Eco-friendly Modification of Bitumen (ECOMOBI). Recycling end of life tyres into an efficient bitumen modifier

Project Information

ECOMOBI

Grant agreement ID: 777888

DOI

10.3030/777888

Project closed

EC signature date 1 August 2017

Start date 1 September 2017

End date 31 August 2019

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 606 750,00

EU contribution

€ 1 124 725,00

Coordinated by

TECNOFILM SPA
Italy

Periodic Reporting for period 2 - ECOMOBI (Eco-friendly Modification of Bitumen (ECOMOBI). Recycling end of life tyres into an efficient bitumen modifier)

Reporting period: 2018-09-01 to 2019-08-31

Summary of the context and overall objectives of the project

Tecnofilm is a leading Italian company specialized in the production of functionalized polyolefins and specialty compounds. We have over 45 years of experience in the sector and count with an expert team of 45 technical and sales experts. Tecnofilm is committed to the research, development and commercialization of eco-friendly compounds, helping to minimize the environmental footprint of our customers.
Every year, polymer modified bitumen (PmB) producers generate over 10 million tons of PmB globally to increase road pavement performance. By 2022, the global PmB market is expected to reach over €12.5 billion. Available bitumen modifiers are either expensive (SBS, the most widely used bitumen modifier has averaged 2€/kg in the last years) or inefficient (plastomers, recycled tyre rubber).
Tecnofilm has developed RD PRENE, an innovative recycled tyre rubber (RTR) based bitumen modifier (already protected by a patent) that will provide PmB producers with a superior performance, affordable and environmentally friendly alternative to current bitumen modifiers. PmB producers substituting SBS by RD PRENE will save up to 40 € per ton of PmB. RD PRENE provides and increment in road service life and reduces traffic noise when compared with SBS. Moreover, it eliminates the need for additional processing, reducing energy and personnel expenses and since it is based on recycled end of life tyres (ELTs), our customers will reduce their environmental footprint, boosting their corporate image.
We have produced a pilot scale version of the compound and tested it in commercial bitumen blends. Through the ECOMOBI project, Tecnofilm aims to bring RD PRENE into the market and make a difference by providing a valuable recovery alternative for ELTs.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the second reporting period, we continued and completed the optimization of the production line for RD PRENE and we implemented all the technical checks before the start of the production trials. We reached the target in terms of production capacity and we are able to face a potential increase of the demand.
We arranged the internal documents in order to support and monitor the standard operational procedures. Moreover, we prepared the official technical data sheet, safety data sheet and certificate of analysis that will be provided to the customers. We have also developed the quality control procedure.
In terms of regulatory issues, RD PRENE complies with the corresponding certification and regulation requirements relevant for the production and commercialization.
After the validation of the production trial, we tested RD PRENE with real end users in real conditions of use, as demonstrated by the trial in bridge joints and in 2 roads in Marche region, where its suitability was verified.
Tecnofilm team worked on the commercialization, communication and dissemination strategy in order to bring RD PRENE into the market. We have updated our market analysis and defined our position. During the period, we reached a wide audience and we identified potential partners for the distribution, agents and customers.
We worked also on the LCA and we calculated that the potential replacement of SBS as bitumen modifier would save to the environment up to 3000 tons of CO2-eq per year.
At the end of the project, we have already got our first customers and orders which represents (at least for us) a great success of the ECOMOBI project.
Any of the defined risks (an no unforeseen risk was identified) affected the proper evolution and the success of the project, since all the objectives were achieved.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

RD PRENE offers a bitumen modifier to producers, which is perfectly aligned with the current EU and industry trends. RD PRENE will provide our end users with the following unique features:
• Reduced production costs: Thanks to reduced raw material costs and increased processability, PmB producers implementing RD PRENE in their production lines will save up to 40 € per each tonne of PmB they produce, resulting in significantly lower production costs and therefore higher margins.
• High performance bitumen modifier: RD PRENE modified bitumen properties (consistency, storage stability) are in line with those of bitumen modified with more expensive SBS. In addition, RD PRENE modified bitumen increases road service life and reduces the traffic noise .
• Environmentally friendly technology: RD PRENE finds a profitable use for ELTs while reducing the need for petrol-based bitumen modifiers (SBS). Through implementing RD PRENE in their PmB production, our end users will significantly reduce their environmental footprint and improve their corporate image.

Promotional video in YouTube

First application of RD PRENE CPS1T in the Province of Fermo

Compounding test

First application of RD PRENE CPS1T in bridge joints

Penetration

First application of RD PRENE CPS1T in Trecastelli, Italy

Website