Catalogo Pneus Inglese

1 We generate clean energy.

PNEUSGINEO

“The world is abeautiful place andfor it worth fi ghting for.”

(Albert Einstein)(Albert Einstein)

P R I M E I T A L I A

4 We help the environment. 5 We generate clean energy.

LESS WASTEMORE ENERGY

www.getenergyprimeitalia.com


INDEX Company Profile 06-07

General Information andSocial and Environmental Issues 08-14

Properties of Worn Tyres 15-16

Relevant legislation 17

Description and Operationof the Plant 18-21

The equipment 22-23

Production capacity of Pneus Gineo 200 24

Management of the Plant 25

Conclusions 26

LESS WASTEMORE ENERGY



Get Energy Prime Italia was founded in 1996 as Get Energy Research (Research Centre) and from the beginning it has always been focused on Research and Development of new energy sources, in collaboration with the research and study centre of the University of Warsaw (Poland) and Horus Energia S.p.A (Italy) (www.horus-energy.com).Founded with private capitals, thanks to its long experience and expertise Get Energy has recently obtained funding from the European Community to build the “Pneus Gineo” tire waste (End of Life Tires or ELT) processing plant and operate it as demonstration unit in the industrial area of Rieti.Our philosophy is to be an important and reliable partner of industries and businesses operating in the international energy sector. The mission of our R&D department is to design a processing plant based on a technology that safely and economically transforms rubber tires waste in valuable by-products which can provide an attractive return on investment. We believe that ELT waste, whose accumulation and storage pose complex environmental issues, can, through the pyrolysis process, not only bring an economic advantage to the operator but be an environmental success story as well.

GET ENERGY PRIME ITALIA IS A COMPANY ACTIVE IN THE FIELD OF RESEARCH, DEVELOPMENT, CONSTRUCTION AND SALE OF PLANTS TO PROCESS WASTE MATERIAL TO GENERATE ELECTRICITY AND COMMERCIALLY VIABLE WASTE BY-PRODUCTS.

COMPANY PROFILE

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8. 4.

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13.

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15.

14.


AT PRESENT, GET ENERGY PRIME ITALIA HAS COMMERCIAL CONTACTS AND NEGOTIATIONS IN THE FOLLOWING COUNTRIES: :1. ALBANIA2. ARGENTINA3. AUSTRALIA4. BULGARIA5. COLOMBIA6. BRITAIN7. HONDURAS8. ITALY9. MOROCCO10. NICARAGUA11. NEW ZEALAND12. POLAND13. REP. DOMINICANA14. SOUTH AFRICA15. TURKEY

3.

11.


The report “L’Italia del riciclo 2010” (Italy Recycling 2010) by the Italian Ministry for the Environment and ISPRA is one of the many studies presenting waste management principles and addressing the issue of ELTs.

In dealing with tires, the many reports indicate that the fi rst problem to be addressed is the inventory and the waste management characteristics of ELTs. This issue is particularly relevant in countries listed as emerging economies.For example, the current evolution of the Chinese economy has dramatically contributed to the increase in generation of used tires. The United

WORLDWIDE, ABOUT 4.5 MILLION TONS PER YEAR END UP IN LANDFILLS,SEAS AND OCEANS OR IS ILLEGALLY BURNED.

General Information andSocial and Environmental Issues


States have now been replaced by China as world leader in ELT generation, with over 200 million tires per year (approximately 5 million tons).

Although until recently ELTs were sent to dedicated or mixed waste landfills, legislation was passed banning (with few exceptions) landfill disposal in the USA and, since July 2003, in Europe. Nevertheless, approximately one third of the 13.5 million tons of ELTs produced every year in the world are still either disposed of in uncontrolled or illegal landfills or burned.



The more alarming illegal practice associated with ELT disposal is, however, ‘open air combustion’ of tires.The smoke produced by uncontrolled burning contains serious pollutants like aromatic hydrocarbons, sulphur compounds, carbon monoxide and nitrogen oxides.


