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ECOFRIENDLY RUBBER MANUFACTURING MAKING USE OF THERMAL POWER PLANT WASTE IN THE PERSPECTIVE OF CIRCULAR ECONOMY #SciChallenge2017
 INTRODUCTION
Waste is an important resource in the chemical industry. Here in this
project, optimum material recovery (recycling) or energy recovery is
achieved by using wastes instead of important raw materials. In this
way, the input of primary raw materials is decreasing and resources are
protected. Fly ash is also used in the construction of cement, but even
so, more than 75% of it is not used but left to the nature. Therefore,
taking that into consideration, we aimed to use 30 cents worth of fly
ash which is thermal power plant waste instead of silica, which is one
of the raw materials of rubber for about 3 euros in order to use it in the
automotive industry
Our purpose in doing this is;
Fly ashes in thermal power plants are carried into the air during
combustion of coal and cause environmental pollution. Therefore, with
the principle of Industrial Revolution 4.0, we aim to gain those fly
ashes into the circular economy that the EU has also issued a call
recently,
Using fly ashes in the recyclable rubber industry to ensure that the
product obtained is also recyclable,
Minimising cost by using fly ash instead of silica (SiO2) contained in
the resin of the rubber,
By producing rubber having about the same properties as silica and
costing a very small amount compared to the cost of rubber made of
silica in order to create a great opportunity for the industry of our
country and contribute to the development of our country.
 1-Fly Ash
Fly ash is a waste product from coal-fired thermal power plants. Electricity in
Turkey is generated from coal-based thermal power plants and hydroelectric power
plants. There are currently 15 coal-fired thermal power plants operating in Turkey.
In thermal power plants where low-calorie lignite coals are burnt, as a result of
combustion of the powdered coal during the production of electricity results in ash
particles in the micron size. These ash particles are entrained by flue gases and are
trapped with the help of electro filters, thus preventing mixing in the atmosphere.
These ashes, which are industrial waste and can fly, are called fly ash.
In the thermal power plants where about half of the electricity energy in Turkey
is produced, 55 million tons / year of low calorific lignite coal is burned and as a
result, 15 million tons / year of fly ash is obtained from the flues according to the
data in 2003. According to 2000 data, fly ash use rate in Turkey is less than 1%.
New data concerning recent years cannot be obtained.
The accumulation or disposal of fly ash leads to significant environmental
pollution. Environmental problems caused by fly ashes include dusting, damaging
agricultural products, toxic material transport due to soil filtration, and radiation.
The above mentioned problems can be solved by making use of fly ashes in
various fields of use and bringing them to the economy of the country. The
construction industry is the most predominant one in the sectors where fly ash is
being made use of.
 Features (2016 average for Seaş and Ilion)
Surface area: 3000 cm2/g
28 day strength: 24.6 MPa
2016 Seaş & Ilion density average: 2.60 gr/cm3
Amount of Production: Approximately 500,000 tons per year
 2-Recycling
Recycling is the process of reusing wastes that can be re-evaluated through various
processes. In other words, recyclable waste materials that are not used in any way are
recycled as raw materials through various recycling methods and they are included in
the manufacturing process again.
The purpose of recycling should be considered as reducing the amount of waste
garbage while preventing the unnecessary use of resources. Recycling and reuse of
materials such as iron, steel, copper, lead, paper, plastic, rubber, glass, and electronic
waste will prevent the depletion of natural resources. This situation will save to a great
extent for the energy used to meet the needs of countries. On the other hand, as
mentioned above, one of the purposes of recycling is the prevention of environmental
pollution to a great extent by reducing the amount of solid waste. Particularly for
countries where there is not enough space to regularly dispose of solid waste, a
reduction in the amount and volume of solid waste is a huge advantage.
 3-Circular economy
Circular economy is an industrial economy that is curative in terms of
its nature and purpose, and resources are managed in a cyclical manner.
The concept of circular economy both allows the society to benefit from
the resources at the maximum level and it also allows the society to adapt
resource consumption to the present and future needs. In this way the
demand for primary resources is optimized and in connection with this the
environmental impact and the use of energy are also alleviated.
In the circular economy, some material and energy flows are
interrelated and therefore require a holistic approach.
A remanufactured product serves a function at least as to be comparable
to the original product. It is obtained from an existing product which has
been upgraded in the same way by passing it through an industrial process
that has been standardized in accordance with the initial specifications.
The remanufactured product becomes a product which has been reused,
repaired, restructured, renewed, reprocessed or rectified.
