Canigou Carlisle Plans

This website provides information on Canigou Group’s proposals to redevelop an existing industrial unit at Kingmoor Park Heathlands Industrial Estate, Carlisle. The new facility will produce carbon black from pre-processed tyre waste. Following an extensive period of pre-application consultation with the local planning authority, statutory consultees and local stakeholders which has helped inform the final plans.

A range of feedback was received via the ‘in person’ consultation event, meetings with stakeholders and the online forms and consultation website which have all helped shape the final plans to be submitted to Cumberland Council in September 2024.

Once the planning application is submitted and validated by Cumberland Council there will be further opportunity to view the final proposals and provide feedback via the Council’s planning portal. In the meantime, this website has been updated with the latest information and plans. Canigou Group remains committed to ongoing consultation with all stakeholders. If you require further information or would like to contact a member of the project team, please do so via the e-mail, telephone number or contact form below.

As well as the text on this website, we have some videos from members of the project team to help explain the proposals.

The proposed employment use is deemed acceptable in principle as it is located within an established employment park and will be contained within existing industrial buildings. The industrial nature of the proposed use is considered suitable, subject to the relevant technical assessments being undertaken to demonstrate that there will be no negative impacts resulting from the proposals.

This application is for the operation of a new recycling facility to process tyres on a site that already holds permission for B1 (Business), B2 (General Industrial), and B8 (Storage and Distribution) uses. The new facility will produce carbon black from tyre waste, which is currently being exported from Carlisle to mainland Europe.

Planning policy is supportive of such uses on industrial sites provided that they do not have an adverse impact on surrounding land uses and do not prejudice the overall development of the area.

Approximately 55 million tyres reach the end of their life in the UK each year (equivalent to 550,000 metric tonnes)

~15% re-use and re-treading.
~25% production of rubber crumb used in shock-absorbing playing surfaces and as secondary raw material in the manufacture of moulded rubber components.
~15% incineration in UK cement kilns.
~35% exported, principally for incineration in cement kilns or pyrolysis.
~10% allocated for other uses

Britain is the world’s largest exporter of waste tyres, which are mostly sent to India:

Tyres are burned in cement kilns in India’s ‘Brick Belt’ where slavery and poor working conditions are rife.
Limited environmental controls.
Cheap fuel sources give India’s factories a competitive advantage.
Open burning is also common.

The UK’s waste tyre infrastructure is inadequate:

Even in the UK, waste tyres are fly-tipped, or burned in the open as they are expensive to dispose of properly.
Waste tyre sites store tyres for too long, which can result in self-ignition causing fires with significant environmental and health impacts.
Some tyre processing generates microplastics, which may limit recycling options in the future.

What is it?

Recycling of small particles of rubber tyres.

Where is the source of the waste tyres?

An existing company located at Carlisle airport (Tyrebin) collect waste tyres from across the North-West and treats these on their site to remove the steel and fibres producing rubber granules ~ 6 mm.
15,000 metric tonnes per year of rubber granules are transported from Carlisle airport in 20 lorry movements per week, a distance of some 8 miles.

What happens onsite?

Rubber granules are stored indoors inside silos, capacity 300 metric tonnes.
Granules are fed to one of three pyrolysis towers where they are heated in the absence of oxygen.
The pyrolysis process generates three product streams:
- 6,400 metric tonnes per year of pyrolysis char (carbon black), which is shipped off site to customer(s) in 12 lorry movements per week. Up to 130 tonnes stored indoors in “big bags”.
- 7,000 metric tonnes per year of pyrolysis oil, which is shipped off site to customer(s) in 10 road tanker movements per week. Up to 160 metric tonnes stored outdoors in ten (10) off vertical tanks.
- 1,700 metric tonnes per year of pyrolysis gas, this gas is used on site for the generation of electricity to power the process. Small buffer storage on site.
Pyrolysers are licensed technology from Pyrum GmbH, first unit operational since 2015, 2nd / 3rd units brought online June 2023.

Carbon Black

Carbon black finds numerous applications, particularly in the realm of recycled goods. Due to its excellent reinforcing properties, it is commonly utilised as a filler material in the production of recycled rubber products such as tyres, conveyor belts, and automotive components.

The addition of carbon black enhances the mechanical strength, durability, and resistance to wear and tear of these recycled materials. Moreover, carbon black's ability to absorb ultraviolet light makes it an ideal additive in recycled plastic products like pipes, films, and containers, providing them with increased stability and protection against degradation from sunlight exposure.

By incorporating carbon black into recycled goods, we not only extend the lifespan of discarded materials but also contribute to sustainable practices by reducing waste and promoting the circular economy.

Liquid Hydrocarbon

A secondary product of the pyrolysis process is a liquid hydrocarbon, which finds application in the manufacturing sector for creating new products. Liquid hydrocarbon can serve as an eco-friendly substitute for materials derived from fossil fuels, thereby contributing to a diminished carbon footprint. Additionally, this process eliminates the need for crude oil extraction and its related environmental consequences and minimises transportation impacts. Within the EU, these liquid hydrocarbons are employed in tightly regulated industry sectors, ensuring adherence to high environmental standards and sustainable practices.