COMPONENT CONCENTRATION(g/kg of burnt ELTs)

CO2 1.450CO 35N2O 0,9NO 3,2SO2 15HCN 4HCI -UNBURNT HYDROCARBONS(Benzene, Toluene, ecc)

23

POWDERS 285METALS (included Al and Zn) 31,9IPA 0,0633PCB 2,66 x 10-4

DIOXINS/FURANS 6,44 x 10-7

Source: SNCP 2007

SMOKE COMPOSITION FROM UNCONTROLLED BURNING OF ELTs


The high temperatures reached during the fi re cause also the decomposition of the rubber mix and the production of hydrocarbon oils of different molecular weight that facilitate the propagation of the fi re.The fi re extinction can also be hazardous since chemical leaches can contain heavy metals in such a concentration as to pollute the underground layer.This is the reason why landfi ll disposal has been progressively outlawed in Japan, North America and Europe.

As it was the case in the USA, the prohibition of landfi ll disposal of ELTs, introduced in Europe by EC Directive 1999/31 and adopted in Italy with Italian Legislative Decree No 36/2003 has revolutionized the entire ELTs chain, favouring the implementation of new recovery methods. Since 2006 landfi ll disposal of both whole and shredded tyres has been forbidden, except for tyres used as engineering material and those with an outside diameter above 1,400 mm.

At present the fi ght is against illegal ETLs dumping sites, that cannot be controlled and represent a further hazard for human health and the environment.

In Europe, as in the United States, until recently tyres have been channelled to landfi ll. With an annual growth of tyres’ production of approximately 2.6%, the amount of waste to be managed has passed from 2.10 million tons in 1994 to 2.28 million tons in 2006 (EU 15); with the enlargement of the European Union to 27 member States, the total of ELTs can be estimated at 3.2 million tons/year.


SMOKE COMPOSITION FROM UNCONTROLLED BURNING OF ELTs


The Italian situation is different: even though approximately 48% of ELTs are used for energy recovery, the corresponding share of the real material recovery does not balance this ratio and there is still a high percentage (>25%) of material whose destination is uncertain.In Italy every year 100 thousand tons of end of life tyres disap-pear unknown, according to a Legambiente report concerning the period 2005 to 2010.The study has identified, since 2005, more than 1.050 illegal dumping sites on a territory of over 6 millions of square meters.

These illegal activities can be ascribed to Ecomafia but also to some operators that build small landfills in order to reduce the costs of disposal.Apulia has 230 ELT illegal sites, that account for 22% of the national total, followed by Calabria with 159 sites, Sicily with 141 and Campania with 131. Lazio has the negative record for the Centre, with 77 illegal dumping sites, whereas Piedmont is leader in the North with 37. For the State, the overall economic damage accounts for 2 billion Euros, including VAT evasion on disposal and reclamation costs. Another bad blow for the environment, in terms of landscape and health.

0

20

50

70

10

40

30

60

80

1994 1996 1998 2000 2002 2004 2006 2008

ENERGY

MATERIAL

EXPORT

LANDFILL


Source: ETRMA, 2008



MAIN APPLICATIONS FOR ELTs IN ITALY

RECOVERY APPLICATION QUANTITY (TON)*

NOTES

MATERIAL SOCCER FIELDSAND OTHER SPORTSURFACES

30.000 Contrary to what happens in Italy, the reuse of tyre frag-ments represents the widest application at international level

ANTISHOCKFLOORINGS

8.000 Including tile forms and in situpreparation

SOUNDPROOFING AND ANTI-VIBRANTSYSTEMS

5.000 Including anti-footstep mats, soundproofi ng, anti-vibrant pa-nels for the railway sector, etc.

APHALT 100 Not yet spread

OTHER 8.000 Urban and road furniture,rubber mixes, etc

ENERGY INITALIAN PLANTS

CEMENT PLANTS 60.000 Including applications as single fl ow and RDFmix → 5 operating plants

