Universiti Sains Malaysia, 11800 Penang,

Malaysia. http://www.usm.my

From Various Rubber Waste into Valuable

Products: A Novel Recycling Approach

Professor Hanafi Ismail

School of Materials and Mineral Resources Engineering
Engineering Campus, Universiti Sains Malaysia
14300 Nibong Tebal, PENANG
Tel: 04-593788 Ext. 6113 ; Fax: 04-5941011
HP : 012-5704601 Email: hanafi@eng.usm.my
 INTRODUCTION
The world annual production of rubber in 2008
– 22.7 million tonnes
NR ~9.94 million tonnes
SR ~ 12.78 million tonnes

The world annual consumption of rubber in 2008

– 22.2 million tonnes

NR ~9.55 million tonnes

SR ~ 12.65 million tonnes
  

World Rubber Production and Consumption

('000 tonnes)
Production Consumption
Year Natural Synthetic Total Natural Synthetic Total
Rubber Rubber Rubber Rubber Rubber Rubber
1998 6,634 9,880 16,514 6,570 9,870 16,440
1999 6,577 10,390 16,967 6,650 10,280 16,930
2000 6,762 10,870 17,632 7,340 10,830 18,170
2001 7,332 10,483 17,815 7,333 10,253 17,586
2002 7,337 10,882 18,219 7,628 10,692 18,320
2003 8,033 11,390 19,423 8,033 11,371 19,404
2004 8,756 12,019 20,775 8,715 11,839 20,554
2005 8,892 12,151 21,043 9,082 11,895 20,977
2006 9,846 12,646 22,419 9,216 12,371 21,587
2007 9,725 13,583 23,489 9,735 13,197 22,932
Source: International Rubber Study Group (IRSG) Vol 52 No 1, October 1997
             International Rubber Study Group (IRSG) Vol 56 No 12, September 2002
             International Rubber Study Group (IRSG) Vol 62 No 6/Vol 62 No 7, May/June 2008
            
Malaysia's Rubber Consumption by Product Sector in 2007 (tonnes)

GRG - General rubber goods

IRG - Industrial rubber goods
 Malaysia's Output of Selected Rubber Products
Selected Rubber Products
Tyres
Year Inner tubes Gloves Catheters Footwear Rubber Rubber
(pneumatic,
(all types, (all types, (all types, (million bands sheet
 all types,
million units) million pairs)  million units) pairs) (tonnes) (tonnes)
million units)
1996 12.22 17.43  8,506.58  87.66 16.95  4,213 5,854
1997 13.72 15.14  8,915.53  88.76 12.83  5,484  4,612
1998 13.57 11.84 10,611.77  75.17  8.09  7,337  4,775
1999 13.52 11.47 10,906.61  94.58  8.28  7,381  5,355
2000 13.64 12.52 11,598.05  91.15  6.29  9,553  5,621
2001 13.12 13.33 12,256.32  86.76  4.17 12,138  5,298
2002 12.95 14.16 12,207.73  99.81  3.30 13,595  6,157
2003 15.10 13.05 15,059.71  85.60  2.67 10,984 7,191
2004 14.96 12.87 18,161.66 101.25  3.37 11,403  5,251
2005 14.12 11.32 19,177.78  82.57  2.95  7,431  4,465
2006 11.55 19.55 20,388.57  75.50  3.89  6,814  5,701
2007 13.37 20.95 20,390.94 108.69  5.41  6,015  4,352

Source: Department of Statistics, Malaysia

 The world total annual output of tyre in 2005 was 1.34 billion

Main sources of waste rubber: discarded tyres, rubber pipes, rubber

belts, rubber shoes, edge scraps and waste products etc.

Amount of discarded tyres reaches 10 million/year worldwide

In Malaysia production of the pneumatic tyres alone in the year of

2000 is 13.64 Mil)while the tyre replacement market average is
1,257,00 (1.3 Mil) pcs per month. 35-40% go to tread market and 65-
70% for disposal dumping or other use (JPM, 2000)
 ENVIRONMENTAL PROBLEM
Scrap tyres piles create many problems such as breeding site for
rats, snakes, termites and other vectors. Mosquitoes breed in
stagnant water collected inside tyre piles, thus creating health
threats, amongst others dengue fever and/or encephalitis.
Tyre piles are also a health hazard because, if set afire either as a
result of arson or by accident, they are difficult to extinguish and
under uncontrolled conditions will release dangerous oils, heavy
smoke and etc thus creating air, ground and water pollution.
Burying on scrap tyres in landfill also creates problems. The tyres
do not compact readily and will destabilize the landfill, making it
costly and difficult to rehabilitate. Furthermore, little is known
about the long term leaching effects of the organic component
from buried tyres.
 Kuala Lumpur NR prices
1st Oct 2007 – 26th Feb 2009
THE STAR
Monday, September 30 2002

