# OAR Box 1878

Prepped by Charmelle Mathews



### Document

Number: 

# 59 ) 11-1-3 8
Docket Number: 

# A-90-1 9

Printed 11/28/200811:47:27

AM Sheet 59of 68 P. 1

### Augus t 14 , 198 7 P. 2



## A-90-1 9 II-I-3 8

FINA L REPOR

T Preliminar y Economi c Analysi s o

f th e Propose dRevision t o th e Standard fo r 1,3-Butadiene : Phas e I

I

I n Partia l Fulfillment o

f Contrac t J-9-F-5-005 8 Submitted

to: Mario DiStasio Office of Regulatory

Analysis Occupational

Safety and Health Administration U.S. Department

of Labor Washington, D.C. 20210 Submitted

by:

JAC A Corp
. Management Consultant s an d Engineer

s 55 0 Plnetown Roa

d For t Washington , P

A 19034

>P. 3

a s a n Intermediat e 1 n nonpolyme r use s suc ha s th e manufactur e o f th e agri cultura l fungicide s Capta nandCaptofol , th e Industria l solven t sulfolane , andanthroquinon e dye s [32] . A breakou t o f butadien e consumptio nb y en d us e i s show

n1 n Tabl e 2-7 . Alone , tire s an

dtir e product s accoun t fo r roughl y hal f o f th e buta dien e consume d1n th e Unite dStates . Othe r en dproduct s manufacture dfro m butadien e Includ e molde dan dextrude dgoods , belts , hoses , wir e an dcabl e coating , footwear , foa m rubber , carpe t backing , automotiv e goods , appliances , recreationa l equipment , adhesives , textiles , pipe , buildin g materials , and toy s [27] . Sketche dou t 1n Figur e 2- 2 1 s th e relationshi pbetwee nbuta diene , It s derivatives , andth e variou s en dproduct s manufacture dfro m thes e derivatives . I t 1 s estimate dtha t domesti c consumptio no f butadien e 1n 198 7 wil l agai nb e in th e neighborhoo do f thre e billio npounds . However , th e deman d fo r butadien e 1 s expecte dt o grow a t a n annua l rat e o f onl y 0. 8 percen t ove r th e nex t 4 year s [3] . Deman dfo r butadien e 1 s derive dmainl y fro m th e demandfo r elastomer s in th e tir e an dautomotiv e Industries . Change s 1n thes e markets , suc ha s smalle r tire s an dImprove d tir e lif e hav e reduce d th e deman dfo r butadiene-base delastomer s an d hence , butadiene . Some o f th e decreas e 1n demandwil l b e offse t b y growt h1n non-elastome r areas , suc ha s acrylonltrlle-butadiene-styrene , bu t thes e application s ar e no t expecte dt o increas e butadien e demandgreatly . 2. 2 STYRENE-BUTADIEN E RUBBE R 2.2. 1 Descriptio n- Styrene-butadien e elastomer s ar e copolymer s consistin g o f monome r unit s o f 1,3-butadien e andstyren e (C.6H5C2H3) . A polyme r wit hmor e tha n5 0 percen t styren e 1 s technicall y referre dt o a s a styrene-butadien e elastomer , whil e on e wit hles s tha n5 0 percen t 1 s calle dstyrene-butadiene

2-1 4 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP. 4

Tabl e 2- 7 U.S . BUTADIEN E CONSUMPTION : 198 6 (Million s o f Pounds )

Breakdow no f Us e Consumptio nEn d Us e (% ) Styrene-butadien e rubbe r (SBR ) Polybutadien e (PBR ) Polychloropren e (Neoprene ) Nitril e Rubbe r (NBR ) Adiponitrile/hexamethylenedlamin e Styrene-butadien e copolyme r latexe s Acrylon1trile-butad1ene-styren e resin s (ABS ) Ethylene-Propylene-D1en e Monome r (EPDM ) Othe r use s (Pesticides , Solvents , Propellants , etc. ) 1,20 7 

