Potential CO₂ reduction in tire manufacturing: Hycamite’s advanced carbon materials

This article was previously published on LinkedIn by Niina Grönqvist

The tire industry is under increasing pressure to minimize its environmental impact and reduce CO₂ emissions. This pressure originates from the significant contribution of manufacturing processes to a tire’s overall carbon footprint. Major tire manufacturers are actively pursuing net-zero strategies to address this challenge. For instance, Nokian Tyres has committed to achieving net-zero greenhouse gas emissions by 2050[1].

The industry uses many petrochemical materials, such as natural and synthetic rubber and carbon black, with a considerable carbon footprint. The tire industry is shifting towards novel alternatives that offer enhanced sustainability and performance, while traditional carbon black remains crucial. Hycamite, a Finnish technology company, is at the forefront of this movement, providing a new generation of carbon materials that can modernize tire manufacturing by enabling advanced low-emission and efficient processing methods.

The role of carbon black in tire manufacturing

Carbon black is a vital ingredient in tire compounds, primarily used as a reinforcing filler. It enhances the tire’s strength, durability, and resistance to wear and tear. Carbon black plays a crucial role in several key areas[2]:

• Improved durability and wear resistance: Carbon black significantly increases the tire’s resistance to abrasion, extending tire life[3].
• Enhanced strength and traction: Carbon black strengthens the rubber matrix, improving the tire’s tensile strength and providing better traction and grip[4].
• Heat dissipation: Carbon black helps conduct heat away from the tread and belts, increasing the tire’s lifespan[5].
• UV protection: Carbon black protects the tire from harmful UV radiation[5].

Types and grades of carbon black

• Carbon black is not a monolithic material. It has different types and grades, each with unique properties and applications in tire manufacturing[6].
• Furnace black is the most common type, produced by the incomplete combustion of petroleum or coal oil.
• Thermal black is produced from natural gas in the absence of air.
• Acetylene black is produced from the thermal decomposition of acetylene gas.
• The industry uses a grading system (N1XX, N2XX, etc.) to classify carbon black based on surface area and structure, which affects its performance in tire compounds.

Hycamite: A low CO₂e emissions alternative to conventional carbon black

While traditional carbon black production methods contribute significantly to CO₂ emissions[7], Hycamite offers a groundbreaking solution. Our proprietary methane-splitting technology not only produces low-carbon hydrogen but also high-quality carbon materials with a significantly lower carbon footprint. Conventional carbon black production causes 1.9-3.75kg CO₂/kg GHG emissions, whereas we are positive we can make EU Taxonomy compliant carbon product with emissions below the 1,141 kgCO₂e/kg limit. Additionally, our carbon products can have negative values when biomethane is used as a raw material.

Hycamite’s carbon materials offer several key advantages for tire manufacturers:

• Local production: Hycamite can produce carbon products locally, as methane is widely available worldwide. This reduces transportation costs and emissions while ensuring a secure and reliable supply chain.
• Scalability: Methane, obtained from various sources such as natural gas and biomethane, is readily scalable and can be transported through existing infrastructure. This allows Hycamite to meet the growing demand for sustainable carbon materials in the tire industry.
• Very low CO₂ footprint: At Hycamite, we are aware of the climate impact of the carbon products and constantly contribute to studying it. While Hycamite’s process does not release GHG emissions, the upstream use of natural gas and heating of the reactor have lifecycle GHG emissions. By choosing them correctly, we can reduce the environmental impact of carbon products or even have negative emissions with biogas.
• Ability to customize: Hycamite has developed several catalyst families that enable the production of a diverse range of carbon materials with tailored properties. This allows tire manufacturers to optimize tire performance and meet specific requirements.

Trends and drivers in the tire market

The tire market is evolving rapidly, driven by factors such as:

• Sustainability: Growing concerns and stricter regulations, such as Eco-Design for Sustainable Products Regulation, are pushing tire manufacturers to adopt sustainable practices and reduce CO₂ emissions[8].
• Fuel efficiency: Rising fuel costs and environmental concerns drive the demand for tires with lower rolling resistance.
• Technological advancements: Continuous innovation in tire technology leads to developing advanced materials, designs, and manufacturing processes that improve tire performance, durability, and sustainability[9].
• Growth of the electric vehicle (EV) market: The increasing popularity of EVs is driving the demand for specialized tires that can handle the unique requirements of electric vehicles, such as instant torque and heavier weight[10]. This presents both challenges and opportunities for tire manufacturers, who need to develop tires that can optimize EV performance while maintaining safety and durability. For instance, the average life expectancy of tires on EVs may be shorter due to the increased torque and weight, leading to a higher demand for replacements[11].
• Five key trends: Five key trends are shaping the future of tire manufacturing: connection, cost reduction, performance, sustainability, and simplification[12]. These trends encompass the need for greater connectivity and data integration, the optimization of manufacturing processes to reduce costs, the development of high-performance tires to meet evolving consumer demands, the increasing focus on sustainability and the use of eco-friendly materials, and the simplification of tire designs and manufacturing processes to improve efficiency.
• Limitations of all-season tires: While all-season tires offer convenience and versatility, they have limitations in extreme summer or winter conditions[13]. This highlights the need for specialized tires designed for specific weather conditions to ensure optimal performance and safety.

These trends create a favorable environment for Hycamite’s carbon materials, which can help tire manufacturers meet the growing demand for more sustainable and high-performance tires.

Latest scientific breakthroughs in tire manufacturing

Several scientific breakthroughs are revolutionizing tire manufacturing:

• Digital tires: Tires embedded with sensors that gather data on tire performance, road conditions, and wear and tear[14].
• Airless tires: Tires constructed from high-tech materials that do not require air pressure[15].
• Self-inflating tires: Tires equipped with sensors and pumps that automatically maintain optimal tire pressure[16].
• Sustainable materials: The use of recycled and renewable materials in tire manufacturing. Leading tire manufacturers are actively engaged in reducing their CO₂ emissions and promoting sustainability. Michelin, for example, has partnered with Enviro to develop technologies for recycling old tires into new rubber, while also focusing on producing lighter and more fuel-efficient tires[17]. Bridgestone is utilizing natural and biomass-derived rubber, reducing fuel consumption through low-rolling-resistance tires, and actively recycling old products.

These breakthroughs, combined with Hycamite’s advanced carbon materials, produced from methane and biomethane, are driving the tire industry towards a more sustainable future.

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Conclusion

Hycamite‘s advanced carbon materials present a compelling alternative to conventional carbon black in tire manufacturing.  Hycamite’s capacity to provide locally produced, scalable, and customizable carbon products with a low CO₂ footprint positions it as a key player in the tire industry’s shift toward sustainability.

Thank you team for your contribution to this article: Davide Bergna Anni Sipilä Carolina M. Ahlstrand Marko Huiskonen Aku Saarenpää Sonja Vermeulen Salla-Mari Marttinen

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References:

[1] https://company.nokiantyres.com/news-and-media/news-article/nokian-tyres-commits-to-net-zero-greenhouse-gas-emissions-continuation-of-the-company-s-long-term-work-on-sustainability/

[2] www.kemipex.com, accessed January 8, 2025, https://www.kemipex.com/news/the-role-of-carbon-black-in-tire-manufacturing#:~:text=One%20of%20the%20most%20vital,component%20in%20the%20automotive%20industry.

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