ELECTRIC POWERPRODUCTION

45.000 Both as single fl ow and RDF mix → 3 operating plants

PYROLYSIS ANDGASIFICATION

0 Plants under development but not in use yet

Source: Ecopneus on operational data of the sector* Note: quantities reported are representative of both the material

used in Italy and the exported material



The prohibition of landfi ll disposal of ELTs in the USA (introduced in Europe by the EC Directive 1999/31 and adopted in Italy with Legislative Decree No 36/2003) has changed the management practices and favoured the implementation of new recovery methods. This legislative change is particularly important in Italy because the Italian situation is rather peculiar: even though approximately 48% of ELTs are claimed to be used for energy recovery, the corresponding share of material recovery does not match this value and a considerable percentage (>25%) of material cannot be accounted for. This fact results in 100 thousand tons per year of ELTs not accounted for in the period 2005/2010 (as per a Legambiente report). The study also indicates that by the year 2005 more than thousand illegal dumping sites had been identifi ed on the national territory.

CONSIDERING ELT AS A RESOURCENOT WASTEThe European Union (EU) considers “waste minimization” the most desirable approach to

A DIFFERENT METHOD OF TREATMENT OF THE ELTHere we will discuss one of the several methods of processing ELT to recover its basic components based on ‘non-combustion’ thermal technologies. This heating process which induces thermal degradation (depolymerization) of granular rubber compound in an inert environment is called “pyrolysis”.PYROLYSIS OF RUBBER ORGANIC COMPOUNDS IN A TEMPERATURE CONTROLLED ENVIRONMENT WILL “CRACK” THEM INTO A SOLID FRACTION (CHAR) AND A GASEOUS ONE WHICH, THROUGH CONDENSATION, WILL YIELD A LIQUID PHASE AND AN INCONDENSABLE GASEOUS PHASE.The result of the pyrolysis process on ELT will be:

processing.

diesel/generator groups that can provide electricity to the processing plant and to the national electric grid.

mean of disposal of the by-product.

waste management while “re-use”, “recycling” and “component recovery” of waste material are all more desirable than ultimate “disposal”.Although the re-use of ELTs is considered the “Best Practicable Environmental Option”, the current ever growing proportion of ELTs not suitable for re-use poses a waste management problem because the recycling options is not available (ELT cannot be re-converted in rubber and steel for use).Only two approaches will prevent non-reusable old tires from being disposed in landfi lls: (a) the recovery of the tire ‘ingredients’ (combustible oils and char) and (b) the recovery of the tire energy content (heat).To defi ne the scale of the issue posed by ELTs in Europe will suffi ce to quantify the yearly rate of generation of ELTs: 3.3M tons/year in Europe, of which ~450,000 tons/year in Italy [source: www.etrma.org]. The “re-use” of old tires in their integral form (rethreading) or granular form (alternative uses, i.e. playground fl oors) is an established industry practice of limited applicability.



Properties of Worn Tyres

Char from pyrolysis

Source: Scientifi c Journal of Riga Technical University Environmental and Climate Technologies 2010 Volume 4.

SUBSTANCE CAR TYRES TRUCK TYRESNATURAL RUBBER 41-43% 34-35%COAL 38-32% 36-32%HYDROGEN 6–7% 5–6%SULPHUR 1–1,5% 1–1,5%IRON 10–12% 20–22%FILLERS 3–4% 3–4%TYRE WEIGHT 5–10 kg < 70 kg

COMPONENTI TIRE FOR PASSENGER CAR, WT % TIRE FOR TRUCK, WT %NATURAL RUBBER 22 30SYNTHETIC RUBBER 23 15SOOT 21,5 22METAL 16,5 25FIBRE 5,5 -ZINC OXIDE 1 2SULPHUR 1 1FILLERS 7,5 5JOINT CARBON MATERIALS 74 67AVERAGE WEIGHT OF NEW TIRE 8,5 KG 65 KGAVERAGE WEIGHT OF OLD TIRE 7 KG 56 KGNET CALORIFIC VALUE 30,2 MJ/KG 26,4 MJ/KGCARBON (C) 69 % 61 %SULPHUR 1,3% 1,4 %