The
The price
price of
of natural
natural rubber
rubber
increased
increased from
from RM2,000
RM2,000 perper
tonne
tonne to
to RM3,400
RM3,400 four
four
months
months ago.
ago.
THE STAR
Wednesday, 24 November 2004

Latest STAR 12 Sept. 2006 SMR 20 RM6.49/kg. Last

June 2006 RM8.52/kg
 A NOVEL RECYCLING APPROACH 1
THERMOPLASTIC ELASTOMERs (TPEs) FROM
VARIOUS WASTE RUBBERS

THERMOPLASTIC ELASTOMER BASED ON:

1) POLYPROPYLENE (PP) /RECYCLED WASTE
RUBBER POWDER (RRP) BLEND
2) POLYPROPYLENE (PP)/WASTE TYRE DUST
(WTD) BLEND
 Introduction

 Thermoplastic elastomers (TPEs) are a new class of

thermoplastic of which the properties can be easily
tailored more than block copolymer by simply
changing the ratio of the rubber blend
 TPEs give better material utilization because scrap
and rejects can be recycled
 Blending of recycle rubber into plastics such as
rubber powder blend with polypropylene plays an
important role in the modern polymer industry not
only for development of new materials but also for
practical recycling purposes
 Introduction

Conventional Rubber Products

Purchase:
Gum rubber
Filler Finished
Extender Mixing Shaping Vulcanization Product
Chemical
scrap scrap scrap

Thermoplastic Rubber Products

Purchase: Shaping Finished

Thermoplastic Product
Rubber

Recycle

Figure 1. Comparison of thermoset and thermoplastic

processing
 Objective of Study 1

Comparison of polypropylene (PP) /natural

rubber (NR) and PP/recycle rubber
powder (RRP) blends
 Table 2.2. Formulation for PP/NR and PP/RR blends

Materials Blends
1 2 3 4 5 6 7 8 9 10 11
Polypropylene (PP) (wt%) 100 80 70 60 50 40 80 70 60 50 40
Natural Rubber (NR) (wt%) * 20 30 40 50 60 * * * * *
Recycle Rubber (RRP) (wt%) * * * * * * 20 30 40 50 60
 Table 2.5. Composition of RRP
Composition Wt%
Natural rubber 47.6
Calcium carbonate 38.1
Curative 13.2
Others 1.1

Data from Watas Holding (M) Sdn. Bhd.

RRP is a waste product from the sanding process (polishing)

Of rubber ball and artificial eggs. The range of particle size
used in this study is 250 – 500 µm.
 Experiment procedure

PROCESS FLOW
(PP/NR/RRP BLEND)

TORQUE
DEVELOPMENT

BRABENDER COMPRESSION Swelling Behaviour

MOLDING Oil Resistance
Chemical Resistance
T = 190 0C
RS = 50 rpm TENSILE
PROPERTIES
T = 190 0C
PP Preheated 6 min Preheated 6 min
Mixing 2 min Compressed 4 min TENSILE
NR/ Blend 5 min Cooling 4 min FRACTURE
RR Total 13 min (under pressure) SURFACE
 Results and Discussion

1. Comparison Termoplastic Elastomer

(TPEs) Properties
between PP/NR and PP/RRP Blends
 Brabender torque

50.00
P P 100
45.00
P P 80/NR20

40.00 P P 70/NR30

P P 60/NR40
35.00
P P 50/NR50
Torque (N m)

30.00 P P 40/NR60

25.00

20.00

15.00

10.00

5.00

0.00
0.00 3.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00
Time (min)

Figure 3.1. Torque development of PP/NR blends

 Brabender torque

50.00
45.00 P P 100

P P 80/R RP 20
40.00
P P 70/R RP 30
35.00
P P 60/R RP 40
Torque (N m)

30.00 P P 50/R RP 50

P P 40/R RP 60
25.00
20.00
15.00
10.00
5.00
0.00
0.00 3.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00

Time (Min)

Figure 3.2. Torque development of PP/RRP blends

 Brabender torque

16.0

14.0 PP/NR BLENDS

PP/RRP BLENDS
12.0

10.0
Torque (N m)

8.0

6.0

4.0

2.0

0.0
0 10 20 30 40 50 60 70
Rubber content (wt% )

Figure 3.3. Stabilization Torque for PP/NR and PP/RRP blends

 Tensile properties

45

40 PP/NR Blends

PP/RRP Blends
35
Tensile Strength (MPa)

30

25

20

15

10

0
0 10 20 30 40 50 60 70
Rubber Content (wt %)

Figure 3.4. Tensile strength vs rubber content

 Tensile properties

1400

1200 PP/RRP Blends

PP/NR Blends
1000
Young's Modulus (MPa)

800

600

400

200

0
0 10 20 30 40 50 60 70

Rubber Content (wt %)

