Final Results

LIFE GREEN VULCAN project has made significant strides in addressing the environmental challenge posed by the recycling of vulcanized rubber, particularly from end-of-life tires (ELT). Through innovative and eco-friendly devulcanization technology, the project has demonstrated that rubber waste can be effectively reintegrated into new products, contributing to the circular economy in the automotive and tire industries.

Environmental and Industrial Context

Vulcanized rubber is notoriously difficult to recycle without compromising its quality and performance characteristics. This limitation has resulted in minimal reuse of end-of-life tires (ELT) in the production of new tires, with recycling rates of waste rubber remaining low, typically below 3% for new tire manufacturing. The automotive industry has increasingly focused on sustainability and circular practices, yet rubber, despite being one of the largest waste streams from end-of-life vehicles, has not matched the technical standards required by the industry.

Natural rubber is considered a Critical Raw Material (CRM) by the European Commission, reaffirmed in two consecutive revisions, underscoring its economic importance and the need to diversify supply sources. The EU’s stringent environmental regulations, such as the European Deforestation Regulation (EUDR), further emphasize the need for deforestation-free supply chains and prioritizing sustainable materials. The LIFE GREEN VULCAN project has addressed these challenges by offering a viable alternative through the use of recycled rubber that meets technical requirements for advanced automotive applications.

Photo: @Rubber Conversion

Key technological achievements

Devulcanized Rubber Masterbatch Production
The project successfully developed high-performance devulcanized rubber masterbatches, specifically designed for advanced technical applications. The project partners achieved significant milestones:

Stellantis: Industrialized elastomeric spring pads with a 20% content of devulcanized rubber.
Bridgestone: Developed and industrialized a PCR tire tread with a 10% content of devulcanized rubber.

These products were rigorously tested for performance, durability, and aging. Both partners confirmed that the recycled rubber met all technical specifications and is ready for commercial-scale production.

SRC 450 HP material developed by Rubber Conversion.

Photo: @Rubber Conversion

Environmental Impact and CO2 Reduction

CO2 Emission Reduction: The new rubber compounds contribute to substantial savings in raw materials and are expected to reduce cumulative CO2 emissions by 500,000 to 1 million tons of CO2 equivalent in the long term.

This technology represents a breakthrough in providing high-quality, sustainable raw materials from ELT for the European tire and automotive industries, helping them meet decarbonization goals.

Life Green Vulcan - illustration of the concept

Project Actions and Outcomes

Calibration of the physically-based rubber compound simulation tool: A fundamental step in ensuring the proper integration of recycled rubber into new products.
Development of Devulcanized SRC Masterbatches: Industrial testing and characterization of the integrated plant were successfully completed.
Preindustrial Production: Both elastomeric spring pads and PCR tire treads formulated with SRC devulcanized masterbatches were produced and validated.
Monitoring of Project Impact: Life Cycle Assessment (LCA) was performed to quantify the environmental benefits of the developed technologies.
Monitoring Exploitable Results: Intellectual property rights, business planning, and the replication and transferability of results were carefully monitored.

Long-Term Perspectives and Applications

The LIFE GREEN VULCAN project has demonstrated the scalability and applicability of its innovative devulcanization technology across different sectors:

Automotive Components: Beyond the development of spring pads and tire treads, both Bridgestone and Stellantis are exploring the use of devulcanized rubber in other automotive components.
Broader Industrial Applications: The technology also has potential applications in other fields, such as the production of seals, shoe soles, and additional rubber products, as demonstrated in the LIFE Re-Shoes project.

The adoption of these circular practices represents a significant step toward achieving more sustainable industrial production processes in Europe and beyond.

Conclusion

The LIFE GREEN VULCAN project has successfully addressed one of the critical challenges in rubber recycling, creating a path for the automotive and tire industries to integrate devulcanized rubber into high-performance products. The environmental and economic benefits of this technology are clear, positioning the project as a key contributor to the European Union’s sustainability goals and circular economy initiatives.

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