RUBBER COMPOSITION OF CAR TYRES

THE VALUE OF ELT


The tire key elements are “natural rubber”, a natural polymeric material that obtained from latex sap of trees, and “synthetic rubber”, a rubber made by copolymerization of isobutylene (2-methylpropene (CH3)2C=CH2 with a small amount of isoprene. The Carbon fraction refers to “Carbon black”, a common tire manufacture additive; it is virtually pure elemental carbon in the form of colloidal particles (produced by incomplete combustion or thermal decomposition of gaseous or liquid hydrocarbons under controlled conditions).THE OVERALL COMPOSITION OF TIRES RESULTS IN A PRODUCT THAT, IN GENERAL, HAS MORE HEAT ENERGY BY WEIGHT THAN COAL (UP TO 37 MJ/KG VS. 27 MJ/KG).End of life tires should therefore be considered an economically valuable energy source and should be separated from general waste streams.

The collection and sorting of ELTs is the first step in managing this resource.

The “re-use” of old tires (by re-treading) will remove a percentage of old tires from the waste stream.The “recovery path” will see tires processed whole (via integrated processing –i.e. cement kilns-or, ultimately, in landfill disposal -where appropriate-) or in granular form (for component recovery).Using ambient or cryogenic processes (cooling of rubber to a temperature between –60o and – 100°C) the milling of tires will produce granular rubber of various sizes. This step allows the material generated to be used in other applications ranging from additive to asphalts, structural material in sport surfaces and children’s playgrounds, etc..The size of crumb rubber is related to the treatment used and is optimized for the final product destination. For example, ~4 cm3 particles seem to be optimal for some type of pyrolysis equipment while small particles (~1 mm diameter) favor other uses. Particle sizing is addressed in ASTM standards: the D5603 and D5644.Waste tires can also be used directly as fuels in incinerators, cement kilns and paper mills. Their high heating value makes them excellent materials for energy recovery. The disadvantages are the need for flue gas cleaning and CO2 emission. Tire pyrolysis (thermal decomposition in an oxygen-free environment) offers an environmentally attractive method. The products of tire pyrolysis process are: solid char (30-40 wt %), organic liquid residue (40-60 wt %), and gases (5-20 wt %). The solid residue contains carbon black and other mineral matters, the organic oils may be used directly as fuels, petroleum refinery feedstock or a source of chemicals and the gaseous fraction, composed of non-condensable organics as CH4, C2H4, C3H6 H2 e H2S, CO, CO2,etc., can be used to generate on-site heat. The energy required in the pyrolysis process can be generated by combustion, ultrasonic, microwave or induction heating.

Properties of Worn Tyres


Fractions of pyrolysis oil


The waste strategy conveyed in the various European Directives has, as its primary objective, the prevention of waste. The Directive 2008/98/EC defi nes prevention of waste as the best option.Used tires constitute a high volume waste because of the estimated 1 billion units generated per year in the world (Environment Agency, 2012; Shulman, 2004). The European Commission identifi ed waste tyres as one of the ‘priority waste streams’ from the mid-1990s (DEFRA, 2007) and it has since introduced legislation regulating their disposal.The Council Directive 1999/31/EC on the landfi ll of waste sets the objectives for landfi ll operational and technical requirements. Of signifi cance here is the fact that the Directive banned certain wastes, particularly tires, from landfi ll disposal. The 2000/53/EC Directive on end-of-life vehicles (2000) aims primarily to prevent waste arising from vehicle disposal and the reuse, recycling and recovery of the vehicles and their components. The reuse and recovery of waste tires makes a contribution toward directive compliance.The Directive 2000/76/EC on the incineration of waste aims to prevent or limit the negative environmental effects and the resulting risks to human health from the incineration and the co-incineration of waste. The Directive describes the requirements to obtain a permit to operate an incineration plant and defi nes incineration

plants as plants that thermally treat waste by oxidizing it, with or without the recovery of the combustion heat generated. It also includes other thermal treatment processes such as pyrolysis, gasifi cation or plasma processes as long as the substances obtained by these treatments are subsequently incinerated. Co-incineration plants include plants intended for the generation of energy or to produce material products such as cement kiln plants, but additionally use a waste stream as fuel or with the intention of its disposal.Directive 2008/98/EC on waste and repealing certain Directives: Article 6 of the Directive sets up conditions where waste ceases to be a waste when it has undergone a recovery operation and fulfi ls the following criteria:

specifi c purposes;

or object;

requirements for the specifi c purposes and meets the existing legislation, and

to overall adverse environmental or human health impacts”.The directive identifi es specifi c waste streams that meet the no-longer-waste criteria, tires are amongst them.