Figure 3.5. Young’s modulus vs rubber content

 Tensile properties

120

PP/NR Blends
100
PP/RRP Blends

80
Elongation at Break (%)

60

40

20

0
0 10 20 30 40 50 60 70

Rubber Content (wt %)

Figure 3.6. Elongation at break vs rubber content

 Oil resistance

70

PP/NR Blends
60
PP/RRP Blends
50
Swelling (wt%)

40

30

20

10

0
0 10 20 30 40 50 60 70

Rubber Content (wt %)

Figure 3.7. Relationship between % swelling and rubber content

of PP/NR and PP/RRP blends in ASTM oil No. 3 at room
temperature for 70 h.
 Chemical resistance

2.20

PP/NR BLENDS
2.00
PP/RRP BLENDS
1.80
Swelling Index

1.60

1.40

1.20

1.00
0 10 20 30 40 50 60 70

Rubber Content (wt%)

Figure 3.8. Relationship between swelling index and rubber content

of PP/NR and PP/RRP blends in toluene at room
temperature for 70 h.
 Morphological Study

a) PP/NR b) PP/RRP

Figure 3.9. Scanning electron micrograph of tensile fracture surface

of PP/NR and PP/RRP 80/20 (wt./wt) at magnification 500X
 Morphological Study

a) PP/NR b. PP/RRP

Figure 3.10. Scanning electron micrograph of tensile fracture surface of

PP/NR and PP/RRP 50/50 (wt.wt) at magnification of 500X
 Morphological Study

a) PP/NR b. PP/RRP

Figure 3.11. Scanning electron micrograph of tensile fracture surface

of PP/NR and PP/RRP 40/60 (wt./wt) at magnification of 500X
 Conclusion
Thermoplastic elastomers (TPEs) can be produced from
recycle rubber powder and polypropylene. Their
mechanical properties and swelling behaviour are better
compare to thermoplastic elastomers based on natural
rubber and polypropylene. This observation is supported
by the SEM tensile fracture surface of the blends which
show that PP/RRP blends need a higher energy to cause
catastrophic failure than PP/NR blends.
 flat sheets as mats in car, flat roof membranes,
cable insulation and durable flooring.
OBJECTIVE 2 THERMOPLASTIC ELASTOMERs (TPEs)
BASED ON POLYPROPYLENE AND WASTE TYRE DUST

EFFECTS OF LATEX ADDITION

AND MECHANICAL MODIFICATION OF WASTE
TIRE DUST (WTD)
ON PROPERTIES OF POLYPROPYLENE-BASED
BLENDS
 Research Objective:

To investigate the effects of natural rubber latex

addition and mechanical modification of waste
tyre dust (WTD) on the tensile properties,
swelling resistance, and morphology of
polypropylene- waste tyre dust blends.
Experimental
Procedure:
Initially, the treatment involves mixing the WTD with sulphur at
50ºC and 1100 rpm for 8 min. Then, the natural rubber latex
was gradually added and the stirring continued until the
1
Modification of WTD temperature increases to 80ºC. The mixture was continuously
stirred for 7 min as to evaporate the water. Subsequently, the
WTD was kept dry in an oven at 70ºC overnight. Finally, the
WTD was mechanically modified by putting it between the nip
of a laboratory mixing mill for 5 min to produce a modified
WTD (WTDML).

2 Blends compositions: 80/20, 70/30, 60/40, 50/50 and

Melt mixing
40/60 (wt %). The blends were prepared in a Haake
Rheomix at a temperature of 180 ºC and a rotor speed of
50 rpm. PP was initially melted for 2 min prior to the
addition of WTD. The mixing was carried out for 7 min.

The blends were preheated for 6 min and compression-

3 molded for 4 min at 180 ºC. The blends were
Molding subsequently cooled down under pressure for 2 min at
ambient temperature.

Preparation of testing 4 Dumbbell specimens of 2 mm thickness were cut

specimen from the sheets.
 Characterization:
Tests were performed using an Instron 3366 tensile
tester according to ASTM 412. The readings of
Tensile properties tensile strength, elongation at break, Eb and
Young’s Modulus were recorded at the end of each
test.

The test was conducted in accordance with ASTM D471.

Swelling Resistance The specimens with dimensions 30 mm x 5 mm x 2 mm
were immersed in ASTM Oil No. 3 and toluene at ambient
temperature for 70 h and 46 h respectively. The swelling
index was identified.

The morphology of the PP/WTD blends’ tensile fractured

Morphological observation surfaces was observed using a Leica Cambridge S360
scanning electron microscope (SEM).
Results
Tensile Properties:
A decrease in tensile strength and modulus is
21 observed as WTD content increases due to
19 PP/WTD(UM)
PP/WTD(ML)
poor dist of WTD in WTD rich blends as
17 compared to in PP rich blends.
Tensile Strength (MPa)

15
Contribute to a poor transfer of stress as well
13
as a weak resistance to stress.
11
9
7
5 WTDM render a significant improvement in
80/20 70/30 60/40 50/50 40/60
tensile strength and Young’s modulus of
Blend Composition of PP/WTD (wt %) blends.

