As a leader in solid waste management, Harden Machinery deeply understands the tire disposal challenges businesses face. With a cutting-edge intelligent control system, we unlock solutions: Abandoned tires enter our precision systems, undergoing efficient dismantling and graded shredding, transforming from stubborn pollutants into environmental black carbon for the rubber industry, clean pyrolysis oil for energy, high-quality steel wire for remelting, and TDF (Tire Derived Fuel) to reduce emissions in cement plants.

This technological leap breaks barriers, delivering a dual triumph of economic gains and environmental care—turning industry headaches into valuable assets. The case ahead showcases how Harden converts challenges into opportunities for growth and ecological stewardship in Guangdong, China.

Case Study: Overcoming Bottlenecks to Produce High-Performance TDF

Client Pain Points: A Multitude of Processing Challenges

Low throughput, material properties driving high equipment wear, and inconsistent output particle sizes

In China, where waste tire production exceeds millions of tons annually, a local environmental firm in Guangdong grappled with a host of pressing issues in its tire processing project. 

The operation was plagued by low throughput, with shredding capacity stuck at a mere 3-4 tons per hour, a bottleneck that worsened when adding just five extra tires triggered "bridging" jams, causing frequent stoppages and plummeting production efficiency. The inconsistency in tire sizes compounded the problem, making it a constant struggle to maintain a steady workflow.

Even more troubling, untreated steel bead rings infiltrated the downstream process, accelerating equipment wear and driving maintenance costs skyward, often exceeding budget expectations. 

This wear not only strained finances but also compromised the quality of the output, as uneven particle sizes hindered performance in subsequent stages. Adding to the burden, fluctuating coal prices pushed fuel costs above 50% of total expenses, severely squeezing profit margins and adding financial pressure.

These pain points didn’t just delay project timelines—they racked up significant economic losses and intensified environmental pressures from unprocessed waste and emissions, creating a perfect storm of operational and ecological challenges.

• Harden's Solution: Efficient Shredding, Unleashing Full Value Potential

Following in-depth client research, Harden's team crafted a tailored pre-processing system, led by the TD1216 dual-shaft shredder, complemented by slat conveyors, multi-star screens, and belt conveyors. 

This setup employs a "primary shredding + cyclic screening" process, directly handling waste tires of varying sizes—including those with steel bead rings—boosting throughput to ≥5 tons per hour and controlling output particle size at 50mm, ensuring a steady, reliable feed for subsequent stages.

Clients rave: "The previous headaches of material bridging, significant equipment wear, frequent maintenance, and uneven sizing have completely vanished. Our production line now runs as steadily as a clock, and we can effortlessly process 130,000 tons of waste tires annually, saving 162,500 tons of coal per year and reducing CO₂ emissions by 432,300 tons per year."

Fueled by a solid investment of approximately $8 million, the project’s three phases, once fully operational, are projected to yield an annual value of $79 million, significantly driving local employment and industry development.

• Technical Highlights: Innovative Processing and TDF Quality Assurance

What sets Harden's solution apart? It hinges on our innovative shredding and screening technology tailored for TDF production: The dual-shaft shredder’s high-torque blade shaft, blending tear-and-shear dual-action mechanisms, effortlessly handles tire flexibility and steel wire strength, dramatically cutting wrapping and jamming issues. 

Paired with the multi-star screen's distinctive design, we achieve over 95% output compliance, effectively barring impurities and guaranteeing top-notch TDF fuel quality. This 50mm TDF substitute excels in cement kilns, delivering a robust 7500 kcal/kg heat value—20% higher than coal—fueling swift economic returns.

Harden doesn't just supply equipment; we optimize the entire chain from raw materials to finished fuel, precisely addressing client pain points: low capacity, high maintenance, and inconsistent output.

• Market Applications: Expanding TDF's Global Value

Across the globe, the transformation of waste tires into TDF fuel is emerging as an industry hotspot. Harden's pre-processing system excels in serving TDF production and extends to rubber powder applications, boasting significant pricing advantages: TDF fuel often exceeds the value of traditional coal substitutes while meeting the stringent environmental standards of the EU and other regions. These high-value products generate substantial revenue from waste tires, significantly easing landfill pressures and driving the growth of a circular economy.

As a clean and efficient alternative fuel, TDF is widely adopted in cement plant kilns, effectively boosting thermal substitution rates (TSR) and reducing carbon emissions. Insights from the Tire Derived Fuel Study—a comprehensive 2023 report by Bhanu Duggirala analyzing TDF's environmental and economic impacts—underscore its superiority: Under specific conditions, TDF emissions outshine conventional fuels, cutting dioxins and furans, alleviating land use pressures, and mitigating tire fire risks. Through controlled combustion, TDF minimizes harmful emissions, propelling a global shift toward sustainable energy.

• Harden: Empowering Technology for a Greener Future

Upgrading waste tires into TDF (Tire Derived Fuel), Harden consistently addresses clients’ core needs: boosting capacity, eliminating jams, and reducing maintenance. Our dual-shaft shredders and multi-star screens, powered by high-torque and modular designs, effortlessly handle a range of flexible and tough tire materials, significantly cutting wear and enhancing efficiency. 

Moving forward, Harden will continue to drive technological breakthroughs, supporting global tire waste recovery to truly transform "black pollution" into "green gold."

Struggling with tire waste? Contact Harden! Tailored solutions, from equipment to full processes—one-stop fix. Join us in unlocking waste's new value! 

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