### 718 22 8 9 8 35 9 294 16 3
1 6 5 0 38. 5

22. 9 

### 7. 3 3. 1 11. 5 

### 9. 4 5. 2

0.5 0 1.6 0

Tota l 3,13 2 100.0 0
Source : Develope d b

y JACA fro m dat a in [3,20 ]

2-1 5 JAC A CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER SFIGUR E 2- 2 iur*oiEH E DERIVATIVE S AN D n o USE S I N EN D PRODUCT S P. 5

IKUB5DIATE 5 FINA L POUHEIS/CHEHICAI S EH ) USE S

•- > s tura riHTlEN E COPROOUC T CIU0 E i I.MUIAOIEH E HONOHEI-- ) I
»-- ) Sll -

- ) PXTtUTAOIEH E tUJIEI -

- ) A01P0NITRUE - - ) HElAltETHTLENEOIAHIH E (IDIOAl

- > CHLOIOPREHE - - > HEOPREH E

- ) ACITLOHIIRIlE-IUIAOlEHE-SiriEN E IESIH S (A8S) - F 0 M tU C IACII W tUIIE t COATE DO t SATURATE DPtPEB S n c con HOH-IIOVE H FABRIC S (HOSPITA L SHEETS . DISPOSABL E DIAPERS , AN D BANDAGES) ADHESIVES MISCELLANEOU

S APPIICATIOK S (UTD-MPFE O GOOOS , PICWK T BINDERS FO I PAWS , ADOIIIVE S FO RfCHlAN I CEHEHI , • A M ASIESTO S BINDIN G AGENT S I N IIAI E LININGS , GASIETS , A M LIMUUH )

» - TIDE S AM

I TIK E PtODUCI S - ) ! HECHAHICA

l GOOO S ! HISCEUAHEOD S APPLIUIIOH S (FOOIWEAI , ADHESIVES , • - SEALANTS , ElECIIICA L PIOOUCI S AH O OTHE RUSES )

• - AUIOIIOtllE , TtUCt , AN D JU S TIKE S ! HIGH-IMPAC T IESIH S (IUIHL T POLTSTTtEKE ) - I ! OIHE I USE S (COKVETO RIELIS , GOL

F BALLS . HOSES , SEALS , ! GASIEIS . SHO

E SOLES , HOIO tKOIMIS , FUIHIIUIE , TOTS , « - CASE S FO I ELECTRICAL APMAHCES , AH O FLOO I TILE )
*- HTLON 4. 4 i HTLON IESIH S (KTLO

N 4, 9 AH O HTLO H 4,12 ) - ) ! HISCaiANEOU S APPLICATION S (POLTURETHAH E COATINGS . ! POLTAHIK E ADItESITES , INI IESIHS , AM I SPECIJHI I • - SURFAC E AC I IV

E AGEHTS ) IHOUSIIIA L IUBSE I GOOO S (HOSE S AND IELIS , HU E ANO CAIL E COATINGS , NON-WOVEN

TEXTILES , AHO COATING S FO I tOll S USE DIH PIIHIIH GAN

O FOO DPROCESSING ) AUIOHOTIV E AN O IRAHSPORIAITOH PIOOUCT S (HOSES , IELIS , H U E AHO CAILE , COATE DFABRICS . HIES , ADHESIVES , AHO GASIEIS ) COHS1IUCIIO H PIODUCI S (LARGE SEAL S FO RSAN S AND RAIEIHA T LOCIS , PIP E AHO IANI LININGS , HEMIAHE S FO t FLA I ROOFS , AOHESIVES , CEHEHIS . CAULIS , SEALANTS , PUITIE S AH O PAIHIS ) CONSUMERPIODUCI S (COATE DFABRICS , PROIECIIY E CLOIHIHG , HEELS , AHO SOU S FO I FOOTUEAI , AH O IECIEAIIONAL EOUirHEHT I
I - APPLIAIICE S (IFFIIGEIAIOIS . DASHERS . FAHS , AH O VACUUH CLEANERS ) BUSINES S HACHINE S AN

