from different types of waste rubber was compared.