 3.1. Reasons for the cyclical approach
Today's societies need to reconsider their production and
consumption in accordance with current trends. To meet the need for
natural resources in a sustainable way is one of the major challenges
in the global sense today. The number of middle class consumers are
expected to increase by three billion by 2030 and it will not only
affect consumption and production habits but it will also accelerate
the demand and the struggle for natural resources. The increase of
natural or political constraints in supply chains, fluctuations in
commodity prices and negative effects on the environment are the
main factors which stimulate economies follow new, durable and
economically sustainable models. In this context, companies and
consumers in Europe have attempted to reshape their own
production and consumption habits for a while
 3.2. Industry perspective
There are many reasons why companies in the EU are more cyclical.
Some of these reasons are as follows:
Cost savings: The efficient use of resources as indispensable for the
circular economy has formed the basis of most business decisions and
activities.
New business opportunities: In most cases, best practices have
benefited consumers and industry by allowing new business models to
move from linear models to cyclic models.
Environmental effects: The saying of "living better within the borders
of the planet" makes it clear that the circularity has a strong reason for
economy and environment. Of course, it means "using better" instead of
"using less".
 3.3. The cyclical economy approach of
companies in Europe
This section shows a concrete example of how the EU industry looks at
more cyclical economic models.
Recreate mechanical parts
An automobile manufacturer redesigns vehicle components such as
gearboxes to increase the rate of use and standardizes these components to
facilitate separation. Reproduction requires more work compared to
production. However, since no investment is required for machines, cutting
and manufacturing products, there is still a net profit and there is significantly
less waste and better material efficiency. Compared to products made from
scratch, 80% less energy, 88% less water and 92% fewer chemicals are used in
remanufactured products and 70% less waste occurs during production.
 METHOD
Fly ashes were taken from Soma Thermal Power Plant Electricity Generation
Incorporation.
The formula of the rubber has been prepared using fly ashes in Erenli Kauçuk
Incorporation.
Three different prescriptions were prepared as shown in Table 1.1.
The doughs given in the prescriptions were mixed in the laboratory mixer. (Picture
1.1)
First the dough was turned into strip form on the shaft and then it was ready to be
processed.
First the dough was turned into
strip form on the shaft and then it
was ready to be processed.
In the processing of rubber
dough, a press machine was used.
(Picture 1.2)
All values ​​were measured in the
measuring instruments in the
laboratory of Erenli Kauçuk
Incorporation.
Some comparisons were made
between the three different
doughs. (Picture 1.3)
At the same time, the dough was
extruded in an extrusion machine
and a rubber hose was obtained.
(Picture 1.4)
Picture 1.1 Laboratory mixer Picture 1.2 Press machine
Picture 1.3 Types of dough Picture 1.4 An extrusion machine
 Results
The data we have collected in our study are indicated by serial numbers D536,
D537 and D538.
D536 (100% silica)
 D537 (50% silica, 50% ash)
 D538 (100% ash)
Tensile Strength (MPa)
Tensile Strength
(MPa)
D536: 10.24
D537: 8.92
D538:4.82
Tear
Resistance
(N/mm)
D536: 24.93
D537:18.76
D538:5.41
Tear Resistance (N/mm))
Elongation at Break (%)
Elongation at
Break
D536: 733.96
D537: 660.92
D538:462.08
 The first attempted and last attempted temperatures in the extrusion machine
during extrusion:
EXTRUSION
MACHINE PARTS
FIRST
TEMPERATURE
LAST
TEMPERATURE
First part
30 °C 40 °C
Head
55 °C 85 °C
Body
60 °C 65 °C
Last part
60 °C 75 °C
Shaft
50 °C 60 °C
As seen in the table, the values ​​of the dough prepared with 100% silica
showed similar values ​​to the dough prepared with 50% silica and 50% ash.
There has been a little decrease in values, but this is an expected result.
The findings show that 50% silica and 50% ash can be used instead of
100% silica. But the dough prepared with 100% ash did not show suitable
values ​​for the desired standards.
50% silica 50% ash is suitable for the standards that dough rubber should
have.
 CONCLUSION AND EVALUATION
A significant reduction in the tensile, rupture and tear resistance
of the dough prepared with 100% ash has been experienced.
However, the values ​​above European standards have been obtained
in the doughs prepared with 50% silica 50% ash.
The dough prepared with 100% ash did not have as much
binding effect as silica. This little binding effect makes it very
difficult to use dough prepared with 100% ash.
The products obtained can be used in air filter hose and various
rubber parts and they can be recycled.