O IELEPHOHE S COHSUNE I ELECIROHIC S (IELEVISION S AND IAOIOS ) FURNITUR E LUGGAG E IIOOIFIERS - ) ! PACfAGIN

G BUILDIN GAN D COHSIIUCIIO H HATFRIAL S (PIPE S AH O PIP E FIITIHGS , FAUCETS , SlfOHE

RHEADS , BATHIUiS , AN

O CONDUITS ) RFCREATIOH EOUIPHEH I IIAHSPOIIAIIOH PIODUCI S (AUIOHOIII E IHIEIIORAH O EIIEIIO RCOHPUHEHIS ) OIHE I USE S

X
2-1 6 JAC A COR P • MANAGEMEN T CONSULTANTS & ENGINEER S 

# f

# 1 P. 6

EIHTUH E COPtOOUCT CRUD E I U-IUTAOIEH E IIOHONEI— > I



# I 1 I 

# a - ) BUTADIEN E ACtrlOHITRIl E UIEX-* -

I J i

• - > NITRII E RUBIEt -

-1,4-HEXAOIEXE - - ) EIHTLEHE-PROPTIEHE-OIE KHOHONE RELASIOHE R(EPOH)-), '

SIAFOtEHE t - 1 SUIFOLAHE NITIIL E LATE X ADHESIVE (NOH-WV W FABRI C tlNDEtS , FLOCIIH G ADHESIVES , PAPE I [NPREGHATIOH , LEAIKER , AID} TEXTILE IRUIKEHI , GAStE T PAPEI . AN D OI L FILTE R BONDING ) SOLUTIO N ITT tADHESIVE (ION D SOF T VIHTl . BETAIS , CUS S PUSIICS , HOOD , tUBtEI . CaiW.OII.aOIH , LEATHER , A W VULCANHE D RUBBER

) miRILE/EPOXID E ADHESIVE (BON O RETAI S AN

D HONTTCOR

I STRUCTURES ) PHEHOL-FORHALOEHTDE/HIlta E ADHESIV E (AUTOHOIIL E BRAC E LIKINGS , NEIA l ALLO

T BONDING FO I AIRCRAF T CONPtSII E STRUCTURES , COPPE RFOI L BONDING I N PIINIE I CIRCUI T IOACSS . AN

D IONDIN G NIHIL E tUIIEI , PTC . LEATHER, ROM , AN

D PLASTICS )

