CHAPTER I

INTRODUCTION AND ITS BACKGROUND

Styrene butadiene rubber (SBR) is one of the cheaper synthetic general-purpose

elastomers that is sometimes used as a substitute for natural rubber. It can be produced
by free-radical solution polymerization or by emulsion polymerization either warm at 30
to 60°C (hot rubber) or cold at temperatures near 0°C (cold rubber). Emulsion SBR
(ESBR) continues to lose ground to solution SBR (SSBR) which is better suited for high-
performance tires. Nevertheless, emulsion SBR grades still account for more than 75%
of the total world capacity as of 2015. However, more and more SBR is produced by
solution polymerization.
Furthermore, the addition of styrene lowers the price and contributes to the good
wear and bonding properties. The addition of styrene also improves the strength,
abrasion resistance, and blend properties of polybutadiene.
As further explained in the Polymer Database (2015), the fatigue resistance and
low temperature properties of SBR are usually inferior to natural rubber, whereas its
heat-aging properties and abrasion resistance are better. Like natural rubber, SBR is
vulnerable to thermal and oxidative degradation due to the presence of double bonds in
the polydiene backbone. Degradation generally occurs through cross-linking, which
leads to an increase in stiffness (embrittlement). SBR also has poor chemical
resistance, that is, its solvent resistance and weathering properties are inferior to most
other elastomers.
Styrene butadiene rubber (SBR) is the highest volume general purpose synthetic
rubber. It can be used in similar applications as NR / IR elastomers, except in severe
dynamic application due to the inferior fatigue resistance. Typical applications include
drive couplings, haul-off pads, conveyor belts, shoe soles and heels, adhesives, roll
coverings and car tires (but not truck tires) and various other molded rubber goods.
Raw Materials
The raw materials to be used in this plant are styrene and butadiene for the
production of polymerized styrene butadiene rubber.
a. Styrene (C8H8)
Styrene is an oil organic colorless liquid that has a sweet floral smell. Styrene is
used, often in combination, to produce numerous products including rubber, plastic,
insulation, fiberglass, pipes, automobile parts, food containers, and carpet backing.
(Toxipedia, 2018)
Styrene monomer is an aromatic hydrocarbon, which, under normal conditions, is
a clear, colourless, flammable liquid. The conventional method for producing styrene
monomer is the alkylation of benzene with ethylene followed by dehydrogenation to
produce styrene monomer. The notable exception to this is the process to co-produce
styrene monomer and propylene oxide via the oxidation of propylene by ethylbenzene
hydroperoxide, also known as the 'SMPO' process. (Shell, 2018)
Styrene monomer is used to make styrene-based polymers. These, in turn, are
used in the manufacture of plastic and rubber products, including polystyrene (PS),
expandable polystyrene (EPS), acrylonitrile butadiene styrene (ABS), styrene-
acrylonitrile, styrene butadiene rubber (SBR), unsaturated polyester resins, and styrene
butadiene latices. The majority of styrene monomer is used in the production of
polystyrene. General purpose, or 'crystal' polystyrene, and high impact polystyrene are
used in everyday items such as CD cases, drinks cups, food containers and refrigerator
door liners. Expandable polystyrene, a light weight foam, is used in home insulation, as
a packaging material, as padding inside motorcycle crash helmets and car interiors, in
bridge construction, and to build film-set scenery.
Table 1. Properties of styrene monomer

Chemical formula C8H8

Molar mass 104.15 g/mol
Appearance colorless oily liquid
Odor sweet, floral
3
Density 0.909 g/cm
Melting point −30 °C (−22 °F; 243 K)
Boiling point 145 °C (293 °F; 418 K)
Solubility in water 0.03% (20°C)