Relevant legislation


Description and Operation of the Plant


WORN TIRES(LIFE

TIRES LT)SHREDDER

DEPOLYME-RIZER

PYROLITHICOIL

(FUEL)

ELECTRICPOWER

GENERATOR

ELECTRICPOWER

COOLINGSYSTEM

FUELTANK

LTSHREDDED

DEPOLYME-


granular rubber hopper

chilled water to cooling coils

power toinduction heating

power supplyto plant/grid

gascondensers

air cooling

water cooling

char collection

diesel generator group

to atmosphere

to atmosphere

fi lter

secondarygroup

gasgenerator

oil collection tank

fi ltro ad acqua

pyrolysis chamberwith screw

displacement

N2 gas

PNEUSGINEO

A PLANT TOPROCESS

GRANULAR ELT




PLANT 1996

PLANT 2015

PLANT 2004


THE “PNEUS GINEO” IS A PLANT, BASED ON A NEW PROPRIETARY DESIGN, TO PROCESS ELT RUBBER IN GRANULAR FORM VIA PYROLYSIS. THE TECHNOLOGY, DEVELOPED BY GET ENERGY PRIME ITALIA IS BEING PATENTED (PYROLYSIS AND DIESEL GENERATOR PATENT PENDING) IS UTILIZED TO PRODUCE SOLID “CHAR” AND DIESEL GRADE COMBUSTIBLE OIL.

The process is optimized to fuel the diesel generator(s) to allow power to be supplied to the national electricity grid. A portion of the electricity generated is diverted to supply the plant with all its energy requirements during normal operation.The char collected is available for commercial use (as fuel, feed for activated carbon production or aggregate in industrial applications).Granular rubber (1 to 4 mm in size) is continuously fed to the large pyrolysis chamber where controlled temperature induction heating will gradually heat it (under inert nitrogen atmosphere) until pyrolysis gas and char are created.The temperature of the exterior of the pyrolysis chamber is controlled by supplying chilled water to cooling coils. (FIG.1)

The char produced is continuously discharged and cooled via a progressive cavity pump whose cooling jacket is supplied with chilled water. The pyrolysis gas is piped to air cooled heat exchangers where a progressive and complete condensation of the compressible gases occurs. The condensates (organic liquid of slightly different properties for each stage of condensation) are collected in temporary storage tanks. (FIG.2-3)

(FIG.4) The remaining small incompressible fraction of the gas is sent to a fi ltering liquid trap before being combusted in a gas burner exhausting to the atmosphere. The diesel grade fuel collected in tank(s) is fi ltered to remove solid particles and supplied to one or more diesel generator groups. The complete process is monitored and controlled via a central PLC.

FIG.1

FIG.2

FIG.3

FIG.4


The equipment

The pyrolysis chamber is approximately 5 m long and 60 cm in diameter, is designed in compliance with all CE Standards and fabricated by a PFT Inc., a Polish company. The chamber is equipped with a proprietary motorized screw mixer that ensures the adequate heating of the granular material and the required chamber residence time at temperature.The tubular heat exchangers are fi nned for ambient air cooling, segmented for liquid fractioning and designed to optimize the condensation of

All components in contact with solids, liquids and gases generated, are manufactured in special steels and stainless steels.

the pyrolysis gases. The progressive cavity pump is designed to transfer and cool to approximately room temperature the char drawn from the chamber. (FIG.5)The diesel generator group is designed to accept all the diesel grade fuel produced without the need of fractioning it and its atmospheric discharge complies with environmental regulations by utilizing special catalytic technology. All the equipment in contact with processed material is fabricated in stainless steel or special specifi cation steel. (FIG.6)

FIG.6

FIG.5

TYPES OF GENERATOR SETS AVAILABLE

PRODUCTION KW IN WORK CONTINUOUS MODEL CONSUMPTION L/H 230 KW CUMMINS NTA 855G4 ~ 60 L445 KW CUMMINS VTA 28G5 ~ 120 L675 KW CUMMINS NTA 855G4