 RECOMMENDATIONS
As mentioned many times in the study we do, ash recycling will
provide us with lots of advantages.
First, it will create great opportunities for environmental pollution
reduction. This is also an important opportunity for the industry. In this
way, both the cost will be reduced and it will contribute to the circular
economy.
The evaluation of this opportunity in Turkey is of great importance. Our
wish is that this area should be supported either by state or private
institutions and contribute to the economy. We hope that necessary steps
will be taken and our country will be developed.
In this respect, our project undertakes important missions.
 REFERENCES
PAGEV(20.08.2015), DÖNGÜSEL EKONOMİ: AVRUPA'DA STRATEJİK
KAYNAK POLİTİKASININ BAŞ FAKTÖRÜ,12.12.2016
https://www.pagev.org/upload/files/Hammadde%20Yeni%20Tebli%C4%9F
%20Bilg.%203/PAGEV%20D%C3%B6ng%C3%BCsel%20Ekonomi%20D
urum%20Raporu.pdf
Keiretsu Forum,(?) Döngüsel Ekonomi, Döngüsel Fikirler,12.12.2016
http://keiretsuforum.com.tr/dongusel-ekonomi-dongusel-fikirler.html
T.C.Bilim Kültür ve Sanayi Bakanlığı,(Nisan2016), Döngüsel Ekonomi
Hollanda Örneği,13.12.2016
https://anahtar.sanayi.gov.tr/tr/news/dongusel-ekonomi-hollanda-
ornegi/3277
ARUNTAŞ,H.,(Mart2006) THE POTENTIAL OF FLY ASH USAGE IN
CONSTRUCTION SECTOR,17.12.2016
https://www.researchgate.net/publication/291957028_UCUCU_KULLERIN
_INSAAT_SEKTORUNDE_KULLANIM_POTANSIYELI_THE_POTENTIAL
_OF_FLY_ASH_USAGE_I N_CONSTRUCTION_SECTOR
TEZCAN,G.,(?),Çevre ve Enerji,20.12.2016
http://arsiv.mmo.org.tr/pdf/000007CD.pdf
Çevreonline,(?),Atık Geri Dönüşümü,20.12.2016
http://www.cevreonline.com/atik2/geri_donusum.htm
Bilkent Üniversitesi,Geri Dönüşüm,22.12.2016
Huri Ayşenur BALDAN
Bilal Batuhan YENEN
11th Grade
İzmir Science High School

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ECOFRIENDLY RUBBER MANUFACTURING MAKING USE OF THERMAL POWER PLANT WASTE IN THE PERSPECTIVE OF CIRCULAR ECONOMY #SciChallenge2017

  • 2.  INTRODUCTION Waste is an important resource in the chemical industry. Here in this project, optimum material recovery (recycling) or energy recovery is achieved by using wastes instead of important raw materials. In this way, the input of primary raw materials is decreasing and resources are protected. Fly ash is also used in the construction of cement, but even so, more than 75% of it is not used but left to the nature. Therefore, taking that into consideration, we aimed to use 30 cents worth of fly ash which is thermal power plant waste instead of silica, which is one of the raw materials of rubber for about 3 euros in order to use it in the automotive industry
  • 3. Our purpose in doing this is; Fly ashes in thermal power plants are carried into the air during combustion of coal and cause environmental pollution. Therefore, with the principle of Industrial Revolution 4.0, we aim to gain those fly ashes into the circular economy that the EU has also issued a call recently, Using fly ashes in the recyclable rubber industry to ensure that the product obtained is also recyclable, Minimising cost by using fly ash instead of silica (SiO2) contained in the resin of the rubber, By producing rubber having about the same properties as silica and costing a very small amount compared to the cost of rubber made of silica in order to create a great opportunity for the industry of our country and contribute to the development of our country.
  • 4.  1-Fly Ash Fly ash is a waste product from coal-fired thermal power plants. Electricity in Turkey is generated from coal-based thermal power plants and hydroelectric power plants. There are currently 15 coal-fired thermal power plants operating in Turkey. In thermal power plants where low-calorie lignite coals are burnt, as a result of combustion of the powdered coal during the production of electricity results in ash particles in the micron size. These ash particles are entrained by flue gases and are trapped with the help of electro filters, thus preventing mixing in the atmosphere. These ashes, which are industrial waste and can fly, are called fly ash.