« - ROSE S ! SEAL S AN

D GASIEI S ! KUD U GOOO

S i o n Fia tEOUIPNEN

I - 1 ! SPONG

E ! BEltlN C

, ' FOOTWEA

R ! HIR E AN

O CABL E
» - NISCEllEANOO S

< ~ AUIOROBILE PARI S HOH-IIR E (HOSES , HEATHE RSTRIPPIN G AN

O

, ' SEALS , GROIOtEIS , AH O MODIFICATIO N O

F PLASTIC S AN

D ! ELASTOMER

S USE D I N (H E lUKUFACIURE O

F AUIOHOBILES ) ! HIE S AH

O TUBES ! HIRE AN

D CABL E INSULAIIO N APPLIANCE S ! POLTHE

RRODIFICAIIO H ! INOUSTIIA I HOS

E (NliH-AUTOHOSIVE ) ! SINGLE-PI T ROOFIN

G ! OI L ADOIIIVE S ! IHERNOriASlI C ElASIOWR S
•- - OIHERUSE S ) LUIRICAH I PRODUCTIO N ) EXIIACIIV E SOLVEN

T FO I AROMATIC

S A ACI O GA S PURIFICATIO N

IETIAHTDIOPHIHALI C AOHTORIDE-* -

• - > CAPIAN - ) l-II —
) IUTADIEHE-VIHTLPTIIDIH E LAIE X

- ) LIOUI D POLTIUIAOIEH E

- > LIQUI D POLTBUIAOIENE RESINS — '- - ALIT D IESIH S - > ! UNSATURATE

D POLTESIE I IESIH S
» - - PVC PLASIICHEI S AN

O STABLUER S

->»- - FOLIAGE FUNGICID E

•• - SEE D DRESSING S -)•
- INSEC T IEPELLAH I '- - OELOUSING AGENI -)• - TII E COR

D ADHESIVE t ~ HIRE AN

D CABL E IHSULAIIO H ) ROCIE I FUE

L BIHDER
l - AOOIIIVE S IN TH

E RUBBE RINDUSIR T

, | HuctEA RREACTO

RCOR E COATINGS ! DEEPHEl l OI L CABL

E COATINGS I - CA N COATING S
) LIOUI D POUBUIAOIEHE-SITIEH E RESIN S

- ) LIQUI D VIHT l POimHAOIEH E RESIN S I - ADOIIIVE S I N TH E RUBIERINDUSIR T - ) l NUCLEA

R(FACTORCOR

E COAIING S
« - DEEPHEl l Oi l CAIL E COAIING S I-- ADOIIIVE S I N IH

E RUBIERINDUSIR T •> ! NUCLEA

RREACTO RCOR E COMING S
» - - DEErwE U OI

L CAILE COAIING S



### s
2-1 7 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP. 7

rubbe r (SBR) . A s th e styren e conten t Increases , th e polyme r become s Increasingl y

plastic , wit ha concomitan t Increas e 1 n rigidit y and los s o f elongatio nproperties . T o simplif y

th e discussion , bot htype s o f polymer s wil l b e referre d t o a s SBR . SB R 1 s markete d1 n a soli d crum bfor m a s eithe r a rando

m copolyme r whic h1 s forme dan dthe ncure dwit hhea t (thermoset) , o r a s a bloc k copolyme r 1 n whic hfairl y lon g sequence s o f th e monomer s ar e joine dt o for m a thermoplasti c elastome r [32] . Productio no f SB Rcrum baccount s fo r th e singl e larges t us e o f butadien e (38.5%) . SB R 1 s als o produce d1 n a liqui d for m know na s latex . Thi s 1 s discusse d1 n Sectio n2. 5 2.2. 2 Manufacturin g Proces s
SB Rcrum bi s manufacture dusin g eithe r a n emulsio nproces s o r a solu tio nprocess . In compariso nt o SBRproduce db y th e emulsio nprocess , SB R produce db

y th e solutio nproces s generall y ha s a narrowe r molecula r weigh t distributio nanda highe r ds-butad1en e composition . Also , becaus e o f dif ference s i n molecula r structure , solutio nSB Rrequire s les s accelerato r t o attai na give ndegre e o f hardness . Thi s lowe r accelerato r conten t result s 1nbette r produc t characteristic s suc ha s greate r resilienc e an dblowou t resistanc e [27] . I nth e emulsio nmetho do f production , th e proces s ma y b e carrie dou t a t eithe r a hig htemperatur e (around60°C ) o r a lo w temperatur e (around 5°C ) i n a monome r an

dwate r dispersio nstabilize db y a surfactant . A

cata lys t i s use di n generatin g fre e radical s t o facilitat e polymerizatio n[32] . Inth e ho t process/polymerizatio ni s allowe dt o continu e unti l 6 0 t o 7 0 percen t conversio nI s achieved . I n th e col dprocess , th e reactio n1 s stoppe da t abou t 6 0 percent . In bot hth e ho t an dcol d processes , th e unreacte dbutadien e an dstyren e ar e recovere db y vacuu m flashin g an

dstea m stripping, the nrecycle dt o th e productio nprocess . Col dSB R1 s produce d mainl y fo r us e 1 n tir e manufacture , andaccount s fo r abou t 9 0 percen t o f th e tota l domesti c productio no f emulsio nSBR . Th e col d proces s produce s a produc t whic hi s superio r t o the ho t proces s becaus e th e col dproduc t con tain s mor e higher-molecula r weigh t polymers . Ho t SBR , whic hi s easie r t o