Tensile strength vs. blend composition. Can be associated with the size reduction
of WTDM during mechanical modification
860 PP/WTD(UM)
PP/WTD(ML) using a two-roll mill.
760
Young's Modulus (MPa)

660

560

460
Being non-polar, the addition of natural
360 rubber latex favors the formation of
260 interphase region and hence interfacial
160
adhesion.
80/20 70/30 60/40 50/50 40/60
Blend Composition of PP/WTD (wt %)

Plots of Young’s modulus and blend composition .

 Tensile Properties:
35
PP/WTD(UM)
Elongation at Break, Eb(%)

30 PP/WTD(ML) All blend compositions with

25 WTDM exhibit superior Eb.
20 Due to the mechanical
15
modification provided a greater
amount of WTDM surface area to
10
interact with the PP matrix and
5 hence increase the formation of
80/20 70/30 60/40 50/50 40/60
interfacial region as a result of
Blend Composition of PP/WTD (wt %)
increased interactions with the
existence of latex

The relationship between elongation at break, Eb and blend compositions

 Swelling resistance:

1,20
1,18 At the equilibrium state, the degree of
PP/WTD(UM) PP/WTD(ML)
1,16
1,14
swelling increases as the WTD content
Swelling Index

1,12 increases due to the increase of

1,10
1,08 elastomer content in the blends.
1,06
1,04
1,02
1,00
80/20 70/30 60/40 50/50 40/60
Blend Composition of PP/WTD (w t%)

Swelling index vs. blend composition in IRM 903 oil for 70 h.

Toluene the blends with WTDM inhibited oil and
1,80 PP/WTD(UM) chemical penetrations better than
PP/WTD(ML)
1,70 those without. These lower values of
1,60 uptake indicate a more restricted
Swelling Index

1,50
molecular movement of the matrix by
1,40
1,30 the increase in cross-link density as
1,20 well as by the improved interfacial
1,10
adhesion between the PP matrix and
80/20 70/30 60/40 50/50 40/60
Blend Composition of PP/WTD (w t%)
WTDM.

Variations of swelling index and blend composition in toluene for 46 h.

 Morphological Observation:

A small detached
WTDML

PP/WTD (80/20)
Unmodified PP/WTD PP/WTDM

A BIG hole
represents the
detachment of
unmodifoed
WTD. PP/WTD (40/60)

SEM micrographs of fracture surfaces

 Conclusion
The modification of WTD seems effective in improving the overall
tensile properties.

The swelling resistance of the blends with WTDM in both oil and
toluene was much better indicating an improvement in interfacial
adhesion between the PP matrix and WTDM rendered by the
modification.

A better dispersion of WTDM in the matrix and a reduction

in the particle size of WTDM were observed in the SEM
micrographs of tensile fracture surfaces.
 OBJECTIVE 3

THERMOPLASTIC ELASTOMERs (TPEs) BASED

ON POLYPROPYLENE AND RECYCLED NBR GLOVES

COMPATIBILIZING EFFECT OF DIGLYCIDYL ETHER OF

BISPHENOL-A EPOXY RESIN (DGEBA) ON PROPERTIES
OF POLYPROPYLENE (PP)/ RECYCLED ACRYLONITRILE
BUTADIENE RUBBER (rNBR) BLENDS
 Research Objective:

To investigate the influence of epoxy resin as a compatibilizer

on the properties of PP/rNBR blends
 METHODOLOGY

1. Preparation of the blends

Melt mixing
Haake Rheomix Polydrive R
600/610 mixer Compression molding
Temperature 180oC Electrically heated hydraulic press
Rotor speed 60 rpm Preheating at 180oC for 6 min
Mixing time 8 min. Compressing at 180oC for 2 min
Blending sequence Cooling under pressure for 2 min
PP – 0 min
rNBR – 6th min
EP – 7th min
2. Characterization

