# Patent

## Title
Method and device for producing highly active rubber powder from rubber wastes

## Abstract

A method for the production of highly-active rubber powder from old tires and scrap vulcanised rubber articles based on various rubbers by 2-stage thermo-mechanical treatment in an extruder. This involves (a) fine pulverisation and (b) sharp reduction of the volume stress. An apparatus for the production of highly-active rubber powder includes a cylindrical housing with feed and discharge connections, a compression zone and pulverisation zone(s), each with a compression screw with grooves decreasing in depth in the machine direction and a rotating coaxial activator with grooves on its outer working surface, the housing, screw and activator being provided with cooling elements.

## Background
The invention relates to the field of the processing of scrap tyres and waste of rubber articles based on different rubber types and is intended for the manufacture of highly active rubber powder for the effective reuse thereof.
The recycling process essentially comprises two stages:

    1. Preprocessing tyres and waste of rubber articles in order to obtain maximum textile and metal cord-free rubber pieces of dimensions 10 to 15 mm.
    2. Final processing of the pieces obtained in order to obtain a rubber powder of maximum effectivity for reuse purposes.


The invention relates to the second stage.
Numerous processes are known for the processing of scrap tyres and waste of rubber articles either through mechanical impact action on waste cooled to low (cryogenic) temperatures using hammer, stud and other crushers (U.S. Pat. No. 3,718,284, B 02 C 11/08, published in 1978 and Russian patent 2 060 833, B 29 B 17/02, priority of 30 Nov. 1993, published on 27 May 1996) or successive impact and cutting action at temperatures of 0 to 60° C. in shredders, grooved rollers, etc. (U.S. Pat. No. 3,923,256, B 02 C 23/14, published 1975, Russian patent 2 076 045, B 29 B 17/00, priority 29 Dec. 1990, published 27 Mar. 1997, Russian patent 2 057 013, B 29 B 17/00, priority 7 Feb. 1994, published 27 Mar. 1996, Russian patent 2 128 115, B 29 B 17/00, 17/02, priority 4 Apr. 1997, published 27 Mar. 1999, Russian patent 2 076 045, B 29 B 13/10, 17/00, priority 29 Dec. 1990, published 27 Mar. 1997, German patent 37 17 571, B 02 C 18/24, 13/26, priority 25 May 1987, published 23 Jun. 1988, German patent 44 25 049, B 29 B 17/00, priority 15 Jul. 1994, published 1 Jan. 1996, EP 937742, priority 20 Feb. 1998, US 27,312 published 25 Aug. 1999, EP 972792, priority 15 Jul. 1998, US 115,975, published 19 Jan. 2000).
These processes do not make it possible to produce rubber powders with a high specific, geometrical surface area, which is a criterion of the activity of the powder, in spite of the possibility of the production of very finely ground powders. The maximum specific, geometrical surface of the powder with a particle size of 20 μm does not exceed 0.12 m2/g.
Numerous apparatuses are known for the production of powders with a relatively high physical and chemical activity from vulcanized rubber waste. In particular, Russian patent 2 038 214, B 29 B 17/00, priority 29 Aug. 1991, published 27 Jun. 1995, Bull. No. 18, German patent 4128630 disclose an apparatus, which has two-worm shafts with three cam zones for crushing, separation and cooling. According to the cited document the crushing of the material results from its successive passage through these zones, which is unjustified from the energy consumption purposes, because more than half of the material is subject three times to heating and cooling, because each of the three cam crushing zones delivers no more than 25% powder with a necessary fraction composition (particle size no more than 0.8 mm).
It is also impossible to achieve in said apparatus optimum crushing or size reduction parameters (temperature, pressure, time), where the specific geometrical surface of the powder would exceed a value of 0.4 m2/g, because the crushing of the material takes place on the contacting cam surfaces having no cooling. In addition, the cam zones are extremely sensitive to the presence in rubber waste of foreign bodies (sand, stones, metal cord) and the latter penetrate the gaps between the cams leading to the fracture thereof.
An apparatus is known (Russian patent 2 143 324, B 02 C 19/22, priority 5 Feb. 1998, published 27 Dec. 1999, Bull. No. 36), where the crushing of polymer materials, including elastomers, takes place on two contacting, conical working elements in the form of polygonal disk cams.
The main disadvantage of this apparatus is that coolants are completely lacking and without them the production of powders with an increased surface area is problematical.