The site is located within the Heathlands Estate, Carlisle, CA6 4HQ, and consists of an existing industrial unit (Unit D) which will be refurbished for the proposed development.

It is accessed via a spur from the road to the north. Junction 44 of the M6 motorway is approximately 1.7 miles away, making it easily accessible for import and export activities.

The site is within Flood Zone 1, indicating a low probability of flooding. Ecological receptors are over 2km away from the site and are unlikely to be impacted by emissions.

No other planning constraints have been identified in close proximity to the site.

In July 2022 an initial stage of consultation was undertaken and led by project architects MDG Ltd which included a consultation event held at the Rockliffe Centre. A number of key themes emerged from the feedback which have been carefully considered by the project team.

Canigou is a global leader in renewable energy, bespoke financing, project management, development, construction and operation.

We are active throughout Europe, Australia and North America where we work with clients at the local level to provide a customised service.

For further information about Canigou please click here.

Redevelopment of an existing under-utilised industrial unit and the creation of circa 20 jobs onsite.
Our plans aim to minimise the export of tyre waste from Carlisle and instead, implement a renewable technology that will recycle the waste within the UK.
The proposed site is well suited to house the process with minimal construction changes required.
Support a circular economy by giving waste tyres a second use, for which there are limited recycling opportunities within the UK.
A significant reduction in the number of road haulage miles that have an impact on the carbon footprint of the waste disposal process, making it a much more sustainable solution for the existing Carlisle business that is exporting the tyres and the area as a whole.
Our proposal will create [10,000 metric tonnes] recycled carbon black to be used in the UK.
32% net gains in biodiversity as a result of the landscape/planting strategy and biodiversity enhancement measures proposed.
The proposed planting will result in the net gain of 37 trees on site to enhance biodiversity and reduce the visual impact of the industrial estate.
Appropriate ecological surveys have been conducted across the site, to ensure there are no potential impacts on habitats.

Rubber crumb is transported from a local waste site

Diverts this difficult waste from less regulated export routes (current disposal route).
Short journey within enclosed vehicles.

Rubber crumb is received on-site

Unloaded within a building then into an enclosed series of conveyors, never outside.
All tyre crumb storage is inside enclosed silos within the building, limiting the risk of self-ignition of tyres and preventing litter.

Rubber crumb is transferred into the pyrolysis process

Sealed process which heats tyre crumb to generate vapour.
Vapour is continually condensed into a liquid hydrocarbon and char (the products).
Liquid hydrocarbon product is stored within sealed, bunded tanks.
Controls in place during off-loading to prevent drips from entering the drainage system.
Extensive process monitoring and alerts if a problem arises.
- Staff trained to resolve the problem.
- Stop process.

Char (recovered carbon black) is pelletised

Abatement plant (filter) will be installed which will minimise the release of dust.
Infrastructure designed so that char is handled within a building or enclosed hoppers and conveyors.
Storage of recovered carbon black within enclosed silos.
All extraction air passes through the filter.

A small amount of non-condensable gas is burned in three small engines, which provide heat and power for the process, reducing reliance on fossil fuels.

Strict, mandatory emission limits in place to prevent pollution, and protect the environment and public health.
Continuous and strict monitoring regime will alert operators to any elevated pollutant levels, which would stop the plant from operating.

The plant will adhere to:

Mandatory regulatory standards.
All applicable guidance.
Additional guidance where necessary. For example, fire prevention standards will adhere to the Environment Agency’s guidance, which was written in consultation with the Fire Rescue Authorities.

Management Techniques:

Operated within a written management system.
Site staff will carry out regular inspections.
Extensive computerised controls through a sophisticated SCADA system (Supervisory Control and Data Acquisition) to continually monitor process conditions.
Staff training.
Auditing (internal and if required, external).

Planning Authority (Cumberland Council).

Permit application will be determined by Cumberland Council, which will also be responsible for checking that the plant is operating in accordance with the permit.

Cumberland Council will:

Check operation is within permit and planning conditions.
Check monitoring results, mandatory reporting data and inspect the facility.
Monitor noise levels if there are local concerns.
If necessary, take enforcement action:
- Issue warnings.
- Stop the process.
- Require improvements.
- Prosecutions.
- Issue fines.

Cumberland Council may consult with the Environment Agency if required.

HSE can inspect the facility regarding the safety of its workers and neighbours.

Tyrebin is a well-established reputable business based at Carlisle Airport. As a longstanding family business Tyrebin have been processing end of life tyres for the past three generations. Tyrebin have been collecting tyres from across the northwest of England and processing them for both international and national markets.

Tyrebin will be collecting, processing, and delivering 15k tons of processed rubber crumb per year to the Heathlands site which will used in the pyrolysis plant. The facility is expected to generate 2 or 3 HGV arrivals per day for imported materials and 2 or 3 departures per day for the transport of products. The expected trip generation is less than the consented B2 and B8 uses currently at the site. (It is worth noting there are 10no. members of staff required per shift and there will be a 3-shift basis across a 24-hour period. The parking provision fully accommodates these staff levels, plus visitor parking).