1. Processing torque 2. Tensile properties 3. FTIR analysis

(ASTM D 412) (SEM)
a. Tensile strength
b. Young’s modulus
c. Elongation at break

4. Swelling percentage 5. Morphology

(ASTM D 471) (SEM)
 RESULTS
1. Mixing torque

Torque development for PP/rNBR-EP blends with different blend ratio

2. Stabilization torque

Stabilization torque of PP/rNBR and PP/rNBR-EP blends at 8 min

 3. Tensile strength

Tensile strength vs. blend composition of PP/rNBR and PP/rNBR-EP blends

 4. Young’s modulus

Young’s modulus vs. blend composition of PP/rNBR and PP/rNBR-EP blends

 5. Elongation at break

Elongation at break vs. blend composition of PP/rNBR and PP/rNBR-EP blends

6. FTIR analysis
PP/rNBR-EP
2331.75
PP/rNBR

Epoxy resin
PP/rNBR-EP

1230.37 913.99

FTIR spectra of PP/rNBR and FTIR spectra of PP/rNBR-EP and

PP/rNBR-EP blends epoxy resin

The peak of the stretching vibration of CN group NBR is appeared around

2300 cm-1 in the spectrum of PP/rNBR
The peaks appearing at around 1230 cm-1 and 913 cm-1 in the spectrum of
epoxy resin are attributed to the epoxy group of epoxy resin
The absence of these three peaks in the spectrum of PP/NBRr-EP blend
might be due to the reaction of epoxy group with NBR
 CH3 CH3

CH2-CH-CH2 [ O C O CH2 CH-CH2 ] O C O CH2 CH-CH2

n
O CH3 O
CH3 OH

[ CH2-CH=CH-CH2-CH2-CH ]
n
CN

Melt mixing at 180oC

[ CH2-CH=CH-CH2-CH2-CH ] CH3 CH3

n

CN CH2-CH-CH2 [O C O CH2 CH-CH2 ] O C O CH2 CH-CH2

+ n
O
O CH3 CH OH CH3 CH
3 3

CH2-CH-CH2 [O C O CH2 CH-CH2 ] O C O CH2 CH-CH2

n
-
O
O CH3 OH CH3

Illustration of proposed reaction mechanism for epoxy resin with NBR

 7. Swelling percentage (In ASTM oil no 3)

Swelling percentage vs blend composition of PP/rNBR and PP/rNBR-EP blends which

immersed in ASTM oil No.3 for 70 hours.
 8. Morphology

PP/rNBR: 80/20 PP/rNBR-EP: 80/20

PP/rNBR: 40/60 PP/rNBR-EP: 40/60

Scanning electron micrograph of tensile fractured surface of PP/rNBR and PP/rNBR-EP

blends at different blend composition at magnification of 60x
 CONCLUSIONS

The stabilization torque decreases with addition of EP

into the blends, indicating the better processibility
Tensile properties and oil resistance of PP/rNBR-EP
blends are superior to that of PP/rNBR blends
The morphology results indicated that the addition of
epoxy resin into the blends has reduced the interaction
tension between PP and rNBR
 PUBLICATION
1. H. Ismail and Suryadiansyah, Polymer Testing, 21 (2002) 389.
2. H. Ismail and Suryadiansyah, Polym. Plast. Technol. Eng., 41 (2002) 833.
3. H. Ismail and Suryadiansyah, Polym. Plast. Technol. Eng., 43 (2004) 319.
4. H. Ismail and Suryadiansyah, J. Ins. Mater. Malaysia, 3(1) (2002) 75.
5. H. Ismail and Suryadiansyah, Jurnal Teknologi, 39 (2003) 65.
6. H. Ismail and R. Nordin, Polym. Plast. Technol. Eng., 43 (2004) 285.
7. H. Ismail, R. Nordin and A.M. Noor, Polymer Testing, 21 (2002) 565.
8. H. Ismail and R. Nordin, Prog. In Rubber Recycling Technol., 20 (2004)105.
9. H. Ismail, R. Nordin and A.M. Noor, Polym. Plast. Technol. Eng., 41 (2002) 847.
10. H. Ismail, R. Nordin and A.M. Noor, Iranian polym. J., 12 (2003) 373.
11. H. Ismail, R. Nordin and A.M. Noor, J. Ins. Mater. Malaysia, 4(2) (2003) 113.
12. H. Ismail, M. Awang and M.A. Hazizan, Polym. Plastic. Technol. Eng., 45 (2006) 463.
13. M. Awang, H. Ismail and M.A. Hazizan, Polymer Testing, 26(2007) 779.
14. H. Ismail, D. Galpaya, Z. Ahmad, Polym. Plastic. Technol. Eng., 48 (2009) 440.
15. H. Ismail, D. Galpaya and Z. Ahmad, Polym. Testing, 28 (2009) 363-370
16. M. Awang and H. Ismail, Polymer Testing. 27(2008) 321-329 .
APPROACH 2: Invention of New Product