> 2-1 8
JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP. 8 

# 1 

# i

i i mil l andextrud e becaus e o f it s low-molecula r weigh t fraction , 1 s use d

mostl y fo r adhesiv e application s [27] . I nth e solutio nmetho do f producin g SBR , a monomer/solven t fee d 1 s polymerize dint o a solutio ncalle d rubbe r cement . Th e polymerizatio n 1 s carrie dou t 1 n th e presenc e o f catalyst s o f th e Ziegler-Natt a o r Friedel-Craft s types . Productio nproceed s 1 n a stepwis e fashio no n a semi continuou s basis , 36 5 day s pe r year . Th e majo r feedstock s use di n th e proces s includ e butadiene , styrene , Isoprene , Isobutylene , ethylene , and propylene . Polymerizatio noccur s throug ha n 1on1 c mechanis m 1n a serie s o f reactors . Reactio ntemperatur e 1 s controlle dthroug hth e us e o f refrigerants . Shortstop s ar e use dt o terminat e th e reactio nwhe nth e desire ddegre e o f conversio nha s bee nachieved . Followin g this , th e rubbe r cemen t 1 s pumpe d t o storag e tank s t o awai t furthe r processing . Whil e th e rubbe r 1 s coagu late dInt o crumb , solven t an dunreacte d monome r ar e strippe d wit hstea m o r ho t water , the nsen t o n t o a recover y

process . Th e crum

bslurr y 1 s washe d wit hwater , screened , dewatered , the nfinished . 2.2. 3 Producers , Capacitie s an dOutpu t
A s show n1 n Tabl e 2-8 , SB Rcrum b1 s currentl y

produce d b

y si xcom panie s a t si xlocations . Al l o f th e facilitie s ar e locate di n th e Gul f Coas t areas , o f Texa s an dLouisiana , ando f th e si xfacilities , onl y th e F1restone v

plan t employ s th e solutio nprocess . However , Goodyea r i s addin g capacit y t o produc e SB Rb

y th e solutio nproces s [9] . Tota l annua l capacit y fo r th e industr y

now stand s a t 2. 3 billio npounds . B y fa r th e larges t pro duce r i s Goodyear , whic haccount s fo r 3 8 percen t o f Industr y capacity . No t liste d 1 n th e tabl e 1 s Shel l Chemical' s Be l pre , Ohio , facilit y fo r manufac turing thermoplasti c styrene-butadien e bloc k copolymers . Thi s plan t ha s no t bee nInclude d sinc e th e propertie s o f thes e copolymer s diffe r fro m thos e o f SBR . Industr y

capacit y

ha s decline dsomewha t 1n recen t years . In 1984 , Phillip s Petroleu

m close ddow

nIt s 198-milllon-pound-a-yea r facilit y 1n Borger , Texas . In 1983 , Fireston e shu t dow nit s 41 9 millio npoundemulsio n plan t i n Lak e Charles , Louisiana . Also , i n 1981 , America nSyntheti c Rubbe r

> 2-1 9 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP. 9

Tabl e 2- 8 PRODUCER S O F STYRENE-BUTADIEN E RUBBE R

Company Copolyme r Rubbe r an d Chemica l Corp . Fireston e Tir e an d Rubbe r Co . Genera l Tir e an

d Rubbe r Co . B.F . Goodric hCo . Goodyea r Tir e an d Rubbe r Co . Synpo l Inc . Locatio n

Bato nRouge ,

Lak e Charle s
Odessa , T X

Por t Neches , Houston , T X

Por t Neches , L

A

, L A

T X

T X Proces s Typ e
Emulsio n

Solutio n
Emulsio n
Emulsio n Emulsio n
Emulsio n TOTA L Annua l Capacit y

(Million s o f Pounds )
27 6

26 5
29 8
32 9 87 1
36 8 2,30 7 Percen t

Industry Capacit y
12. 0

11. 5
8. 5
14. 2 37. 8
16. 0 100. 0
Sources : [19,27 ]

