BRM-loading · layering pigment…
BRM-loading · layering pigment…
Substrate · D5 · RE-TYRE FDPT · per-tonne ELT
Five out of six substrate domains emit carbon over their useful life. The Full Devulcanisation Process Train is the sixth — it takes end-of-life tire (ELT), separates Prof. Pradip K. Maji's five characterised fractions (Fine / Medium / Large / Fibre / Mixed) plus steel cord, and credits each downstream displacement against virgin equivalents. Every kg of recovered carbon black avoids 1.6 kg CO₂e of virgin furnace black; every kg of large- grade rubber avoids 3.0 kg CO₂e of virgin EPDM; landfill methane diverted is 0.6 kg CO₂e per kg ELT (IPCC AR6 Annex 5). At pilot-001 throughput, the dividend dominates the operational + embodied debit by ≈ 30×.
Net per tonne ELT
-2724
kg CO₂e
Annual saved
25,526
t / year
Lifetime saved
382.9
kt over 15 yrs
Savings vs landfill
+554 %
vs +600 kg/t baseline
Process train left-to-right from ELT intake at 1 t/h through 7 stages to 7,680 t/yr × 0.28 + 0.22 + 0.30 rubber + Fibre + Mixed + Steel outputs. The Rembrandt-style light shaft falls on Stage 5 (devulc reactor) — the value-generating step where Maji-derived Arrhenius kinetics convert vulcanised crumb back to reactivated rubber. Per-fraction yield × avoided-virgin factor sums to 2,800 kg CO₂e carbon dividend per tonne ELT; subtract 73.2 kg/t operational + 3.51 kg/t embodied = net -2,723.7 kg CO₂e / t ELT (climate-positive). Lifetime saved over 15 years: 382,890 t CO₂e. Verra VCS + Gold Standard MRV-eligible.
downstream-use route per Maji 2026-05-13 §9
| fraction | yield | avoided | downstream-use route |
|---|---|---|---|
| Fine | 28 % | 1.60 kg/kg | Reinforcing CB extender→ 448 kg CO₂e/t-ELT |
| Medium | 22 % | 3.00 kg/kg | Silica-tread compound blend→ 660 kg CO₂e/t-ELT |
| Large | 30 % | 3.00 kg/kg | Devulc feedstock / asphalt→ 900 kg CO₂e/t-ELT |
| Fibre | 7 % | 0.40 kg/kg | Nylon 6.6 + PET sec. fibre→ 28 kg CO₂e/t-ELT |
| Mixed | 6 % | 0.50 kg/kg | Surface-treat / further sort→ 30 kg CO₂e/t-ELT |
| Steel | 7 % | 1.92 kg/kg | Steel cord recycle→ 134 kg CO₂e/t-ELT |
Each fraction's avoided-virgin factor (kg CO₂e per kg displaced) × its yield mass per tonne ELT processed gives the per-fraction contribution to the carbon dividend. Fine + Large together provide the biggest single-fraction credits despite Fibre and Mixed being lower-grade outputs (the substrate doesn't paper over the quality cascade — Mixed gets 0.50 kg/kg, not 3.00).
Total dividend = 2800 kg CO₂e per tonne ELT processed. Operational debit on UK low-carbon grid (0.18 kg CO₂e/kWh) = 73.2 kg CO₂e/t. Embodied amortised across 115.2 kt lifetime throughput = 3.51 kg CO₂e/t. Net per-tonne = -2723.7 kg CO₂e (climate-positive).
Read left-to-right: facility embodied (amortised across 15-year × 7,680 t/yr lifetime throughput) plus per-tonne operational electricity = small positive debit. The Maji-derived dividend + landfill methane avoided is a large negative credit. Net comes out roughly −2724 kg CO₂e per tonne ELT — climate-positive on every well-tuned line.
| branch | mass (kg) | cost ($) | embodied (kg CO₂e) | solver wired | dominant material |
|---|---|---|---|---|---|
| elt-intake-dismantling | 9,500 | 466,800 | 46,807 | harness-route | ASTM A36 mild steel |
| primary-shredder | 7,600 | 72,960 | 21,839 | material-fea.linear | AISI 4140 alloy steel |
| granulator | 6,650 | 95,760 | 23,135 | material-fea.linear | AISI 4140 alloy steel |
| cryogenic-separator | 9,500 | 205,200 | 64,168 | pipe-flow.darcy-weisbach | Stainless 304 |
| fdpt-devulcanisation-reactor | 19,000 | 896,400 | 185,155 | devulcanisation | AISI 4140 alloy steel |
| polymer-treatment | 8,550 | 153,900 | 42,545 | pipe-flow.darcy-weisbach | Stainless 304 |
| byproduct-steel-recovery | 4,750 | 51,300 | 17,145 | flatpack-nest | ASTM A36 mild steel |
| byproduct-fibre-recovery | 4,750 | 39,900 | 19,247 | harness-route | ASTM A36 mild steel |
| energy-recovery-loop | 7,600 | 127,680 | 55,305 | pipe-flow.darcy-weisbach | Al 6061-T6 |
| ai-control-mezzanine | 6,650 | 848,100 | 41,563 | circuit-mna | Al 6061-T6 |
| safety-fire-explosion | 5,700 | 165,120 | 35,383 | circuit-mna | Stainless 304 |
| packaging-output-silos | 4,750 | 39,900 | 17,145 | — | ASTM A36 mild steel |
windows
NVIDIA GeForce RTX 5090 Laptop GPU
silicon DNA
d7ffb9a2d13e1a2759f026d691537f31…
physics-hash
3d97ba1373acac84b294942b225fbb03…
atom
brmste-atom (ATOM GB10 Grace Blackwell aarch64)
silicon DNA
458dcf26478bd82afc871b9375ae53e4…
physics-hash
3d97ba1373acac84b294942b225fbb03…
captured-at
2026-05-14T04:33:46
MRV anchor: Verra VCS + Gold Standard MRV (per-tonne ELT diverted). Per-tonne credits at current voluntary-market price ≈ £25–50 per t CO₂e. Brand discipline: only MPI (= Maji Process Integration · IIT Roorkee partnership) and Imperial (= Imperial College London WP2 + WP7 research partner) named in this page; vendor no-list per BRMSTE voice rules MUST NOT appear.