Product 1: Interlocking Rubber Tiles/Blocks

From Recycle Rubber Wastes using a Novel
Recycling Chemical Called DeCrossChem
 Main Purpose of The Invention
1. To recycle rubber wastes such as tyres, scrap gloves,
catheters, motorbike tubes, etc. into interlocking
rubber tiles/blocks which can be used as bound
rubber tiles/mats or pavers under playground
equipments, gymnasium weight rooms and aerobics
halls or with a textured /corrugated surfaces to
prevent slipping for walkways and ramps in airport,
factories and office buildings.
2. Help Malaysian government to solve the
environmental problem of disposal various rubber
wastes through the recycling of scraps into valuable
products.
3. To find the simplest and cheapest technology to
recycle rubber wastes.
 Conventional Process for recycling
Rubber Wastes
1. Mechanical Grinding – Process which convert scrap
rubbers into rubber crumb ( 4 steps: shredding ---
separating --- granulating --- classifying ).
2. Cryogenic Grinding – Shredded rubber wastes are frozen
with liquid nitrogen ( - 196 0 C ) and then pulverized with a
hammer mill.
3. Pyrolysis – Thermal distillation of rubber wastes into
carbon black and pyrolytic oil at temperature 650 – 900 0C
in the absence of oxygen.
Easiest Way….
 Direct Burning
 LandFill
 Artificial Reef, Decoration etc.

New and Novel Process for Recycling

Rubber Wastes … !!!!!!!
 Special Feature and How It’s Work (3 Steps)

Various Rubber Wastes 1. Rubber processing Equipment Recycle Rubber

i.e. tyres, tubes, catheters, (De-Crosslink of
gloves (Sulphur Crosslink)2. DeCrossCHEM sulphur)
(Room Temperature)
STEP 1

STEP 2
1. Rubber Processing
Equipment
(Room Temperature)
2. Add Curative Agents

STEP 3
Compression
Interlocking Rubber Recycle Rubber
Tiles/Blocks Moulding at 150 oC
Compounds
SPECIAL FEATURE AND HOW IT’S WORK
De-Crosslink of
s s sy 1. DeCrossCHEM s s sy the Sulphur Links
s s sx
s 2. Mechanical Shearing s +
sx
(Rome Temperature)
s s DeCross Compound
Wastes Rubber (Recycle Rubber)
(sulfur crosslink)
Add Curative
Agent Blend with
Heat at 150 C0
New Rubber
Add Curative
Agent
s sy s
Heat at 150 0C
s s
s
New Rubber Products

DeCrossPRO – A Mechano-Chemical Process of Recycling Rubber Wastes

1 3

Recycling of Scrap Motorcycle Tube using DeCrossPRO

2 4
 5

Recycling of Scrap
Motorcycle Tube using
DeCrossPRO (continue) 6
1 3

Recycling of Rejected catheter using DeCrossPRO

2 4
1 3 3

2 44
 The Major Advantages of The Invention
1. Using the conventional rubber processing equipments,
all rubber wastes can be recycled and converted into
interlocking rubber tiles/blocks with the help of a
novel rubber recycling chemical, DeCrossCHEM.
2. Only 5 gram of DeCrossChem is needed to recycle and
converted 100 gram of rubber wastes into interlocking
rubber tiles/blocks.
3. Advantages of intelocking rubber tiles/blocks are:
Sound deadening durable
 Moisture proof impact absorption
 Easy to install non-slip/anti-fatigue
 Cheap multicolour
 Interlocking adhesive are not required
 Awards
 Gold medal at International Invention, Innovation,
Industrial Design & Technology Exhibition, 2003,
Sunway Convention Center,
16 –18 May 2003, Kuala Lumpur.
 Silver medal at Expo Science & Technology (MOSTE),
2003, 7 – 9 August 2003, Putra World Trade Center,
Kuala Lumpur.
 Silver medal at International Exhibition of Invention
New Techniques and Products, 31 Mac-4 April 2004,
Geneva, Switzerland.
 Product 2: OilZob – A Novel and
Reactive Oil Adsorbent From Various
Rubber Wastes
 Main Purpose of The Invention
1. To recycle various rubber wastes such as
tyres, scrap gloves, catheters, motorbike
tubes, etc into A Novel and Reactive
Rubber Oil Adsorbent.
2. Help Malaysian government to solve the
environmental problem of disposal
various rubber wastes through the
recycling of scraps into valuable
products.
3. To find the simplest and cheapest
technology to recycle rubber wastes.
THE MAJOR ADVANTAGES OF THE INVENTION
Using the conventional rubber processing
equipments, simple manufacturing process and
low cost, all rubber wastes can be recycled and
converted into A Novel and Reactive Rubber Oil
Adsorbent.

OilZob –The cost effective and contemporary

way to deal with the clean-up and removal of
oil spill on land and in water.

Ideal for cleaning up oil spill in congested areas

of warehouses and factories, petrol stations,
car workshops, petrochemicals and shipping
industries and all chronically spill prone areas.
 The recovered oil can, in some cases be
collected and recycled.

OilZob plus adsorbed oil can also be landfilled

or incinerated.

OilZob can adsorb up to 5 times their own

weight and will remain floating after saturation
with oil.