One-worm apparatuses with cylindrical casings are known within which in coaxially succeeding and aligned manner are mounted in rotary form a compacting worm and a working member (Russian patent 2 167 056, B 29 B 17/00, 13/10, B 02 C 18/44, 19/22/B 29 K 101.00, priority 23 Feb. 2000, published 20 May, 2001, Bull. No. 14 and Russian patent 2 167 057, B 29 B 17/00, 13/10, B 02 C 18/44, 19/22/B 29 K 101.00, priority 23 Feb. 2000, published 20 May 2001, Bull. No. 14).
The processing of the material in these apparatuses does not take place in an elongated annular clearance between the casing and the working member, but instead in annular chambers. In these apparatuses elements such as the casing, worm and working member in each case have independent coolants. Simultaneously the use of the working member in the form of successively positioned, small, annular chambers with a decreasing depth or the construction on the casing or working member, downstream of the worm, of a chamber does not make it possible to achieve the necessary temperatures and pressures in the annular clearance enabling the production of active rubber powders to take place.
Technically the closest to the process proposed is an extrusion processing process, which is performed by the action of shearing deformations, which are sufficient to destroy a large number of rubber pieces and give powders with a particle size up to 0.1 mm (Russian patent 2 057 013, a 29 B 17/00, priority 7 Feb. 1994, published 27 Mar. 1996, Russian patent 2 173 634, B 29 B 13/10, 17/00, 7/42, B 02 C 19/20, 19/22/B 29 K 101.00, priority 23 Aug. 2000, published Sep. 20, 2001, Bull. No. 26).
The main disadvantage of this processing process is a low efficiency of the procedures involved (up to 104 kg/h). In addition, it is difficult when processing vulcanized rubber using the described process to take account of technical and technological characteristics of the differently based rubbers, particularly those based on a high plastic deformation component. In the case of rubbers with a high elastic deformation component which for processing require much higher values of the sliding stress and pressure, it is difficult to adjust the pressure and temperature permitting the maximum size reduction of the product. In addition, the rubber powders produced by this process are characterized by a short storage time of 7 to 10 days, after which their activity decreases and capability greatly increases. It is therefore most appropriate to create in a rubber processing apparatus zones which ensure the obtaining of higher pressure and temperature values for the material to be processed and the provision of chemical modifiers in order to maintain the powder activity.
Closest to the apparatus according to the invention is an apparatus for producing a powder from polymer material (Russian patent 2 173 635, B 29 B 13/00, 17/00, B 02 C 18/44, 19/22/B 29 K 101.00, priority 23 Aug. 2000, published 20 Sep. 2001), which has a cylindrical casing provided with a charging connection and a discharging connection and within which are formed compacting and size reducing zones, which are provided with a compacting worm with a depth of the grooves between the combs decreasing in the direction of the size reduction zone and a working member in the form of a rotary body on whose working outer surface are formed slots. The two elements are mounted in a coaxially rotatable manner relative to the inner face of the casing, accompanied by the formation therewith of an annular clearance. The casing, compacting worm and working member are provided with coolants. Although it is possible with the described apparatus to produce powder having an adequately large specific surface (up to 0.5 m2/g), the capacity or output of the apparatus is not particularly high (max. 104 kg/h). In addition, this apparatus does not make it possible to crush all rubber types, e.g. rubbers having high deformation plastic component values (based on polychloroprenes, cis-isoprene rubbers with a high plasticizer content, chlorobutyl and bromobutyl rubbers, because the apparatus lacks a gas saturation zone and a second crushing zone.
The technical result of the invention is a universal, high efficiency, energy-saving process making it possible to produce highly active rubber powders from scrap tyres and vulcanized waste of rubber articles with a specific, geometrical surface up to 5 m2/g, as well as an apparatus for performing this process.
The technical result is achieved in that in the process for the production of a highly active rubber powder with a specific, geometrical surface of 0.4 to 5.0 m2/g from scrap tyres and vulcanized waste of rubber articles based on different rubber types, preferably isoprene, butadiene, butadiene styrene, butadiene nitrile rubbers, including hydrogenated, carboxylated, ethylene, propylene, fluorine, fluorosilicone, butadiene vinyl pyrinine, silicone, epichlorohydrin, polychloroprene, chlorosulphonated, polyisobutylene acrylic rubbers and mixtures thereof crushing takes place in an extruder-type apparatus under thermomechanical action. According to the invention, the crushing of vulcanized rubbers takes place in two stages:

    
    
        Under the conditions of a volume stress of 15 to 150 MPa increasing at a rate of 5 to 90 MPa/s with an amplitude of ±5 to 20 MPa and pulsating at a frequency of 5 to 500 Hz, as well as one with a temperature rising at a rate of 50 to 150° C./s in a range of 90 to 380° C. accompanied by the simultaneous gas saturation of rubber with degradation products of plasticizers and other constituents belonging to the rubber composition, their comminution initially takes place accompanied by the formation of a porous structure in the volume of the rubber particles.
        Whilst greatly reducing the volume stress at a rate of 50 to 150 MPa/s, the porous structure is destroyed, the specific, geometrical surface of the rubber particles is increased and said rubber particles are cooled.
    
    


During the performance of the process for the production of a rubber powder with a specific, geometrical surface of no less than 0.4 m2/g from scrap tyres and vulcanized waste of rubber articles, for the destruction thereof a deformation is possible in a range of 105 to 250% of the limit of the elastic component of rubber deformation.
The effectiveness of this process is increased in the presence of heterogeneity modifiers, namely alcohol telomers of general formula H(CF2—CF2)n—CH2OH, N-nitrosodiphenylamine, N-cyclohexylthiophthalimide and chlorinated paraffins in a quantity of 0.1 to 1.9%, which makes it possible to increase the specific, geometrical surface by 15 to 40%, the efficiency of the process by 10 to 55% and the powder storage time from 1 to 6 to 9 months, whilst avoiding caking during transportation.
A considerable increase in the efficiency is also brought about by a physicochemical treatment of the working surfaces of the sleeves with fluorine-containing, organic substances, e.g. with alcohol telomers and/or with materials containing tungsten, nickel, chromium, boron, molybdenum, as well as carbides and nitrides of very high melting point metals, which leads to a reduction of the rubber on metal friction coefficient from 0.82-0.87 to 0.36-0.42.
In the performance of the process for producing a highly active powder from rubber waste, in whose formulation constituents degradable at high temperatures are lacking, rubber crushing takes place the presence of modifiers in a quantity of 0.7 to 5.0% and which combined with the rubber form volatile substances at a temperature of 70 to 120° C. The modifiers used are sulphenamide M, sulphenamide Z, alcohol telomers, stearic, oleic, citric and oxalic acid.
The process of the invention can also be used for the production of mixed thermoelastoplastics, where a joint size reduction of the waste of rubber articles and thermoplastics and/or thermoelastoplastics such as polyethylenes, polypropylenes, polyvinyl chlorides, polyethylene terephthalates, butadiene-styrene-block copolymers, etc. takes place.
The technical result is also achieved by the fact that in an apparatus for the production of active rubber powders from scrap tyres and waste of rubber articles and having a casing with a charging connection and a discharging connection together with coolants, within which is mounted in rotary coaxial manner a drive, accompanied by the formation of an annular clearance and equipped with a cooling element are installed a compacting worm with a variable depth decreasing in the discharging connection direction and an activator, on whose outer surface and on the casing inner surface facing the activator are formed cutting grooves, on the casing inner surface facing the compacting worm longitudinal ribs are provided, according to the invention on a shaft are mounted a multistart compacting worm and an activator rigidly connected thereto and constructed as a rotary body, as well as a discharging worm, which can be constructed as an independent part or in one piece with the compacting worm. The activator is externally provided with multistart, helical notches with a constant depth in the direction of movement of the material to the discharging connection and in the reverse direction, with an equal number of starts and with a pitch which is 1.1 to 2.5 times greater than the pitch of the compacting worm, and the discharging worm is provided with multistart, helical combs in the straight direction with a pitch, which is 1.15 to 3.0 times greater than the pitch of the compacting worm, with an interturn gap between the worms, which increases in the straight direction through the reduction in the number of worms, the combs being constructed in continuous manner or interrupted by multistart, helical notches in the reverse direction with a pitch equal to the pitch of the combs and the ratio of the length of the activator along the axis to the length of the discharging worm being in a range 0.2:1 to 1:0.3 and in the casing inner surface, which is connected to the worms with a pitch of 0.5 to 1.5 of the starting cut pitch of the particular worm, are formed multistart notches in the straight direction and/or crossing notches in the straight and reverse direction with a semicircular profile and with a radius corresponding to 0.01 to 0.03 diameter of the worm and a depth 5 to 15% smaller than the radius, the number of notches in one direction being in the range 3 to 50 and the ratio of the number of notches in the straight and reverse direction being 0.3:1.0 to 1.0:0.3.
In the apparatus the notches are made in the straight and reverse direction within the casing in the inner surface of a detachable or releasable sleeve comprising one or two parts.
The worms can be formed on the outer surface of one detachable sleeve or both sleeves.
The cooling elements in the apparatus are constructed as single start, helical grooves with an increased surface area of the walls on the detachable sleeves of the casing and the worms on the side free from the starting cuts for the through-flow of the cooling medium.
In the construction of the apparatus, the drive is based on an electric motor with a constant or variable speed and a control range of 1:15.
Such a construction of the apparatus provides conditions for the two-stage crushing of rubber, initially an increase in the volume stress and temperature with the necessary speed and the simultaneous gas saturation of rubber accompanied by the formation of a porous structure in the particle volume and then on greatly reducing the volume stress with the preset speed where the porous structure is destroyed, the specific, geometrical surface of the rubber particles is increased and the particles are cooled.
Thus, according to the invention, the crushing of scrap tyre pieces and rubber article waste with a size of 10 to 15 mm takes place in the above-described apparatus in two stages ensuring a comminution of rubber in accordance with the following diagram. On the rubber pieces acts an increasing, pulsating volume stress with an amplitude of 5 to 20 MPa and a frequency of 5 to 500 Hz in a range of 15 to 150 MPa. The increase rate is 5 to 90 MPa/s, which leads to a rapid heating and crushing of the rubber to be processed. Heating takes place at a rate of 50 to 150° C./s to 90-380° C./s, as a function of the rubber type to be processed.
The precision of maintaining the temperature of the object to be crushed is ensured by a regulatable liquid cooling of the apparatus.
Such a diagram of producing in the apparatus the pulsating pressure and heating not only contributes to the crushing of the rubber, but also to its gas saturation with volatile substances, which are formed during the heating and degradation of the plasticizers and other constituents, which contain volatile substances or which are separated during degradation.
The construction of the porous structure in the particles of the crushed rubber can be clearly gathered from FIG. 1. It is also pointed out that the necessary volume stress values are also determined by the rubber type and are dependent on the rubber deformation elastic component. The elastic component limit during deformation with uniaxial expansion can be obtained mathematically according to the formula:

γ=δ/2 δT

Where δ is the difference of the normal stresses and δT the tangential stress—Tager A. A., Physical Chemistry of Polymers, 1968, “Chimiya” publishing house, Moscow, p 261.
In this crushing stage it is necessary to deform the vulcanized rubber in a range of 105 to 250% of the rubber deformation elastic component limit. The deformation quantity of the rubber of 105 to 145% makes it possible to destroy particles of vulcanizates with a high plastic component of deformation and 150 to 250% with a high deformation elastic component.
The next rubber crushing stage in the apparatus comprises a strong decrease in the volume stresses at a rate of 15 to 150 MPa/s, which leads to the tearing of the pores and to the formation of large numbers of microcracks on the surface of the rubber particles, which gives rise to a marked increase in the specific, geometrical surface thereof and correspondingly an increase in the physical and chemical activity (FIG. 2) and the cooling of the powder to be discharged to a temperature of 40 to 60° C.
As has been shown by experiments, the use of heterogeneity modifiers leads to a marked increase in the number of microcracks in rubber powder particles, these including alcohol telomers of formula H(CF2—CF2)n—CH2OH, where n>4, N-nitrosodiphenylamine, N-cyclohexylthiophthalimide and chlorinated paraffin.
The use of these modifiers in a quantity of 0.1 to 1.9% makes it possible:

    
    
        to shorten the time for reaching the optimum stress values in the first processing stage by increasing the volume of the rubber pieces to be transported (reduction of the rubber/metal friction coefficient), which makes it possible to increase the apparatus efficiency by 10 to 55%,
        to increase the specific, geometrical surface of the powder by 15 to 40%,
        to increase the maintaining of the nigh physical and chemical activity of the rubber powder from 7 to 30 days to 6 to 9 months,
        to avoid caking of the active rubber powder during storage and transportation.
    