-> 1-W JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP.1 0

Mothballe dIt s 220-m11l1on-poun d uni t i n Louisville , Kentucky . Altogether , Industr y capacity

ha s decline dby

abou t 3 0 percen t sinc e 198 0 [19] . Tabl e 2- 9 show s productio no f SB R1 n th e Unite dState s ove r th e year s 1968-1985 . Th e pea k durin g thi s perio dwa s reache d1 n 1973 , whe n2,96 3 millio npound s o f SB Rwer e produced . Th e lo w poin t wa s 1 n 1983 , whe noutpu t wa s onl y 1,48 9 millio npounds . Productio no f SB Rrecovered , and 1 n 198 5 wa s 1,53 8 millio npounds . However , thi s figur e stil l represent s a declin e o f 4 3 percen t fro

m 197 9 productio nlevels . Change s I nth e automobil e and tir e industrie s hav e drasticall y reduce ddeman dfo r SBRove r th e las t 1 0 years . Productio no f SB Ri s expecte dt o b e fla t ove r th e nex t 5 years . Foreig ntrad e 1n SB R1 s show n1 n Tabl e 2-10 . I n 1985 , th e U.S . importe d20 9 millio npound s o f SB R(13 % o f demand ) andexporte d13 4 millio n pound s (almos t 9 % o f production) . Currently , producer s coul dmanufactur e considerabl y mor e SB Rtha n thei r officia l liste dcapacitie s suggest . Some estimate s plac e over capacit y o f domesti c producer s a t clos e t o 3 0 percent . Becaus e o f thi s overcapacity , pric e cuttin g ha s become a majo r problem fo r domesti c produ cers . Th e economi c recover y ha s encourage d a numbe r o f SB Rmanufacturer s t o continu e production ; however , depresse dprice s coul ddiscourag e rein vestmen t i

n plan t andequipment , andeventuall y leadt o mor e closure s [25] . i 2.2. 4 Uses-an d Consumptio nTrend s
I nal l o f th e application s o f SBR , th e mos t attrativ e featur e 1 s it s lo w cost . SB R i s stil l th e lowes t price dgeneral-purpos e rubbe r on th e market . Othe r attractiv e feature s includ e goo dresistanc e t o abrasion , cracking , an

dwear . I n compariso nwit hnatura l rubbe r andman y syntheti c rubbers , SBRha s superio r hea t resistanc e an dallow s smoothe r extrusions . Inaddition , SB Radhere s wel l t o man y surface s becaus e o f It s stickiness , i s easil y moldable , ha s relativel y hightensil e strengt hcompare dwit h othe r inexpensiv e elastomers , andha s goo delongatio npropertie s [32,40] . Tabl e 2-1 1 show s th e curren t patter no f en duse s fo r SBR . Th e larges t us e —

7 9 percen t —

i s 1n th e productio no f tire s andtir e pro ducts . Mechanica l rubbe r good s accoun t fo r anothe r 9 percent , andth e

2-2 1 JAC A CORP
. •MANAGEMEN T CONSULTANT S & ENGINEER SP.1 1

Tabl e 2- 9 U.S . PRODUCTIO N

AN D CONSUMPTIO N

O F SBR : 1968-8 5 (Figure s i n Million s o f Pounds )



### Yea r
198 5 198 4 198 3 198 2 198 1 198 0 197 9 197 8 197 7 197 6 197 5 197 4 197 3 197 2 197 1 197 0 196 9 196 8
Estimated . Production
1,53 8 1,88 5 1,48 9 1,73 8 2,08 5 2,24 7 2,69 2 2,82 1 2,81 9 2,67 9 2,39 8 2,67 7 2,96 3 2,95 3 2,84 8 2,65 0 2,77 6 2,77 6

Sources : [4 5 t o 56 ] 

### Consumptio n
1,60 6 1,47 5 1,45 2 1,68 7 1,98 2 2,00 9 2,54 2 2,76 8 2,750 a 2,589 a 2,372 a 2,81 2 3,02 7 2,94 9 2,78 2 2,45 1 2,61 4 2,56 7