Manufactured in 2 different sizes and

multicolour 
(a)  Fine powder – removal of oil in
warehouses, garages, factories, kitchen,
etc.
(b)  Rough powder – in water (oil spill at sea)
HOW IT’S WORK

Rubber powder
oil adsorbent
(OilZob)

Sea Water Oil spill in the garages or factory

Oil attach to OilZob

Hand net Vacum cleaner

Sea Water Garages/ factory floor free from oil

SIMPLE AND LOW COST MANUFACTURING PROCESS

COMPOUNDING

Rubber wastes + Special

additives in [Two Roll Mill/
Internal Mixer] at Room
Temperature
COMPRESSION
MOULDING
Curing of Rubber
Wastes Compound in
[Hot Press] at 150 °C
PRODUCTION OF
POWDERED RUBBER AS
OIL ADSORBENT
Shearing of Cured Rubber Wastes
Compound in [Two Roll Mill] at
Room Temperature
OilZob-Oil adsorbent Rubber
OilZob-Oil adsorbent Rubber
 ABTEK Oil-Absorbent Mats   

ABTEK can produce custom-made oil-absorbent mats made from Reba oil-absorbent
bark, jute and discarded wool. For example, oil-absorbent beach mats can be made
according to customer specifications, so that in the event of an oil spill at sea, they
can be placed at the water’s edge to prevent oil from coming onto the beach.  

Industrial Products
The following products have been developed for businesses such as petrol stations,
car workshops and factories, as well as the petrochemical and shipping industries.
- Made of 100% natural materials
- Hydrophobic contents 
- Effective in retaining absorbed oil

AT2001 and AT2002: ABTEK quilted oil-absorbent mats

AT2011 and 2012: Oil-absorbent mats

AT2001 and AT2002: Abtek oil-absorbent mats have been thoroughly

tested by the Esso oil refinery in Norway. The mats were used to build a
dam around a 50 litre oil spill on concrete. Used together with Abtek bark,
the mats absorbed the oil completely within 15 minutes.
 Wonder Wool Oil Absorbent Mats and Pads
Wonder Wool is a perfect product for the age of big business and the growing desire to
protect the earth from the damage. It is perhaps the only oil absorbent material that
combines great durability and high adsorption capacity. It is made from low-grade domestic
wool in a weight of approximately 14 ounces per square yard. It is reusable and, at the same
time, recyclable.

This means, firstly, that Wonder Wool can be put into service to soak up oil around a machine
or along oily factory walkways until it is saturated. Then, it can be collected, squeezed out
using a laundry-style ringer designed for just this purpose, and redeployed up to 15 (fifteen)
times until its effectiveness has been exhausted. And, then, it “ain't dead yet.” Why? Because,
secondly, Wonder Wool can than be processed by a commercial industrial laundry able to
clean oily fabrics to make it ready for re-manufacturing. The Mat King will arrange to "buy-
back" the laundered fibers (in quantities of 200 pounds or greater, free from metal filings) for
re-manufacture into new Wonder Wool pads.
100% Natural Organic Biodegradable Oil Absorbent from modified organic fibers.

• CRUNCH-OIL is a Natural Organic Hydrocarbon Absorbent, which will absorb all kinds of
hydrocarbons.

• Its Organic Biodegradable Oil Absorbent fibers, will act on ground and on water with same
absorption capacity, and will even biodegrade after a period of time.

• CRUNCH-OIL is an Encapsulating Oil Absorbent that will absorb much faster than most
products in today’s market, and as a non-leaching oil absorbent product, will eliminate all
further contamination.

• The speed of absorption makes Crunch-Oil one of the very best Oil Absorbents available
today.

• CRUNCH OIL absorbent fibers makes a difference with all Oil Spill absorbents products
available, since been a natural organic oil absorbent, is environmentally friendly, and can be
used on authorized landfills or can easily be incinerated.

• Crunch-Oil absorbent fibers are Non-Toxic if not used, and has unlimited shelf life if stored
and kept dry. After oil absorption, use recommended procedures for product absorbed, and
dispose as per local regulations.
 Awards

 Gold medal at International Invention,

Innovation, Industrial Design & Technology
Exhibition, 2004, Mid Valley Exhibition Centre, 20-
22 May 2004, Kuala Lumpur.
 Gold medal at the International Trade Fair “Ideas
Inventions New Products (IENA 2005), 1-6 Nov.
2005, Nuremberg, Germany.
 UNIVERSITI SAINS MALAYSIA

A NOVEL ENVIRONMENTAL
FRIENDLY AND DEGRADABLE OIL
ABSORBENT FROM MIXED WASTE
MATERIALS

INVENTOR:
Prof. Dr. Hanafi Ismail
School of Materials and Mineral Resources Engineering
Engineering Campus, Universiti Sains Malaysia
14300 Nibong Tebal, PENANG
Tel: 04-593788 Ext. 6113 ; Fax: 04-5941011
HP : 012-5704601 Email: hanafi@eng.usm.my
Powder Absorbent Production
 UNIVERSITI SAINS MALAYSIA