    


All the elements of the movable and stationary parts of the apparatus ensures the performance of the process according to the invention.
The first crushing stage characteristic for sliding crushing takes place between the combs of the compacting worm at the end thereof. The necessary rate of rise of the volume stresses and temperature, as well as the efficiency of rubber crushing in this stage are determined by the speed of the worm, the ratio of the thread lead of the combs of the compacting worm and the notches on the casing surface facing the worm, together with the extension of the worm along the rotation axis.
The pulsation of the volume stress intensifies the compacting, heating and crushing processes. The frequency and amplitude of the pulsation of the volume stress are predetermined by the number of helical notches in the reverse direction on the casing surface facing the worms, the number of starts on the compacting worm and the number of helical notches on the activator surface.
The gas saturation of the rubber particles and the formation of gas-filled micropores therein starts at the end of the compacting worm following on to the activator and ends at the start of the discharging worm, when the pressure on the material starts to decrease sharply. As a result of the starting cut pitch of the notches and their number on the activator surface, as well as by the length thereof, it is possible to regulate the gas saturation process via a more uniform thorough heating of the material and a more complete evaporation of the rubber constituents.
Thus, the activator regulates the crushing process in that it creates the conditions of a more uniform thorough heating of the material up to higher temperatures.
The second crushing stage starts at the beginning of the discharging worm following on to the activator and ends in the vicinity of the discharging connection. During the performance thereof it is important to maintain the material volume stress drop rate and avoid a premature reduction to the pressure in the micropores, which destroy the micropore walls and therefore greatly reduces the specific, geometrical surface of the particles and decreases the temperature thereof. The volume pressure drop rate is determined by the interturn space volume between the combs in the straight direction of this worm part, their starting cut pitch and the depth of the turns, as well as the starting cut pitch and number of starts of the helical notches in the straight direction on the casing surface facing the worm.
The presence of multistart, helical notches in the reverse direction with the same pitch as the combs in the straight direction, but with a smaller number of notches (or starts) on the discharging worm influences the temperature of the powder passing out of the discharge opening of the apparatus.
The comparison of the inventive technical solution with the closest prior art makes it possible to assert that the novelty criterion is fulfilled and the lack in the known technical solutions of the characterizing features of the inventive process and apparatus for the production of a highly active rubber powder makes it clear that the solution according to the invention has the necessary inventive merit.



FIG. 1 is a photograph of the rubber particles obtained by scanning electron microscope JSV-840 (JOEL) at the time of the formation of the porous structure in the initial (first) tyre rubber crushing stage.
FIG. 2 is a photograph of rubber particles obtained with the same scanning electron microscope after the formation of microcracks by tearing of the pores in the case of a strong volume stress drop during tyre rubber crushing.
FIG. 3 is a longitudinal section through the apparatus according to the invention.