b. Butadiene (C4H6)
Butadiene, either of two aliphatic organic compounds that have the formula
C4H6. The term ordinarily signifies the more important of the two, 1,3-butadiene, which
is the major constituent of many synthetic rubbers. It was first manufactured in Germany
during World War I from acetylene. During World War II, butenes from petroleum and
natural gas were the raw material for 60 percent of American butadiene production,
ethyl alcohol for the rest. Butadiene rubber has now completely displaced natural rubber
in the manufacture of automobile tires. Nearly all butadiene is made by dehydrogenation
of butane or butenes or by high-temperature cracking (breaking up of large molecules)
of petroleum distillates.
The 1,3-butadiene is the simplest member of the series of conjugated dienes,
which contain the structure C=C−C=C, the C being carbon. The wide variety of chemical
reactions peculiar to this system makes butadiene important in chemical synthesis.
Under the influence of catalysts, butadiene molecules combine with each other or with
other reactive molecules, as acrylonitrile or styrene, to form elastic, rubberlike materials.
In uncatalyzed reactions with reactive unsaturated compounds, such as maleic
anhydride, butadiene undergoes the Diels-Alder reaction, forming cyclohexene
derivatives. Butadiene is attacked by the numerous substances that react with ordinary
olefins, but the reactions often involve both double bonds (e.g., addition of chlorine
yields both 3,4-dichloro-1-butene and 1,4-dichloro-2-butene). (Britannica, 2018)
At atmospheric conditions, 1,3-butadiene exists as a colorless gas, but it is
liquefied either by cooling to -4.4° C (24.1° F) or by compressing to 2.8 atmospheres at
25° C (77° F).
Table 2. Properties of butadiene monomer

Chemical formula C4H6

Molar mass 54.0916 g/mol
Colorless gas
Appearance
or refrigerated liquid
Odor Mildly aromatic or gasoline-like
3
Density 0.64 g/cm at −6 °C, liquid
Melting point −108.9 °C (−164.0 °F; 164.2 K)
Boiling point −4.4 °C (24.1 °F; 268.8 K)
Solubility in water 1.3 g/L at 5 ℃, 735 mg/L at 20 ℃

Very soluble in acetone;

Solubility
Soluble in ether, ethanol
Vapor pressure 2.4 atm (20 °C)

The primary source of raw material will be JG Summit Petrochemical

Corporation. JG Summit Petrochemical Corporation uses Butadiene Extraction Units
(BTD) that recovers 1,3-butadiene and other 4-carbon chemicals. It also produces
ethylene by steam cracking, which is used as precursor to styrene. It houses a naphtha
that can produce 320,000 tons/year of ethylene. JG Summit Petrochemical operates a
naphtha cracker in Batangas that currently yields 110,000-120,000 tons/year of mixed
C4 from which butadiene can be extracted.
Product
This plant produces Styrene Butadiene Rubber. Styrene butadiene rubber (SBR)
is the largest volume synthetic rubber. Compared to natural rubber, SBR has better
processability, heat aging and abrasion resistance but is inferior in terms of elongation,
hot tear strength, hysteresis, resilience and tensile strength. With over 70% being
consumed in the manufacture of tyres and tyre products, demand is very much
dependent on the automotive sector.
The random copolymer has characteristics like natural rubber and contains:
 Styrene content in the range of 10-25% contributing to good wearing and
bonding characteristics
  While the butadiene unit is composed approximately 60 to 70% trans-1,4; 15 to
20% cis-1,4; and 15 to 20% 1,2 configurations for the polymer at 50°C.
Key benefits of SBR include:
 Abrasion resistance
 Perfect impact strength
 Good resilience
 High tensile strength
Proposed Plant Location
The SBR plant will be located in Batangas City, particularly Brgy.Mabacong. It is
approximately 11.26 km from the Batangas Port. It is near by several industries like
Ilijan Combined-Cycle Power Plant, which is a dual-fuel power station, JG Summit
Petrochemical Corporation which is an integrated polyethylene and polypropylene resin
manufacturer, and Pilipinas Shell Petroleum which is a downstream oil refining plant
and marketing business. The amount of land required for the proposed plant is three
hectares.

