Tire Wire Separation System: Recycling Waste Tires with Over 99% Efficiency

In the global trend of environmental protection and resource recycling, the disposal of waste tires has always been a challenging issue. Piles of tires not only occupy land but also release harmful substances. At the same time, they are a “urban mine” rich in valuable rubber and steel wires. Today, we will delve into the tire wire separation system to see how it transforms waste tires into valuable resources.

I. Core of the System: The Complete Process from Shredding to Separation

The tire wire separation system is the core component of waste tire recycling, converting entire tires into reusable resources through three main steps: shredding—separation—purification.

1.Feeding and Initial Shredding

Entire waste tires are first conveyed into a Tire Shredder. Under strong shear forces, tires are broken into small pieces, preparing them for subsequent fine separation. The key here lies in the shredder’s blade design and power configuration, ensuring efficient handling of various tire types.

2.Fine Shredding and Initial Separation

The shredded rubber pieces enter a Tire Rasper, where most steel wires are separated from the rubber through high-speed impact and friction. This step improves separation efficiency and lays the foundation for subsequent magnetic separation and purification. The rasper’s rotational speed, blade material, and arrangement all affect separation efficiency and the uniformity of rubber granules.

3.Magnetic Separation and Purification

The separated mixture passes through a high-intensity magnetic separator, where steel wires are automatically separated and collected, resulting in clean recycled steel wires. The rubber is further processed into uniformly sized 30mm granules. Key parameters affecting separation purity include the magnetic field strength, drum speed, and tilt angle of the separator.

II. Equipment and Technology: Secrets to Efficient Separation

1.Tire Shredder

• Function: Coarsely shreds entire tires into small pieces for subsequent processing.
• Features: Robust and durable, suitable for various tire types (passenger car, truck, radial, etc.).
• Technical Parameters: Processing capacity of 500–15,000 kg/h; motor power varies by model, typically 75–250 hp.

2.Tire Rasper

• Function: Further refines rubber pieces using high-speed rotating rasp blades and initially separates steel wires.
• Features: High separation efficiency, producing uniformly sized rubber granules (≈30 mm).
• Technical Parameters: Rotational speed typically 500–1,500 rpm; blades are made of wear-resistant alloy steel for long service life.

3.Magnetic Separator

• Function: Separates steel wires from rubber granules using a strong magnetic field.
• Features: High automation, achieving separation purity of over 99%.
• Technical Parameters: Magnetic field strength typically 10,000–15,000 gauss; drum diameter and length are customized based on processing volume.

III. System Advantages: Efficiency, Quality, and Energy Savings

1.High Separation Rate

Unique separation technology ensures a steel-rubber separation rate exceeding 99%, yielding high-purity, high-value products. This means nearly all steel wires can be recovered, significantly improving resource utilization.

2.High-Quality Products

• Rubber Granules: Uniformly sized (≈30 mm) with very low impurity content, suitable for recycled rubber products, road paving, etc.
• Steel Wires: Clean and can be sold directly as high-quality scrap steel, re-entering steel production processes.

3.Energy Efficiency

Scientific power configuration and streamlined process design ensure high output (500–15,000 kg/h) while maintaining low energy consumption. Energy use is reduced by over 20% compared to traditional processes.

4.Automation and Intelligence

The system uses PLC control for fully automated operation, reducing manual intervention and improving production stability and safety. Some advanced systems also incorporate AI vision recognition to further optimize separation results.

IV. Applications and Prospects: A Win-Win for the Environment and Economy

1.Environmental Value

The tire wire separation system effectively addresses waste tire accumulation, reducing land occupation and environmental pollution, and supporting circular economy and sustainable development. Statistics show that processing 10,000 tons of waste tires reduces land occupation by approximately 30,000 m³ and carbon emissions by about 5,000 tons.

2.Economic Value

• Recycled Rubber: Used in rubber tracks, waterproof materials, shoe soles, etc., with strong market demand.
• Recycled Steel Wires: Can be melted for steel production, reducing reliance on primary resources. At current market prices, processing 10,000 tons of waste tires generates direct economic benefits of approximately 5 million yuan.

3.Social Value

The system creates jobs, promotes green industry development, and raises environmental awareness. It also supports the construction of “zero-waste cities.”

4.Policy and Market Prospects

As global emphasis on environmental protection and resource recycling grows, countries are introducing policies to support waste tire recycling. The global tire wire separation system market is expected to grow at an annual rate of over 15% in the next five years.

V. Case Study: Practice at a Tire Recycling Plant

A tire recycling plant in an industrial park introduced an advanced tire wire separation system. Since commissioning, the system has operated stably, meeting or exceeding design specifications:

• Processing Capacity: 10,000 kg/h
• Separation Rate: Steel-rubber separation rate exceeding 99.5%
• Product Quality: Uniform rubber granule size with impurity content <0.5%; high-purity steel wires suitable for direct scrap steel sales
• Economic Benefits: Annual processing of ~100,000 tons of waste tires, annual revenue of ~50 million yuan, and an investment payback period of ~3 years.

VI. Future Development Trends

1.Technological Innovation

• More efficient shredding and separation technologies to further improve resource recovery rates.
• Intelligence and digitization for self-optimizing and predictive maintenance.

2.Industrial Chain Extension

• From a single separation system to an integrated “shredding—separation—deep processing” chain.
• Development of high-value-added recycled rubber products to increase overall industry profits.

3.Global Expansion

As vehicle ownership rises in developing countries, demand for waste tire disposal will grow rapidly, shifting market focus to emerging markets.

VII. Conclusion: Turning “Black Pollution” into “Black Gold”

The tire wire separation system is not just a technological innovation but a shift in mindset—seeing “waste” as misplaced “resources.” With technological progress and policy support, waste tires will continue their impressive transformation, contributing to a more beautiful planet.