The apparatus for the production of a highly active rubber powder from scrap tyres and rubber article waste (FIG. 3) has a casing 1 with a charging connection 2 and a discharging connection 3 within which is located an activator 4, in whose lateral face are formed multistart, helical notches in the straight and reverse directions, as well as a discharging connection 5 with multistart, helical combs in the straight direction and which are cut through in the reverse direction by helical notches.
On the charging connection side of the activator is coupled a multistart compacting worm 6 and/or is constructed in one piece therewith. The compacting worm and the activator are fitted to a shaft 8 and constructed on the outer surface of a detachable sleeve and on the inside thereof is provided a cooling element in the form of a single-start, helical channel.
On the inner surface of the casing 1 is mounted a detachable sleeve 9, on whose inner surface facing the compacting worm 6 are formed multistart, helical notches with a semicircular profile in the straight and reverse direction, as well as on the surface facing the activator. On the outside of the sleeve 9 is formed a cooling element 10 as a single start, helical channel.
Below the charging connection there are three to six rectangular ribs 11 uniformly distributed around the circumference of the casing 1.
Thus, within the casing 1 two size reduction or crushing zones are formed.
The first zone has a charging area, a compacting area and a first crushing area and is formed by the multistart compacting worm 6 and a part of the sleeve 9 surrounding the same and on whose inner surface is provided a conical opening up to the first crushing area with the three to six ribs 11 and also a cylindrical opening with a diameter 1.003 to 1.02 times larger than the diameter of the compacting worm 6 and in the inner surface of the latter and with a pitch which is 0.5 to 1.5 times larger than the starting cut pitch of the compacting worm, are formed 3 to 50 multistart, helical notches with a constant depth and located in the straight and/or reverse direction. The ratio of the lengths along the rotation axis of the compacting area and the first crushing area is in a range 1:05. to 0.5:1. The multistart, helical notches are formed with a semicircular cross-sectional profile with a radius amounting to 0.005 to 0.03 times the compacting worm diameter and with a depth which is 5 to 15% smaller than the radius, the ratio between the number of notches in the straight and reverse direction being in a range 0.3:1.0 to 1.0:0.3.
The second crushing zone has a gas saturation area, a second crushing area and a discharging area. They are formed by an activator in the form of a rotary body and a discharging worm rigidly coupled thereto, as well as a casing surrounding the two components. The activator with the discharging worm is aligned with the compacting worm and is coaxial to the casing inner surface. In the outer surface of the activator and with a pitch which is 1.1 to 2.5 times greater than the starting cut pitch of the compacting worm are formed multistart, helical notches with a constant depth in the straight and reverse direction and with the same pitch and the same number of starts and on the outer surface of the discharging worm are provided multistart, helical combs in the straight direction with a pitch which is 1.15 to 3.0 times greater than the starting cut pitch of the compacting worm, with a volume of the interturn space which increases in the discharging connection direction. The worm combs are either continuous or are interrupted by the helical notches in the reverse direction with a pitch equal to the starting cut pitch of the combs.
The casing inner surface which is cylindrical and surrounds the activator and discharging worm is provided with multistart, helical notches, which are formed with a pitch which is 0.5 to 1.5 times smaller than the starting cut pitch of the notches on the activator and the combs on the discharging worm in the straight and reverse direction. The ratio of the lengths along the rotation axis of the activator and the discharging worm are in a range 0.2:1 to 1:0.3 and the multistart, helical notches on the casing, activator and discharging worm have a semicircular cross-sectional profile with a radius which is 0.005 to 0.03 times the compacting worm diameter and a depth which is 5 to 15% smaller than the radius, the ratio between the number of notches in the straight and reverse directions being in a range of 0.3:1.0 to 1.0:0.3.
The main principle of the process is implemented in the apparatus shown in FIG. 3.
The rubber fragments previously crushed to a size of 15 mm are uniformly supplied to the charging connection 2 by a dosing mechanism not shown in FIG. 3. In the apparatus the rubber fragments are taken up by the combs of the compacting worm 6 and guided over the turns thereof with a decreasing depth start to compact. There is an increase in the volume stresses and temperature of the material. When the material reaches the first crushing area the volume stress rise rate reaches a maximum, the pulsation amplitude increases and as a result the rubber rapidly heats through. On reaching the first crushing area the rubber is destroyed under the action of the pulsating volume stress at a specific temperature (characteristic of the particular rubber). Simultaneously the gas saturation of the particles with the degradation products of the rubber and the formation of the porous structure therein commences.
On passing to activator 4 of the gas saturation area there is a thorough heating of the rubber under the action of the volume stress pulsation up to the maximum temperature. The rubber degradation products evaporate to an extreme level and the rubber particle gas saturation reaches a maximum. At the discharging worm of the second crushing area there is a pronounced decrease in the volume stresses acting on the rubber and the gas pressure tears the pores of the fine rubber particles, the specific, geometrical surface of the particles being enlarged many times. Simultaneously there is a reduction in the temperature of the rubber particles and this is continued on contact with the walls of sleeves 6 and 9.
Crushing temperature control is maintained in an optimum manner as a result of the constant pumping of the refrigerant through the coolants of the compacting worm, working member and casing. The presence of these zones in the inventive apparatus contributes to a considerable increase in its efficiency (1.5 to 2.7 times).
FIG. 3 does not show the apparatus drive. The operating parameters of the processing of tyre rubber with textile cord are given in table 1.
In an example of the implementation of the process in the apparatus the operating parameters thereof are given with a compacting worm diameter of 230 mm. The ratio of the compacting worm length along the rotation axis to the length of the activator and the discharging worm is 0.91 and the ratio of the activator length to the discharging worm length is 0.33.
The compacting worm has two starts and the casing inner surface starting cut following on to the compacting worm is formed by multistart, helical notches, the ratio of the number of notches in the straight and reverse directions being 0.5.
The activator is formed by the starting cut on the outer surface of multistart, helical notches in the straight and reverse direction in equal numbers and with a pitch which is 1.2 times greater than the starting cut pitch of the compacting worm combs.
The discharging worm is formed by the starting cut on the outer surface of multistart, helical combs in the straight direction with a pitch which is 1.2 times greater than the starting cut pitch of the compacting worm combs with a number of combs being equal to 0.5 times the number of notches of the activator in the straight direction.
The helical combs are cut through by the same number of notches with the same pitch, but in the reverse direction.
On the casing inner surface surrounding the activator and the discharging worm are formed multistart, helical notches in the straight and reverse direction with a ratio of 0.5 and a pitch 1.2 times smaller than the starting cut pitch of the activator notches.







TABLE 1





Operating parameters of processing tyre rubber with textile cord

























Vol. stress
Temperature
Rubber






in first
in first
powder


Test
Shaft speed
Output
Apparatus
crushing zone
crushing
temperature


No.
min−1
kg/h
transit times
MPa
zone, ° C.
at outlet ° C.





1
32
80
6.0 + 0.8
42
155
35


2
47
145
3.4 + 1.0
68
167
40


3
56
166
2.1 + 1.3
90
170
42


4
67
130
1.3 + 0.9
70
176
48


5
76
105
1.7 + 0.4
60
153
57


6
96
91
1.5 + 0.3
30
150
34


7
60
154
3.3 + 2.7
150
185
71


 8*
56
192
2.2 + 1.3
92
171
44





















Specific




Volume
Volume
Volume
Volume
energy



stress
stress
stress
stress
consumption
Specific



pulsation
pulsation
increase
decrease
for powder
geometrical



amplitude ±
frequency
rate
rate
production
surface


Test No.
MPa
Hz
MPa/s
MPa/s
kWh/t
m2/g





1
3-7
16-305
5-7
50-55
800
0.51


2
5-9
23-450
20-25
60-70
540
0.78


3
 8-14
28-535
42-46
70-75
430
0.82


4
12-16
34-645
52-55
80-95
515
0.68


5
15-18
38-731
85-90
140-150
760
0.59


6
15-20
48-922
60-70
120-130
800
0.56


7
 8-14
30-576
45-50
56-61
486
0.9


 8*
 8-14
28-535
42-46
70-75
415
1.05





*N.B. During rubber powder production crushing took place in the presence of the heterogeneity modifier.