  • 5. In the thermal power plants where about half of the electricity energy in Turkey is produced, 55 million tons / year of low calorific lignite coal is burned and as a result, 15 million tons / year of fly ash is obtained from the flues according to the data in 2003. According to 2000 data, fly ash use rate in Turkey is less than 1%. New data concerning recent years cannot be obtained. The accumulation or disposal of fly ash leads to significant environmental pollution. Environmental problems caused by fly ashes include dusting, damaging agricultural products, toxic material transport due to soil filtration, and radiation. The above mentioned problems can be solved by making use of fly ashes in various fields of use and bringing them to the economy of the country. The construction industry is the most predominant one in the sectors where fly ash is being made use of.
  • 6.  Features (2016 average for Seaş and Ilion) Surface area: 3000 cm2/g 28 day strength: 24.6 MPa 2016 Seaş & Ilion density average: 2.60 gr/cm3 Amount of Production: Approximately 500,000 tons per year
  • 7.  2-Recycling Recycling is the process of reusing wastes that can be re-evaluated through various processes. In other words, recyclable waste materials that are not used in any way are recycled as raw materials through various recycling methods and they are included in the manufacturing process again. The purpose of recycling should be considered as reducing the amount of waste garbage while preventing the unnecessary use of resources. Recycling and reuse of materials such as iron, steel, copper, lead, paper, plastic, rubber, glass, and electronic waste will prevent the depletion of natural resources. This situation will save to a great extent for the energy used to meet the needs of countries. On the other hand, as mentioned above, one of the purposes of recycling is the prevention of environmental pollution to a great extent by reducing the amount of solid waste. Particularly for countries where there is not enough space to regularly dispose of solid waste, a reduction in the amount and volume of solid waste is a huge advantage.
  • 8.  3-Circular economy Circular economy is an industrial economy that is curative in terms of its nature and purpose, and resources are managed in a cyclical manner. The concept of circular economy both allows the society to benefit from the resources at the maximum level and it also allows the society to adapt resource consumption to the present and future needs. In this way the demand for primary resources is optimized and in connection with this the environmental impact and the use of energy are also alleviated. In the circular economy, some material and energy flows are interrelated and therefore require a holistic approach. A remanufactured product serves a function at least as to be comparable to the original product. It is obtained from an existing product which has been upgraded in the same way by passing it through an industrial process that has been standardized in accordance with the initial specifications. The remanufactured product becomes a product which has been reused, repaired, restructured, renewed, reprocessed or rectified.
  • 9.  3.1. Reasons for the cyclical approach Today's societies need to reconsider their production and consumption in accordance with current trends. To meet the need for natural resources in a sustainable way is one of the major challenges in the global sense today. The number of middle class consumers are expected to increase by three billion by 2030 and it will not only affect consumption and production habits but it will also accelerate the demand and the struggle for natural resources. The increase of natural or political constraints in supply chains, fluctuations in commodity prices and negative effects on the environment are the main factors which stimulate economies follow new, durable and economically sustainable models. In this context, companies and consumers in Europe have attempted to reshape their own production and consumption habits for a while
  • 10.  3.2. Industry perspective There are many reasons why companies in the EU are more cyclical. Some of these reasons are as follows: Cost savings: The efficient use of resources as indispensable for the circular economy has formed the basis of most business decisions and activities. New business opportunities: In most cases, best practices have benefited consumers and industry by allowing new business models to move from linear models to cyclic models. Environmental effects: The saying of "living better within the borders of the planet" makes it clear that the circularity has a strong reason for economy and environment. Of course, it means "using better" instead of "using less".
  • 11.  3.3. The cyclical economy approach of companies in Europe This section shows a concrete example of how the EU industry looks at more cyclical economic models. Recreate mechanical parts An automobile manufacturer redesigns vehicle components such as gearboxes to increase the rate of use and standardizes these components to facilitate separation. Reproduction requires more work compared to production. However, since no investment is required for machines, cutting and manufacturing products, there is still a net profit and there is significantly less waste and better material efficiency. Compared to products made from scratch, 80% less energy, 88% less water and 92% fewer chemicals are used in remanufactured products and 70% less waste occurs during production.
  • 12.  METHOD Fly ashes were taken from Soma Thermal Power Plant Electricity Generation Incorporation. The formula of the rubber has been prepared using fly ashes in Erenli Kauçuk Incorporation. Three different prescriptions were prepared as shown in Table 1.1. The doughs given in the prescriptions were mixed in the laboratory mixer. (Picture 1.1) First the dough was turned into strip form on the shaft and then it was ready to be processed.