Product 3: DEGRA TPE-A NOVEL

ENVIRONMENTAL FRIENDLY AND
DEGRADABLE POLYMER

INVENTOR:
Prof. Dr. Hanafi Ismail
Sam Sung Ting
School of Materials and Mineral Resources Engineering
Engineering Campus, Universiti Sains Malaysia
14300 Nibong Tebal, PENANG
Tel: 04-593788 Ext. 6113 ; Fax: 04-5941011
HP : 012-5704601 Email: hanafi@eng.usm.my
INTRODUCTION
One of the main problems which mankind faces as it
enters into the 21st century is the problem of waste
disposal management.
Synthetic polymers, such as polyethylene (PE),
polypropylene (PP), polystyrene (PS), polyvinyl chloride
(PVC), etc are used in various application such as
packaging, building and construction, electrical and
electronics, transport, agriculture, etc.
Since polymeric materials do not decompose easily,
disposal of waste polymers such as various plastics
and rubbers is a serious environmental problem.
After a certain period these polymeric materials are
not serviceable and discarded. These waste
polymeric materials need very long time for natural
degradation due to crosslink structure and the
presence of various stabilizers and additives.
The world’s consumption of polymeric materials has
increased from around 5 million tones in 1950s to
nearly 100 million tones today. Malaysian citizen
produced more than 15,000 tonnes of rubbish every
day and contains of 27% paper, 16.4 % plastic, 36.5 %
household wastes, metal 3.9 %, glass 3.7 % and others
12.5 %.
We produce and use 20 times more plastics today than we did
50 years ago.
Beside non-degradable of synthetic polymers, the shortage
of landfill space, the depletion of petroleum resources, the
increasing price of petroleum and concerns over emissions
during incineration have spurred efforts to produce
degradable polymers.
 THE IMPORTANCE OF INVENTION
(Problem Solving)

1. To produce A Novel Environmental Friendly

and Degradable Polymer using a cheap and
breakthrough technology.

2. This invention is the first time ever where the

waste plastic and rubber are used to produce
Degradable Polymer .

3. To solve the environmental problem caused by

disposal of non-degradable petroleum-derived
polymers
NOVELTY AND INVENTIVENESS

1. Degra TPE is degradable polymer and contain

15% waste plastic and rubber.
2. Degra TPE is “ready to use” polymer.
3. Degra TPE shows rubbery properties but it
can be processed using conventional plastic
equipment such as injection moulding, blow
moulding, extrusion, compression moulding,
etc.
4. Degra TPE scrap can be recycled .
5. Degra TPE is very easy to color with many
types of pigments.
6. Degra TPE is produced using Optimised Formulation
and Optimised Processing Conditions.
 USEFULNESS AND APPLICATION
1. The cost effective and contemporary way to
overcome the disposal of non-degradable petroleum
derived polymers.
2. Less labour skill is needed .
3. Mechanical properties are comparable with
commercial polymers .
4. Degra TPE can be used to manufacture any
commercial polymer products.
5. The manufacturing cost is about 30% cheaper than
commercial available polymers (lab scale) [RM5/Kg]
CHEAP AND BREAKTROUGH
TECHNOLOGY Blends of LLDPE/Waste
Step 1 Plastic/Waste Rubber/Special
COMPOUNDING Additives (accelerate
degradation) Using Optimised
(Twin Screw Compounder) Formulation and Optimised
Processing Conditions

Step 2
EXTRUSION

Step 3 PELLETIZING
(Pelletizer)

PRODUCTION OF
DEGRADABLE TPE
(Ready to use)
Compounding Process
(Twin Screw Compounder)
EXTRUSION
(Extruder)
DEGRA TPE
 Degradation Study
14
Weathering Test
Tensile Stength (MPa) 12

10

8
52% reduction
6

Before After

600

500
Elongation at break (%)

400

300

200

100
97% reduction
0

Before After
 Morphological study
Before weathering After weathering
( after 3 months)
 SOIL BURIAL TEST
10
Tensile Stength (MPa)

27% reduction
6

Before After

400
Elongation at break (%)

300

38% reduction

200

100

Before After
 Morphological study
Before Soil Burial After Soil Burial
( after 3 months)
APPLICATION – Products from
DEGRA TPE
 Grant
 USM Research University Grant with total
amount of RM867,100.00
 Award
 Gold medal at the 19th International Invention,
Innovation, Industrial Design and Technology
(ITEX 2008) Exhibition, at Kuala Lumpur
Convention Center, 9-11 May 2008.

 Silver medal at the 37th International

Exhibition of Inventions, New Techniques and
Products , Geneva, Switzerland, 1-5th April
2009.