As is apparent from the characteristic values given in table 1, the proposed apparatus makes it possible to implement the process for the production of a highly active power over the entire range of the inventive operating parameters with the technical characteristics, which are much higher than those described in the prototype (closest prior art).
As is apparent from table 1, when crushing tyre rubber with textile cord, the apparatus makes it possible to produce powder under optimum operating parameters by modifying the shaft speed and the material a supply rate (output).
Thus, the powder to be produced at a shaft speed of 56 min−1 (test no. 3) and output of 166 kg/h, had a specific geometrical surface of 0.82 m2/g and a specific energy consumption of 430 kWh/t.
Moreover, the output was 192 kg/h when processing tyre rubber with textile cord in the presence of a heterogeneity modifier in a quantity of 0.2% (test no. 8) for the same shaft speed of 56 min−1, whilst the specific, geometrical surface increased to 1.05 m2/g and the energy consumption decreased to 415 kWh/t.
The tests performed confirmed a very extensive industrial usability.
The implementation of the composed, complex technical solution for the production of active rubber powders from scrap tyres and rubber article waste on the basis of different rubber types can be illustrated by the following examples.
EXAMPLE 1
The up to 15 mm pieces of scrap bus types with textile cord underwent crushing in the described apparatus with and without a heterogeneity modifier and with the following operating parameters:

    
    
        volume stress rise: 10 to 90 MPa, amplitude: 8 to 14 MPa rate of rise: 42 to 46 MPa/s,
        rubber particle deformation: 150 to 180% of the elastic component limit,
        crushing temperature: 170° C., temperature rise rate: 80 to 95° C./s,
        volume stress decrease with speed of 70 to 75 MPa/s.
    
    


The crushing led to rubber powders with the following fraction composition (without modifier):

    
    
        69% of the particles with a size of 0.1 to 0.8 mm and 24% of the particles with a size of 0.81 to 1.6 mm,
        7% synthetic cord fibres, and (with modifier)
        78% of the particles with a size 0.1 to 0.8 mm and 15% of the particles with a size of 0.81 to 1.3 mm,
        7% synthetic cord fibres.
    
    


The rubber powder also underwent a vibration-air separation with respect to synthetic cord fragments and was simultaneously fractionated in accordance with the desired particle size.
The fraction of the active rubber powder with a particle size of up to 0.8 mm was used for producing recycling rubber by prior mixing of the powder with the raw rubber mixture, which was intended for the manufacture of bus tyre rubber tread.
Table 1.1 gives technical data of the process for the production of active rubber powder and the characteristic values of its activity (specific surface). The starting material was bus tyres.










TABLE 1.1









Specific power consumption
Specific geometrical surface



for powder production kWh/t
of powder m2/g












without
with
without
with


Test no.
modifier
modifier
modifier
modifier





1
420
405
0.65
0.78


2
430
415
0.82
1.05









Table 1.2 reveals the plastoelastic and physicomechanical characteristics of bus tyre tread rubber, having the active rubber powder produced by various processes.







TABLE 1.2





List of plastoelastic and physicomechanical characteristics of bus tyre tread rubber having


the active rubber powder (ARP) produced during the disposal of tyres (size up to 0.8 mm).

















Number of ARP parts by weight/100 parts by weight of rubber phase



ARP type










ARP unmodified
ARP modified


















Characteristics
0
5
10
15
20
40
5
10
15
20
40





Plasticity, agreed unit
0.40
0.41
0.42
0.40
0.46
0.40
0.43
0.45
0.41
0.49
0.44


Mooney viscosity
60
61
61
60
61
65
55
58
52
53
50


100° C. × 4 min


Vulcanization rate*,
10
10
9.5
9.7
9.7
9.7
8.0
9.0
9.0
10.0
9.0


150° C. × 30 min,


T = 90 min


Modulus of elasticity
8.8
8.8
8.8
8.5
7.8
7.5
10.4
10.1
9.9
7.6
9.0


300%, MPa


Tensile strength, MPa
18.9
19.5
17.8
17.6
15.2
12.5
19.3
19.7
19.5
16.6
16.1


Relative elongation
510
526
510
510
510
504
482
517
470
517
470


at break, %


Relativeresidual
16
16
17
17
19
14
16
17
12
12
12


elongation after break, %


Breaking strength, MPa
8.6
11.3
9.1
8.9
8.7
8.2
9.6
9.1
9.1
9.0
8.4


Shore A hardness
61
64
67
65
63
65
66
66
65
60
64


Volume losses on abrading
32
34
24
29
35
55
32
34
32
32
35












Number of ARP parts by weight/100 parts by weight of rubber phase



ARP type



ARP modified + 3% cord












Characteristics
5
10
15
20
40





Plasticity, agreed unit
0.48
0.46
0.46
0.42
0.48


Mooney viscosity
55
54
56
57
61


100° C. × 4 min


Vulcanization rate*,
8.0
7.0
8.0
8.0
8.0


150° C. × 30 min,


T = 90 min


Modulus of elasticity
10.9
10.9
10.2
9.9
9.8


300%, MPa


Tensile strength, MPa
19.8
18.8
18.9
18.3
17.3


Relative elongation
500
492
495
510
492


at break, %


Relative residual
16
12
12
12
12


elongation after


break, %


Breaking strength, MPa
9.0
9.0
8.4
8.1
9.7


Shore A hardness
66
67
66
66
66


Volume losses on abrading
32
34
34
32
34





*Monsanto rheometer


Notes:


1. Modified ARP can be very well homogenized during the production of rubber mixtures.


2. Vulcanized, modified ARP-containing rubbers have a planar, smooth surface.






As is apparent from the tables, the process according to the invention makes it possible to produce a high grade, active rubber powder, whose introduction into the tread rubber in values of up to 10 parts by weight leads to no deterioration in the characteristics thereof. When using the heterogeneity modifier during crushing, the quantity of powder to be introduced can be increased by at least up to 15 parts by weight. The use of modifiers also makes it possible to reduce energy consumption during crushing and increase the plant output (by 15 to 55%, as shown by the tests).
EXAMPLE 2
Waste from rubber articles based on ethylene-propylene rubber with a particle size of up to 15 mm were crushed in the described apparatus with and without a heterogeneity modifier and with the following operating parameters:

    
    
        volume stress rise: 10 to 140 MPa, amplitude: 6 to 12 MPa, rate of rise: 40 to 50 MPa/s,
        deformation of rubber particles: 130 to 170% of the elastic component limit,
        crushing temperature: 210 to 240° C., temperature rise rate: 70 to 90° C./s,
        volume stress decrease at rate of 30 to 40 MPa/s.
    
