Raw Materials Supply Chain for Rubber Products
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John S. Dick Charles P. Rader Raw Materials Supply Chain for Rubber Products Overview of the Global Use of Raw Materials, Polymers, Compounding Ingredients, and Chemical Intermediates Contents, Preface, Introduction, Chapter 4, Index Book ISBN HANSER 978-1-56990-537-1 Hanser Publishers, Munich • Hanser PublicaƟ ons, CincinnaƟ Contents Preface . V Acknowledgments . VI 1 Introduction . 1 1.1 Rubber Industry’s Place in the World Economy . 2 1.2 The Structure of the Tire Industry . 2 1.3 The Structure of the Nontire Industry . 5 1.4 Sectors of the Nontire Rubber Industry . 7 1.4.1 The Rubber Hose Industry ...................................... 7 1.4.2 The Belt Segment ............................................. 7 1.4.3 Seals and Gaskets ............................................. 7 1.4.4 Blowout Preventers and Packers ................................. 8 1.4.5 Single-Ply Roofing ............................................. 8 1.4.6 Bushings and Motor Mounts .................................... 8 1.4.7 Molded Rubber Goods ......................................... 8 1.4.8 Tank Lining .................................................. 8 1.4.9 Wire and Cable Insulation ...................................... 9 1.4.10 Shoe Heel and Sole Applications ................................. 9 1.4.11 Sponge Rubber Products ....................................... 9 1.4.12 Rubber Weatherstripping ....................................... 9 1.4.13 Rubber Latex Products ......................................... 9 1.4.14 Rubber Rollers ................................................ 9 1.4.15 Rubber Tiles ................................................. 10 1.4.16 Rubber Bands ................................................ 10 1.5 Market Forces . 10 2 Basic Raw Materials from Earth Extractions and Agriculture . 13 2.1 Vital Basic Raw Materials for Rubber . 14 2.1.1 Crude Petroleum Oil . 14 2.1.2 Natural Gas . 20 2.1.3 Natural Rubber . 23 2.1.4 Sulfur . 25 2.1.5 Zinc Ore . 26 2.1.6 Copper Ore . 27 2.1.7 Iron Ore . 28 VIII Contents 2.1.8 Silica . 29 2.1.9 Brine and Sea Salt . 30 2.1.10 Fluorspar . 30 2.2 Important Basic Raw Materials for Rubber . 31 2.2.1 Antimony Ore . 31 2.2.2 Aluminum Ore . 31 2.2.3 Clay . 32 2.2.4 Coal . 33 2.2.5 Cobalt Ore . 34 2.2.6 Limestone . 35 2.2.7 Phosphate Rock . 35 2.2.8 Pine Trees . 36 2.2.9 Tallow (from Cattle) . 37 2.2.10 Titanium Ore . 38 2.2.11 Vegetable Oils . 38 2.3 Summary . 40 3 General-Purpose Elastomers . 41 3.1 Natural Rubber . 41 3.2 Synthetic Natural Rubber . 43 3.3 Styrene Butadiene Rubber (SBR) . 45 3.4 Butadiene Rubber (BR) . 53 3.5 Ethylene Propylene Diene Rubber (EPDM) . 58 3.6 Summary . 62 4 Specialty Elastomers . 65 4.1 Butyl Rubber . 66 4.2 Halobutyl Rubber . 69 4.3 Brominated Copolymer of Isobutylene and para-Methylstyrene (BIMSM) . 73 4.4 Nitrile Rubber . 75 4.5 Hydrogenated Nitrile Rubber (HNBR) . 79 4.6 Curable PVC/NBR Polyblends . 82 4.7 Acrylic Rubber . 