Figure 1. Proposed Plant Location

The location of the plant was determined by considering different factors, these
factors were the availability of raw materials, road accessibility, and distance from
households.
The proposed plant location is 13km away from JG Summit Petrochemical
Corporation which is the primary source of raw material for the plant. This is done to
achieve easier transportation of raw material. In regards to road accessibility, the
proposed location is adjacent to Batangas-Tabangao-Lobo Road hence, transportation
by means of land vehicle would be safe and straightforward. Furthermore, the chosen
location would mean that it would offer job opportunities to those residents living near
the plant. Since, the plant location would be estimated 340 meters to the nearest
residential houses, those who live from that specific area would be the priority in these
job opportunities, taking consideration to the capability of those individuals.
Demand Outlook
The global styrene butadiene rubber market size was valued at USD 7.84 billion
in 2015. The growing global demand from new automobile as well as replacement tires
is one of the major factors that is driving the market. Over 70% of the styrene butadiene
rubber (SBR) that is produced globally is used in the manufacturing of tires.
Synthetic rubber has replaced natural rubber (NR) across a host of applications
due to its inherent advantages in terms of stability and physical properties. In addition,
the weakening supply of natural rubber is leading to a high volatility in prices. In the light
of this situation, it has become imperative to use alternate sources such as SBR.
APAC styrene butadiene rubber market volume by application, 2014 -
2025 (Kilo Tons)

Figure 2. Global SBR Market Projection

Crude oil prices directly impact the prices of raw materials. Crude oil prices were
at an all-time high in 2011, which clearly reflected in butadiene prices that touched USD
3.0/kilo during the same period. However, the recent dip in prices of crude oil has
brought butadiene and styrene prices to record lows. These factors have led to a
significant impact on the SBR prices over the past few years.
Asia Pacific dominated the SBR market in 2015, accounting for 53.8% of the
global demand in terms of revenue. The growing automobile industry in China, India,
and Japan is expected to fuel the demand for tires, which in turn is expected to have a
positive impact on the product demand over the coming years.
For the past 10 years, Philippines have been a major importer of SBR and for
some rare occasions a minor importer of SBR. The country’s economic growth created
greater capacity for consumption for different segments of the population. This has
stipulated the demand for various products including those made from rubber, thus,
generating the need and opportunity to develop the country’s rubber product industry.
Market Share

Figure 3.
Styrene
Market
Summary
The
Philippines
styrene market
is expected to 2018 2023
witness a
CAGR of
6.11%, during
the forecast period, 2018 - 2023. In 2017, the packaging application accounted for the
highest market share with more than 48% in 2017, recording a steady growth over the
period. The application of plastics in automotive, electronics, and construction
witnessed a higher growth in the recent past.
With that, if the proposed plant will be constructed on 2020, the market share will
be 6.11% which is inclusive of all rubber production like natural and other forms of
synthetic rubber.

Figure 4. Annual Market Share for Rubber Production in the

Philippines Initial data.
Design Objectives
 The principal thrust of this project proposal is to design a Styrene Butadiene
Manufacturing Plant that will process styrene and butadiene as its raw materials to
produce Styrene-Butadiene Rubber.
Specifically, this study aims to meet the following objectives for the proposed
plant in order to come up with a feasible and economical project design:
1. To be able to construct three (3) design options following some of the engineering
standards and realistic constraints.
2. To gather data and information needed in relation to technical and economic aspects
that will justify the viability of the proposed project.
3. To assign the proper technical design specifications for the equipment of the three
design options following standard requirements.
4. To determine the capacity and efficiency of each of the design option by the
computation of the:
4.1. Material Balance
4.2. Energy Balance
5. To present acceptable designs having processes that are capable of operating
under conditions which will yield a profit providing an evaluation and under
conditions which will yield a profit providing an evaluation and computations of the
economical expenditures:
5.1 Capital Expenditures
5.2 Operating Expenditures
5.3 Net Present Values
5.4 Rate of Return
5.5 Payback Period
6. To provide safety and loss prevention in the process designs under the following:
6.1 Identification and assessment of the hazards;
6.2 Control of hazards;
6.3 Control of the processes; and
6.4 Limitations of the loss
7. To provide a construction management, project scheduling of assembling each
sections of the plant’s manufacturer’s site and the sequence and arrangement of the
major items of equipment given on the process flow sheet.
8. To provide a summary of findings, conclusion and recommendation for the proposed
Styrene-Butadiene Manufacturing Plant.
Plant Process