    


The rubber powder produced with the modifier consists of 84% particles of size 0.1 to 0.8 mm and 16% of particles of size 0.81 to 1.25 mm and the rubber powder produced without a modifier consists of 79% particles of size 0.1 to 0.8 mm and 11% particles of size 0.81 to 1.45 mm.
The fraction of the active rubber powder with the particle size of up to 0.8 mm was used for producing recycling rubber by premixing the powder with the raw rubber mixture based on ethylene-propylene rubber intended for the production of rubber articles.
Table 2.1 gives the technical data of the process for the production of the active rubber powder and it's specific, geometrical surface.










TABLE 2.1









Specific power consumption
Specific, geometrical powder



for powder production kWh/t
surface m2/g











Starting
without
with
without
with


material
modifier
modifier
modifier
modifier





Rubber
400
370
0.75
1.05


article


waste









Table 2.2 gives the physicomechanical characteristics of rubber based on ethylene-propylene rubber containing the rubber powder produced with and without modifier.









TABLE 2.2









Number of ARP parts by weight/100 parts by weight of rubber phase



ARP type










ARP unmodified
Arp modified
















Characteristics
0
5
10
20
40
5
10
20
40



















Plasticity
0.52
0.52
0.50
0.50
0.52
0.54
0.56
0.56
0.54


Tensile
160
165
168
170
155
170
172
176
170


strength MPa


Relative
280
286
284
284
280
296
296
290
284


elongation %


Impact
36
38
38
40
38
38
40
42
42


elasticity %









The results make it clear that the process according to the invention leads to the obtaining of rubber mixtures based on ethylene-propylene rubbers containing up to 40 parts by weight of the powder with no significant deterioration in the technical and technological characteristics.
EXAMPLE 3
Rubber article waste based on fluorinated rubber-vinylidene fluoride-trichlorofluoroethylene copolymer—of particle size up to 15 mm underwent crushing in the described apparatus in the presence of a modifier and with the following operating parameters:

    
    
        volume stress rise: 10 to 190 MPa, amplitude: 10 to 16 MPa, rate of rise: 40 to 70 MPa/s,
        deformation of rubber particles: 150 to 190% of elastic component limit,
        crushing temperature: 240 to 270° C., temperature rise rate: 90 to 125° C./s,
        volume stress decrease with rate of 60 to 80 MPa/s.
    
    


The fraction of the active rubber powder with particle size up to 0.8 mm was used for introduction in a quantity of 5 to 15 parts by weight into the rubber mixture having the following composition:

    
    
        SKF 32*: 100 parts by weight,
        copper-salicylalimine: 5 parts by weight,
        zinc white: 5 parts by weight,
        technical carbon η-701: 30 parts by weight,
        calcium stearate: 5 parts by weight.
    
    


Technical characteristics of the test rubber are given in table 3.1.














TABLE 3.1










Relative
Relative
Weight



Tensile
Relative
Residual

elongation
compression
change SZR-1,



strength,
elongation,
elongation,
Shore A
change at
set 20%,
23° C.,


Sample
MPa
%
%
hardness
200%, 72 h, %
150° C., 24 h
24 h %






















Starting
25.5
105
2
80
−50.9
62.8
2.5


sample


Starting sample + 5
20.5
95
4
82
−49.4
65.0
1.5


parts by weight of powder


Starting sample + 10
23.5
120
5
81
−48.3
66.7
1.6


parts by weight of powder


Starting sample + 15
22.0
115
6
78
−41.5
61.1
1.5


parts by weight of powder


Standard value
no less
no less
no more
76-86
−65 + 25
no more
0-3.5



than 20
than 90
than 10


than 70





*SKF-32: vinylidene fluoride-trichlorofluoroethylene copolymer.






As is apparent from the results submitted, the introduction of the active rubber powder produced from fluorinated rubber-based product into the primary starting rubber in a quantity of up to 15 parts by weight does not modify the technical characteristics thereof.
EXAMPLES 4 to 10
The processes were performed similar to examples 1 and 2. However, in addition, 20 to 40% of the waste of high and low pressure polyethylene and polypropylene were introduced. A mixed material was obtained with a volume stress rise of 15 to 200 MPa, amplitude of 12 to 16 MPa, rate of rise 50 to 60 MPa/s, temperature of 180 to 230° C., temperature rise rate of 100 to 110° C./s and volume stress values giving rise to a deformation of the rubber particles of 115 to 175% of the limit of the elastic deformation component of the starting rubber and a volume stress decrease with a rate of 70 to 90 MPa/s. The modifier must be present. The mixed powders obtained consisted of 82 to 94% of particles with a size up to 0.8 mm. These powders were also treated using an extrusion or calendering process at temperatures of 290 to 240° C. in order to obtain plate-like, thermoplastic materials, whose properties are given in table 4.1.









