End-of-Life Tire Recycling
Brazil generates 450,000 tons of end-of-life tires per year (Reciclanip). CONAMA Resolution No. 416/2009 requires manufacturers and importers to collect and properly dispose of tires at a 1:1 ratio (passenger) or 1:3.5 (truck/off-road). Fines for non-compliance reach R$ 50 million. Landfill disposal and open-air burning are prohibited.
Shredding transforms end-of-life tires into a marketable product. Tire chips supply rubberized asphalt, co-processing in cement plants, industrial flooring and drainage works, priced at R$ 200-600/ton depending on particle size.
Process
Collection and preparation — Tires collected from reverse logistics points, tire shops and dealers. Sorting by type (passenger, truck, off-road). Removal of metal rims when present.
Primary shredding — D Line — Whole tires (passenger/pickup) or cut into 4-8 pieces (truck) feed the dual-shaft shredder. Low rotation (20-40 RPM) with high torque processes steel-reinforced rubber. Slip clutch absorbs bead impacts. Automatic reverse expels non-shreddable materials. Output size: 50-150 mm, adjustable.
Magnetic separation — Ferrous metal extractor removes steel beads and radial steel wires.
Secondary granulation (optional) — For flooring (1-10 mm) or rubber products (1-5 mm), chips pass through secondary granulators.
Classification and commercialization — Chips classified by particle size and stored for sale.
End Uses and Particle Size by Application
| Application | Particle Size | Notes |
|---|---|---|
| Drainage and civil works | 20-100 mm | Lightweight and permeable |
| Co-processing in cement plants | 50-100 mm | NCV 7,000-8,000 kcal/kg |
| Flooring and playgrounds | 1-10 mm | |
| Rubber products | 1-5 mm | |
| Rubberized asphalt | 0.8-1.0 mm | 40-60% longer lifespan than conventional |
Equipment: D57 Shredder
| Feature | D57 |
|---|---|
| Power | 125-250 hp |
| Cutting chamber | 1,250 x 1,375 mm |
| Rotor diameter | 665 mm |
| Blade width | 50-100 mm |
| Rotation | 12-30 RPM |
| Output size | 50-150 mm (adjustable with classifier) |
| Weight | 14,600 kg |
| Capacity | 5-20 ton/h |
- Bolted blades with high-hardness steel inserts (58-62 HRC).
- Insert replacement with hand tools, no welding required.
- Typical lifespan: 2,000-3,000 tons of passenger tires before insert change.
Other D Line models for tires
| Model | Power | Cutting chamber | Estimated capacity |
|---|---|---|---|
| D290 | 40 hp | 580 x 900 mm | Up to 1 ton/h |
| D365 | 75 hp | 710 x 1,025 mm | Up to 2 ton/h |
| D460 | 125 hp | 890 x 1,372 mm | Up to 3 ton/h |
| D535 | 200 hp | 1,068 x 1,610 mm | Up to 8 ton/h |
| D610 | 250 hp | 1,250 x 1,610 mm | Up to 15 ton/h |
- Capacities estimated for whole passenger tires.
- Actual capacity depends on tire type, preparation and particle size.
Operator Profile
- Tire recyclers and waste managers meeting CONAMA 416/2009 targets and selling chips.
- Manufacturers and importers structuring their own reverse logistics.
- Co-processing operators receiving whole tires and shredding them to feed cement kilns.
