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KleanCarbon USA

Ohio: The birth of a green rubber industry

Organisations Consulted: Klean Industries Inc., Sacre-Davey Engineering, Lafarge North America, Less Carbon, Artech, Ohio EPA, Eco-fuels, Bibb & Associates Inc., many tire manufacturers & tire retailers

The Challenge:

North America is one the world's largest producers of end-of-life tires, currently generating over 500,000,000 tires every year. Similar numbers are stockpiled and monofills containing tens of millions of tires are not un-common and these landfills are growing every day. Current markets for tire derived product are all low end applications with state funding usually required to provide a waste management solution for tire disposal.

The current challenge for many states is to reduce the burden on their tax payer while recovering greater value from their wastes either in the form of energy of recovered resources. The state of Ohio, a hub of the US motor industry and the birth place of all rubber formulations has suffered more than most during this recession having struggled to re-invent itself and find its place in the emerging green economy.

The Solution:

Klean Industries has identified an opportunity to bring a new industry to Ohio, one that produces green commodities and energy from the wastes of automobile industry. Klean's planned Resource Recovery Facility will not require any subsidies and will provide a fully sustainable solution to the region's 12 million scrap tires. Klean plans on solving part of the issue by using the company's patented advanced thermal conversion technology to recover fuel oil, steel and a refined carbon black. The high quality end products will be comparable to virgin commodities with the exception of being far more cost effective with a substantially low carbon footprint.

Klean's tire pyrolysis and gasification technology was developed in Japan in the early 1970's was the world's first thermal process specifically designed to recover oil and energy from waste tires. Historically, Japan has always been short on energy and fuel resources and keen on finding viable substitutions. It should be noted that Japan was already producing bio-diesel oil 70 years ago with the Japanese engaging in World War 2 and yet Bio-diesel production has only recently become a topic of alternative energy conversations.

Klean Industries sees significant value in the application of this technology to industry and by obtaining complete ownership of the patents and technology know-how it's our intention is to integrate this revolutionary indirect flame, tire gasification system into the tire manufacturing industry. See below flow chart:

Klean has secured feedstock with an industry leading semi truck-tire re-treading business located in Akron Ohio. The business has been in operation for over fifty years and generates substantial waste tires of approximately 100 - 150 tonnes per day. The disposal of these unsuitable truck tire casings has an increasingly high cost of both environmentally and financially. Through this partnership Klean intends to change the complete tire recycling supply chain and plans on rapidly expanding its tire capture capacity to neighbouring states.

Klean has secured a 5 acre site and able to process 200 tons a day of scrap tires at full capacity, that's approximately 14,000 tires a day. This will be Klean's North America flagship facility that is located in close proximity to Akron city center and is located near major highways for excellent product logistics for both its tire feedstock and end product distribution. Klean has long term plans to roll out a minimum of 15 facilities in the US alone.

The end result is the preservation of finite resources through the production of the following sustainable commodities (approximate volume):

  • 7 million tires a year recycled
  • 100's of job created in region that requires economic development
  • 6MW of electricity generated for export
  • 21,000 TPA of CBk carbon black
  • 32,000 TPA of diesel grade fuel oil
  • 10,000 TPA of steel
  • 300,000 TPA of Carbon Dioxide emission offset