  • 13. First the dough was turned into strip form on the shaft and then it was ready to be processed. In the processing of rubber dough, a press machine was used. (Picture 1.2) All values ​​were measured in the measuring instruments in the laboratory of Erenli Kauçuk Incorporation. Some comparisons were made between the three different doughs. (Picture 1.3) At the same time, the dough was extruded in an extrusion machine and a rubber hose was obtained. (Picture 1.4)
  • 14. Picture 1.1 Laboratory mixer Picture 1.2 Press machine Picture 1.3 Types of dough Picture 1.4 An extrusion machine
  • 15.  Results The data we have collected in our study are indicated by serial numbers D536, D537 and D538. D536 (100% silica)
  • 16.  D537 (50% silica, 50% ash)
  • 18. Tensile Strength (MPa) Tensile Strength (MPa) D536: 10.24 D537: 8.92 D538:4.82
  • 20. Elongation at Break (%) Elongation at Break D536: 733.96 D537: 660.92 D538:462.08
  • 21.  The first attempted and last attempted temperatures in the extrusion machine during extrusion: EXTRUSION MACHINE PARTS FIRST TEMPERATURE LAST TEMPERATURE First part 30 °C 40 °C Head 55 °C 85 °C Body 60 °C 65 °C Last part 60 °C 75 °C Shaft 50 °C 60 °C As seen in the table, the values ​​of the dough prepared with 100% silica showed similar values ​​to the dough prepared with 50% silica and 50% ash. There has been a little decrease in values, but this is an expected result. The findings show that 50% silica and 50% ash can be used instead of 100% silica. But the dough prepared with 100% ash did not show suitable values ​​for the desired standards. 50% silica 50% ash is suitable for the standards that dough rubber should have.
  • 22.  CONCLUSION AND EVALUATION A significant reduction in the tensile, rupture and tear resistance of the dough prepared with 100% ash has been experienced. However, the values ​​above European standards have been obtained in the doughs prepared with 50% silica 50% ash. The dough prepared with 100% ash did not have as much binding effect as silica. This little binding effect makes it very difficult to use dough prepared with 100% ash. The products obtained can be used in air filter hose and various rubber parts and they can be recycled.
  • 23.  RECOMMENDATIONS As mentioned many times in the study we do, ash recycling will provide us with lots of advantages. First, it will create great opportunities for environmental pollution reduction. This is also an important opportunity for the industry. In this way, both the cost will be reduced and it will contribute to the circular economy. The evaluation of this opportunity in Turkey is of great importance. Our wish is that this area should be supported either by state or private institutions and contribute to the economy. We hope that necessary steps will be taken and our country will be developed. In this respect, our project undertakes important missions.
  • 24.  REFERENCES PAGEV(20.08.2015), DÖNGÜSEL EKONOMİ: AVRUPA'DA STRATEJİK KAYNAK POLİTİKASININ BAŞ FAKTÖRÜ,12.12.2016 https://www.pagev.org/upload/files/Hammadde%20Yeni%20Tebli%C4%9F %20Bilg.%203/PAGEV%20D%C3%B6ng%C3%BCsel%20Ekonomi%20D urum%20Raporu.pdf Keiretsu Forum,(?) Döngüsel Ekonomi, Döngüsel Fikirler,12.12.2016 http://keiretsuforum.com.tr/dongusel-ekonomi-dongusel-fikirler.html T.C.Bilim Kültür ve Sanayi Bakanlığı,(Nisan2016), Döngüsel Ekonomi Hollanda Örneği,13.12.2016 https://anahtar.sanayi.gov.tr/tr/news/dongusel-ekonomi-hollanda- ornegi/3277 ARUNTAŞ,H.,(Mart2006) THE POTENTIAL OF FLY ASH USAGE IN CONSTRUCTION SECTOR,17.12.2016 https://www.researchgate.net/publication/291957028_UCUCU_KULLERIN _INSAAT_SEKTORUNDE_KULLANIM_POTANSIYELI_THE_POTENTIAL _OF_FLY_ASH_USAGE_I N_CONSTRUCTION_SECTOR TEZCAN,G.,(?),Çevre ve Enerji,20.12.2016 http://arsiv.mmo.org.tr/pdf/000007CD.pdf Çevreonline,(?),Atık Geri Dönüşümü,20.12.2016 http://www.cevreonline.com/atik2/geri_donusum.htm Bilkent Üniversitesi,Geri Dönüşüm,22.12.2016
  • 25. Huri Ayşenur BALDAN Bilal Batuhan YENEN 11th Grade İzmir Science High School