Production of Rubber

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Production of Rubber

(Synthetic, Dry Rubber and Latex)


Industrial Waste Management
Cherry Ann L. Largo
Carmelita E. Nool
Brief History
 1920- German Hermann Staudinger
succeeded in determining the structure of
natural rubber which was the key to the
subsequent development of synthetic rubber
in many countries.

 1929- It was followed by a patent for a


synthetic rubber.

 1939- the first large-scale industrial


production began
Synthetic Rubber
 The respective product was called Buna,
from Butadiene as raw material and
Natrium (sodium) as catalyst.

 Process gas chromatographs are part of


the standard instrumentation of most
production plants for synthetic rubber.
Synthetic Rubber
 Their objective is to continuously monitor
and control processing variables such as
composition of the process streams.

 Measuring results are essential to plant


efficiency and product quality.
Process of Synthetic Rubber
Process of Synthetic Rubber
1. It starts with the refining process of oil,
coal or other hydrocarbons with naphtha as
one of the resulting products.

2. The naphtha is then combined with natural


gas to produce monomers. As feed material,
typical monomers such as butadiene, styrene,
isoprene, chloroprene, acrylonitrile, ethylene
or propylene are used.
Process of Synthetic Rubber
3. These are then treated by polymerization
using catalyst and process steam to form chains
of polymers which finally results in rubber
substances.

4. These substances are then processed to


rubber products by vulcanization.

5. In integrated plants, naphtha or even the


monomers and process steam are delivered as
raw materials from other production facilities
which are located close to the rubber plant.
BUTYL RUBBER PROCESS
BUTYL RUBBER PROCESS
1. Feed Blending
2. Polymerization and stripping
unreacted monomers
3. Recycle compression and purification
4. Finishing
RUBBER INDUSTRY
 The rubber industry can be divided into 2
areas :
Dry Rubber Industry
Eg. Tyre, Fenders, O-rings, Shoe soles, Industrial Rubber
Goods, etc.
Latex Industry
Eg. Gloves, Condoms, Catheters, Foam, Rubber Threads
etc
Dry Rubber Industry Process
WASTES HANDLING AND
TREATMENT
 Used Packaging Materials
Collected for recycling
PE / PP bag can be made into useful raw
materials like Thermoplastic Elastomers (TPE).
Heat Recovery
WASTES HANDLING AND
TREATMENT
 Chemical powder from mixing
 Factory sweeping of rubber chemicals can be
filtered and collected.
Collected in the dust collector, Can be re-
used back into rubber formulation.
WASTES HANDLING AND
TREATMENT
 Grease and lubricant oil used in
Machineries
Collected to be used as lower grade
oil/lubricant for different industries.
WASTES HANDLING AND
TREATMENT
 Unvulcanized Compound from Process
Re-used back into production
Re-formulated to cater for other rubber
products
WASTES HANDLING AND
TREATMENT
 Scorched Compound (Large volume)
Can be used to produce other rubber
products eg. Tyre compound, Car Mats,
industrial parts.
WASTES HANDLING AND
TREATMENT
 Vulcanized / Rejected Product
Trims and flashes to be crushed into rubber
powder for reclaiming.
Metal recovery using technology.
INTRA INDUSTRY WASTE
UTILIZATION
LATEX INDUSTRY
 Consists of the glove, condoms, thread
and foam industry.
 All Natural Rubber waste can be recycle
and reuse efficiently.
Latex Glove Industry Process
Waste and Handling in Latex
Industry
 Coagulant from latex tank
Currently being collected and be made into
dry rubber raw material.
Wastewater Treatment
 Pond Technology for treating the effluents.
◦ High loaded aerobic ponds and low aerobic
ponds
◦ Pre-treatment before the pond treatment
system
 Biological Method:
◦ Using Azolla and water hyancinth
Waste and Handling in Latex
Industry
 Water Treatment Tank
Sludge collected at the treatment can be
recycled back as Dry Rubber Raw Materials
Waste Problems faced by the
Rubber Industry
 DryRubber and latex waste contain metal
oxide.
◦ Requires special handling according to DOE’s
schedule waste management.
◦ Complicate the recycling process through the
Tripartate discussion between
DOE/MRB/Industry.
◦ DOE has made a great move to classify materials
as factory waste
 Latex coagulum
- Awaiting DOE’s approval on MRB proposal for
Re-use, Recycling and handling process.
THANK YOU

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