TABLE 4.1









Physicomechanical characteristics















Rela-






Tensile
tive
Shore A
Breaking


Exam-

strength,
elonga-
hard-
strength,


ple No.
Material
MPa
tion, %
ness
MPa















1
Scrap tyre rubber +
26.5
450
68
12.6



40% high pressure



polyethylene waste


2
Scrap tyre rubber +
24.8
400
70
11.8



20% low pressure



polyethylene waste


3
Scrap tyre rubber +
25.4
220
84
13.6



20% polypropylene



waste


4
Scrap tyre rubber +
29.2
180
88
14.8



40% polypropylene



waste


5
Rubber waste based
26.2
380
72
8.9



on ethylene-



propylene rubber +



40% high pressure



polyethylene waste


6
Rubber waste based
26.8
260
84
9.2



on ethylene-



propylene rubber +



40% low pressure



polyethylene waste


7
Rubber waste based
28.0
210
82
9.1



on ethylene-



propylene rubber +



20% polypropylene



waste









EXAMPLE 11
The waste from rubber articles based on ethylene-propylene rubber with a particle size of 10 to 20 mm underwent crushing in the apparatus with the following operating parameters, the working surfaces of the sleeves being treated with fluoro-organic alcohol telomers and coated with an underlayer of tungsten carbide containing cobalt and with a total thickness of 0.3±0.1 mm:

    
    
        volume stress rise: 20 to 120 MPa, amplitude: 8 to 12 MPa, rate of rise: 50±5 MPa/s,
        crushing temperature: 200 to 215° C., temperature rise rate: 60 to 75° C./s,
        volume stress decrease with a rate of 20 to 30 MPa/s.
    
    


















Rubber powder





quantity with


Starting
Power consumption
Capacity
particle size


material
cf modifier, kW
kg/h
below 0.8 mm
















Rubber article
without treatment of the working surfaces of the sleeves










waste based
67 to 70
160 to 165
64 to 66


on ethylene-








propylene
with treatment of the working surfaces of the sleeves










rubber
55 to 60
210 to 225
72 to 75

## Claims

1. An apparatus for the manufacture of highly active rubber powders from scrap tires and waste of rubber articles, which apparatus comprises a cylindrical casing having a charging connection and a discharging connection, and within which casing are first and second size reducing crushing zones, wherein present through each of these zones is a compacting worm with a reduction in the depth of grooves between combs decreasing in a direction of the crushing zones, and an activator in the form of a rotating body, on whose outer working surface slots are formed, each of the compacting worm and the activator being mounted in rotary manner coaxial relative to an inner surface of the casing accompanied by the formation of an annular clearance with the casing's inner surface, and within the casing, the compacting worm and the activator being provided with cooling elements; and
wherein the first size reducing crushing zone has a charging area, a compacting area and a first crushing area, and the compacting worm is a multistart compacting worm with an interturn gap volume decreasing in a direction of the discharge connection and the casing surrounding the discharge connection;
wherein the casing's inner surface in the compacting area includes a conical opening inclined in a direction of the discharge connection and having 3 to 6 ribs with a rectangular cross-section engaging in the interior of the casing; wherein the first crushing zone the casing inner surface includes a cylindrical opening having a diameter which is 1.003 to 1.02 times larger than a diameter of the compacting worm, and the casing inner surface includes a starting cut pitch 0.5 to 1.5 times larger than a starting cut pitch of the compacting worm, wherein helical notches are present in multistart form with 3 to 50 starts and a constant depth in a straight and/or reverse direction and where a ratio of the of the compacting area and the first crushing area along a rotation axis of the worm is in the range 1:0.5 to 0.5:1; wherein said first and second size reducing crushing zones are formed on replaceable, detachable sleeves, which are mountable on a shaft or on the casing, and have on one side of each sleeve are working surfaces and on the other side of each sleeve are helical grooves with an increased surface area of walls of the sleeves for pumping a cooling medium; the second size reducing zone having a gas saturation area, a second crushing area, and a discharging area, and including an activator in the form of a rotating body and a discharge worm rigidly connected thereto and fitted in aligned manner with the compacting worm, as well as a cylindrical casing surrounding the activator and the compacting worm, while an outer surface of the activator includes a pitch which is 1.1 to 2.5 times greater than a starting cut pitch of the compacting worm, multistart helical notches with a constant depth in straight and reverse directions with the same pitch and the same number of starts, and on an outer surface of the discharge worm are multistart, helical combs in a straight direction with a pitch 1.15 to 3.0 times greater than the starting cut pitch of the compacting worm with an interturn gap increasing in the direction of the discharge connection, the helical combs being constructed continuously or are interrupted by helical notches in a reverse direction with a pitch equal to a starting cut pitch of the helical combs; the cylindrical casing inner surface surrounding the activator and a discharge worm includes multistart, helical notches constructed with a pitch of 0.5 to 1.5 times smaller than a starting cut pitch of notches on the activator and the combs of the discharge worm in the straight and reverse directions, the ratio of extensions of the activator and the discharge worm along their rotation axis being in the range of 0.2:1 to 1:0.3 of said working surfaces of the activator, the discharge worm and the casing on the replaceable sleeves being on one side of the sleeve, and on the other side of the sleeve are cut helical channels with an increased surface area of the sleeve walls for pumping the cooling medium, the multistart, helical notches being constructed with a semicircular profile with a radius which is 0.005 to 0.03 times the discharge worm diameter and a depth which is 5 to 15% smaller than the discharge worm radius, and the ratio of the number of notches in the straight and reverse directions being in the range of 0.3:1.0 to 1.0:0.3.

2. The apparatus according to claim 1, wherein the replaceable, detachable sleeves of the casing and the shaft are constructed in the form of one or more parts.

3. The apparatus according to claim 1 wherein the casing is constructed in the form of one or more parts.

4. The apparatus according to claim 1 wherein the annular clearance between the activator and the discharge worm and the casing inner surface is 1.4 to 2.5 times and the depth of the multistart notches on the casing and activator are 2.0 to 4.5 times larger than the annular clearance between the compacting worm and the casing inner surface.

5. The apparatus according to claim 1 wherein the ratio of the extensions of the first and second size reducing zones along the rotation axis is in the range of 0.5 to 1.2.

6. The apparatus according to claim 1 wherein the working surfaces of the replaceable, detachable sleeves of the casing and the shaft have been treated with materials containing tungsten, chromium, nickel, boron, molybdenum, as well as carbides and nitrides of very high melting point metals, in the presence of fluoroorganic substances.