+ VTA 28G5~ 180 L

820 KW CUMMINS KTA 50G3 ~ 215 L1050 KW CUMMINS NTA 855G4

+ KTA 50G3~ 275 L

1265 KW CUMMINS VTA 28G5+ KTA 50G3

~ 335 L

1640 KW CUMMINS KTA 50G3 X 2 ~ 430 L


Production capacity of Pneus Gineo 200

The plant PNEUS GINEO 200 is the basic system of the Get Energy Prime Italian.The loading of the granules in the reactor is adjusted to 200 kg/hr.The pyrolysis conditions for normal power, generate approximately 90 kg/hr of solid residue and 80 kg/hr of organic liquid. The remaining fraction of uncondensed gases is 30 kg/hr.The diesel generator produces 200 kWe when it

is powered by 40 L/hr of fuel, and then the loading of granules should be at least 100 kg/hr to obtain the maximum output from the generator.Of the 200 kWe available from the generator set, 50 kWe are disseminated to the pyrolysis system for own consumption.The heat generated by the combustion of the pyrolysis gases not condensed (but not further used), is approximately 20 kWe.

CODES AND STANDARDSTHE DESIGN, FABRICATION AND OPERATION OF THE PLANT ARE IN COMPLIANCE WITH ALL THE RELEVANT NATIONAL AND INTERNATIONAL CODES AND STANDARDS.

IMPIANTO COMPLETO



Management of the Plant

the main assistance centre ( data collected in real time allow to go on with production andoperation);

and underground water.

Noise emission: 75 dB at 23 ft awayNoise emission: 65 dB at 3,28 ft awayEquipment or location Noise level, dBThreshold of hearing, unaudible 0Quiet bedroom 35Windmill farm 380 yards away 35-45Noisy offi ce, fully operational 60Truck running at 30mph, 110 yards away 70Jackhammer at 23 ft away 95Wind turbine, at 33 ft away 95-105Pain threshold, hearing damage 140

Source: Cubasolar, Energéticas Renovables (CETER). Cuba.



Conclusions

GET ENERGY PRIME ITALIA IS READY TO SET UP, WITH ITS PARTNERS, A STRONG AND DYNAMIC SYSTEM FOR ELTS RECOVERY, THAT INVOLVES THE MARKET OF ENERGY PRODUCTION FROM ALTERNATIVE SOURCES.

At a time when the ongoing increase of waste cannot be handled through the use of landfi lls or incinerators, which cause highly pollutant emissions and residues, the only possible solution is to use waste components.The search for new energy sources that has been carried out in these last years by Get Energy prime Italia has identifi ed ELTs as a possible solution allowing to produce electric and thermal energy by exploiting the alternative recycling processes.ELTs composition makes their use suitable for different industrial sectors: electric power, thermal energy, Carbon Black, metal. We learnt from our experience that the higher the number of applications, the higher the compensation effect is when a sector is in crisis.Furthermore, the social problem at world level

gives us only one perspective: ELTs recycling.PNEUS GINEO is at the core of this objective, since it is characterised by the innovative solutions applied and, in the meantime, by a structural simplicity that makes the plant easy to manage.Choosing to recover end of life tyres and convert them can solve two critical points: eliminating a polluting material that is destined to destruction and producing energy thanks to alternative methods, in compliance with eco-sustainable principles and objectives.Now that the key word is “recover”, transforming tyres into a resource means to optimise two processes. But it also means to tackle the spreading of illegal dumping sites and help the planet. A choice for the environment. A valuable choice from the point of view of costs and profi ts.




Conclusions

PRESIDENTGiovanni [email protected]

CEOGianluca [email protected]

ADMINISTRATIVE OFFICEFederico Staunovo [email protected]

LEGAL OFFICERaffaella [email protected]

GEPI ITALIA


28 We help the environment.


GET ENERGY Prime Italia srlViale delle Milizie, 22

00165 Roma

Catalogo Pneus Inglese

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