86 4.8 Polychloroprene (CR) . 88 4.9 Chlorinated Polyethylene Rubber . 92 4.10 Chlorosulfonated Polyethylene (CSM) . 94 4.11 Epichlorohydrin Rubber . 96 4.12 Ethylene Acrylic Elastomer (AEM) . 99 4.13 Ethylene Vinyl Acetate (EVA) . 101 4.14 Fluoroelastomers . 104 4.15 Perfluoroelastomers (FFKM) . 109 4.16 Silicone Rubber . 110 4.17 Summary . 113 Contents IX 5 Textile Reinforcing Materials and Their Adhesive Systems Used in Rubber . 115 5.1 Textile Reinforcing Materials . 115 5.1.1 Aramid . 115 5.1.2 Carbon Fibers . 118 5.1.3 Glass Fibers . 120 5.1.4 Nylon . 122 5.1.5 Polyester Fiber . 127 5.1.6 Rayon . 130 5.1.7 Steel Cord and Cable . 134 5.2 Adhesive Systems Used in Rubber . 136 5.2.1 Dips for Rubber-to-Cord Adhesion . 136 5.2.1.1 Resorcinol Formaldehyde Resin (Liquid) . 137 5.2.1.2 Styrene Butadiene Vinylpyridine Latex . 139 5.2.1.3 Isocyanate and/or Epoxy Treatment . 142 5.2.2 Rubber Compounding Additives for Cord Adhesion . 143 5.2.2.1 Hydrated Precipitated Silica . 144 5.2.2.2 Resorcinol Formaldehyde Resin (Solid) . 146 5.2.2.3 Hexamethoxymethylmelamine (HMMM) . 148 5.2.2.4 Hexamethylene Tetramine (HMT) . 151 5.2.2.5 Cobalt Stearate . 152 5.3 Summary . 154 6 Thermoplastic Elastomers . 155 6.1 Styrenic Block Copolymers (SBC) . 156 6.2 Thermoplastic Olefins (TPO) . 160 6.3 Thermoplastic Vulcanizate (TPV) Based on PP/EPDM . 163 6.4 Thermoplastic Vulcanizate (TPV) Based on NBR/PP . 167 6.5 Thermoplastic Vulcanizate (TPV) Based on IIR/PP . 169 6.6 Thermoplastic Vulcanizate (TPV) Based on ACM/Nylon . 172 6.7 Thermoplastic Vulcanizate (TPV) Based on BIMS/Nylon . 174 6.8 Thermoplastic Polyurethanes (TPUs) . 175 6.9 Copolyester and Polyamide Block Copolymers . 177 6.10 Summary . 178 7 Polyurethane . 179 7.1 Polyols . 181 7.2 Adipic Acid-Ethylene Glycol Polyester Polyol . 181 7.3 Polypropylene Glycol Polyol . 183 7.4 Isocyanates . 184 7.4.1 4,4'-Diphenylmethane Diisocyanate (MDI) . 185 7.4.2 Toluene Diisocyanate (TDI) . 188 7.5 Chain Extenders . 189 7.5.1 1,4-Butanediol (1,4-BD) . 190 7.5.2 Bis(beta-hydroxyethyl) Ether of Resorcinol (HER) . 192 X Contents 7.5.3 Hydroquinone Di-(2-hydroxyethyl) Ether (HQEE) . 194 7.5.4 Trimethylolpropane (TMP) . 196 7.6 Methylene-Bis-o-chloroaniline (MBCA) . 197 7.7 Summary . 199 8 Carbon Black, Fillers, Reinforcing Agents, and Coupling Agents . 201 8.1 Furnace Carbon Blacks . 201 8.2 Thermal Carbon Black . 206 8.3 Acetylene Carbon Black . 208 8.4 Hydrated Precipitated Silica . 210 8.5 Fumed Silica . 213 8.6 TESPT Organosilane Coupling Agent . 215 8.7 Kaolin Clay . 217 8.8 Calcium Carbonate . 220 8.9 Talc . 222 8.10 Titanium Dioxide . 224 8.11 Ground Coal . 226 8.12 Iron Oxide . 227 8.13 Summary . 229 9 Process Oils, Synthetic Ester Plasticizers, and Processing Aids . 231 9.1 Aromatic Process Oil . 231 9.2 Naphthenic Process Oil . 234 9.3 Paraffinic Oil . 236 9.4 Rosin Oil . 239 9.5 Dioctyl Phthalate (DOP) . 240 9.6 Diisodecyl Phthalate (DIDP) . 244 9.7 Dioctyl Adipate (DOA) . 246 9.8 Dioctyl Sebacate (DOS) . 248 9.9 Butyl Oleate . 250 9.10 Dibutoxyethoxyethyl Adipate (DBEEA) . ..