Polybutadiene Rubber Project Review

MANUFACTURE
OF
POLY BUTADIENE
RUBBER (PBR)
GUIDED BY:
P.RAMYAKRISHNA
Md. Javeed ali
12021A2531
Presented By
CONTENTS
INTRODUCTION
PROPERTIES
APPLICATIONS
GLOBAL AND INDIAN SCENARIO
DIFFERENT MANUFACTURING PROCESSES
SELECTION OF PROCESS
DESCRIPTION OF PROCESS
INTRODUCTION
Polybutadieneis asynthetic rubberthat is apolymerformed

from
thepolymerizationprocess
of
themonomer1,3butadiene.
About 20% of the synthetic rubber manufactured all over the

world is PBR.
Other IUPACnames are : poly (buta-1, 3-diene) and
Poly (but-1-ene-1, 4-diyl)
PROPERTIES
PHYSICAL PROPERTIES:
Elongation
Hardness Range
450% to
Low Temperature
650%
Range
40 to 80
Shore A
Density
940 kg/m
Tensile strength
500 to
2000PSI
Youngs modulus
THERMAL PROPERTIES:
2 to 10MPa
-150 F to -100 F
Minimum for
- 90 F
Continuous Use
High Temperature
+ 180 F to + 220 F
Range
Maximum for
+ 200 F
Continuous Use
Brittle point
- 100 F
MECHANICAL PROPERTIES:
Compression set
Good to Excellent
Rebound Rating
Fair to Excellent
Tear Resistance
Poor to Good
Impact
Poor to Good
Resistance
Abrasion
Fair to Excellent
Resistance
Adhesion to
Metal
Adhesion to
Rigid Materials
CHEMICAL RESISTANCE:
Alkalies, Dilute
Fair to Good
Alkalies,
Fair to Good
Concentrated
Alcohols
Fair to Good
Aldehydes
Good
Amines
Poor to Good
Oil Resistance
Poor
Good
Fair to Good
APPLICATIONS
Polybutadiene
is largely used in various parts of

automobile tires.
About 25% of the produced polybutadiene is used to
improve the mechanical properties of plastics.
Mostgolf
ballsare made of an elastic core of
polybutadiene surrounded by a layer of a harder material.
This rubber can also be used in railway pads, bridge
blocks, etc.
Polybutadiene is used in the manufacturing of the highrestitutiontoySuper Ball.
GLOBAL AND INDIAN SCENARIO
The
overall consumption of PBR by Indian rubber industry

today is over 33000 TPA (1993-94), amounting to a
compounded average growth rate of 6.5% per year in
last decade
PBR demand supply in India
2011-
2012-
2013-
2014-
2015-
2016-
12
13
14
15
16
17
Capacity
74
74
94
114
114
164
Production
72
74
94
114
114
164
Exports
Imports
57
68
60
55
66
31
Consumption
131
141
153
167
178
193
(KT)
Cons Growth
(%)
DIFFERENT
PROCESSES
MANUFACTURING
The various manufacturing process available are:

Solution
polymerization
Emulsion
polymerization
SOLUTION POLYMERIZATION:
Solution
polymerizationis a method of
industrialpolymerization. In this procedure, amonomer 1, 3
butadieneis dissolved in a non-reactivesolventthat contains
acatalyst.
Most
polybutadienes are made by a solution process, using

either a transition metal (Nd, Ni, or Co) complex or an alkyl
metal, as catalyst.
Since
the reaction is very exothermic, and can be explosive,

particularly with alkyl lithium catalysts, the reaction is
normally carried out in solvents like hexane, cyclohexane,
benzene or toluene.
The
solvents are used to reduce the rate of reaction,

control the heat generated by the polymerisation and to
lower the viscosity of the polymer solution in the reactor.
typical polybutadiene polymerisation would be run at

about 20% monomer and 80% solvent.
EMULSION POLYMERIZATION:
A typical emulsion polymerization formulation comprises

four basic ingredients:
1)
Monomer,
2) dispersion medium,
3) emulsifier,
4) initiator.
Monomer 1, 3 butadiene can be polymerized by emulsion
polymerization.
SELECTION OF PROCESS
WHY
This
SOLUTION POLYMERIZATION ?
is easy and simple technique

Precise control of the chemical reaction
Control of the resulting heat and viscosity
control over auto acceleration of the process
Polymer isolation step can be avoided by solvent
evaporation, distillation
DESCRIPTION OF PROCESS
Polybutadiene
rubber is produced by solution polymerization

of Butadiene monomer.
Normal heptane and toluene is used as solvents. Three
component based Ziegler-Nata catalysts system is employed
(Tri alkyl aluminium, Nickel naphthenate and Boron
trifluoride) to carry out polymerization reaction to produce
nickel based Butadiene Rubber so that high stereo specificity
is achieved.
Exothermic heat of polymerization is removed by liquid
ammonia boiling at sub-zero temperature inside reactor
jackets.
Flow diagram of PBR Polymerization
Four
stirred tank reactors are used in series to achieve

Butadiene conversion to the tune of 90%.
The rubber solution so obtained is stabilized by addition of
antioxidant at reactor outlet and stored in homogenization
tanks. Subsequently the solution is flashed (stripped) with hot
water and steam to precipitate rubber in hot condensate.
Solvent so evaporated is sent for purification in distillation
towers from where they are recycled to reactors. From
solvent purification section, high boiler bottoms is recovered
as by product and sold.
The
rubber crumbs precipitated in hot water is sent to

rubber drying /finishing section where they are dewatered
thru series of mechanical equipment (shaker screen,
expeller and expander etc.) and dried to meet volatile
matter specification.
The dried crumbs obtained, are then pressed into 35 kgs.
Bales in a baler machine and wrapped by LDPE films in a
film wrapper. They are then packed in paper bags and
stored in metal crates in the warehouse for dispatch.
Rubber bales, due to their cold flow properties get
deshaped under pressure.
Hence
metal crates are used for storing of rubber bales.

Fine rubber particles which come out during equipment
cleaning are processed in slop stripper and recovered as
PBR scrap Butadiene polymerization reaction is highly
sensitive to moisture and other impurities present in
monomer as well as in solvents and special care is required
to be taken to operate purification and other operating
systems to run within very close tolerances with respect to
process parameters.
BLOCK DIAGRAM OF PBR

POLYMERIZATION
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MANUFACTURE

Polybutadieneis asynthetic rubberthat is apolymerformed

About 20% of the synthetic rubber manufactured all over the

is largely used in various parts of

GLOBAL AND INDIAN SCENARIO

overall consumption of PBR by Indian rubber industry

The various manufacturing process available are:

polybutadienes are made by a solution process, using

the reaction is very exothermic, and can be explosive,

solvents are used to reduce the rate of reaction,

typical polybutadiene polymerisation would be run at

A typical emulsion polymerization formulation comprises

is easy and simple technique

rubber is produced by solution polymerization

Flow diagram of PBR Polymerization

stirred tank reactors are used in series to achieve

rubber crumbs precipitated in hot water is sent to

metal crates are used for storing of rubber bales.

BLOCK DIAGRAM OF PBR

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