### 1-11 JAC A CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER S

# 1 1 1 1 1 1 1 1 1 f i 1 1 

# fl fl 1 

# fl fl J „ * *

Yea r

198 5 198 4 198 3 198 2 198 1 198 0 197 9 197 8 1977 197 6
Sources : IMPORT

S AN D

Import s 209 10 3 92 8 3 7 9 5 6 11 7 92 30

' 4 5 [4 5 t o 52 ] Tabl e 2 - 1 0

EXPORT S O F STYRENE-BUTADIEN E RUBBER: (Million s o f Pounds)

Import s a s a Percen t o f Productio n
13. 0 7. 0 6. 3 5. 0 4. 0 2. 8 4. 6 3. 3 1. 1 1. 7

> 2-2 3 Export s
13 4 17 1 13 9 13 5 18 1 29 4 21 6 14 5 12 7 14 2 1976-8 5

Export s a s a Percen t o f Productio n
8. 7 9. 1 9. 3 7. 8 8. 7 13. 1 8. 0 5. 1 4. 5 5. 3

.

JAC A CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER S P.1 2P.1 3

Tabl e 2-1 1 EN D USE S FO R SB R

Products Breakdow n b y En d Us e (% )
Tire s and tir e product s 79. 1 Mechanica l rubbe r good s 9. 9 Footwear , adhesives , sealants , 11. 0 electrica l products , and othe r use s TOTA L 100. 0
Sources : [19,27 ]

2-2 4

JAC A CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER SP.1 4

remainde r b

y footwear , adhesives , sealants , electrica l productions , and miscellaneou s uses . Tabl e 2- 9 present s annua l domesti c consumptio no f dr y SB Rfo r th e perio d1968-85 . I n 1985 , a tota l o f 1,60 6 millio npound s wer e consumed . Thi s represente da 1. 6 percen t Increas e over th e precedin g year' s leve l o f 1,45 2 millio npounds . Th e upturn , however , doe s no t appea r t o signa l a long-term recover y

1 n demand . Some Industr y expert s hav e predicte dtha t th e domesti c deman dfo r SB Rwil l declin e b y 0. 3 percen t a yea r unti l 199 1 [9] . Thi s expectatio n1 s base di n larg e measur e on a projecte ddeclin e i n th e deman dfo r automobil e tires . Th e U.S . automobil e Industry' s stron g 198 5 performanc e booste ddeman dfo r SBRtemporarily , bu t 1 t i s unlikel y tha t th e Industr y

wil l continu e a t tha t level . A s in th e past , th e deman dfo r SBRwil l continu e t o b e shape dlargel y b y development s 1n th e automobil e andtir e industries . Th e marke t fo r SB R ha s bee npermanentl y

reduce db

y th e trendtowar dsmalle r car s equippe dwit h longe r wearin g radia l tire s (whic hconsume les s SBRb y weigh t tha nbia s tires) . Othe r factor s havin g a negativ e influenc e on deman dar e th e growin g popularit y

o f importe dcar s whic hcome equippe dwit hforeign-mad e tires , andth e significan t uptur ni n sale s o f importe dreplacemen t tires , whos e lo w cos t ha s adversel y

affecte dsale s o f retreade dtires . Problem s hav e als o begu nt o develo p 1n non-tir e markets . I n th e manufactur e o f automobil e andelectrica l parts , fo r example , SB Rha s begu n t o los e sale s t o thermoplasti c blend s and ethylene-propylen e elastomer s [19] . 2. 3 POLYBUTADIEN E 2.3. 1 Descriptio n Abou t 2 3 percen t o f th e tota l consumptio no f butadien e goe s int o th e productio no f polybutadiene . Polybutadien e i s a homopolyme r produce db y polymerizin g butadien e wit hitself . Althoug hpolybutadiene , Itself , i s a commerciall y

importan t en

dproduct , th e bul k o f thi s polyme r i s blende d wit hnatura l rubbe r o r copolymer s suc ha s SBRo r acrylonitrile-butadien e

2-2 5 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP.1 5

styrene . Whe ninclude dina blend , polybutadien e add s rubbery , flexibl e properties , provide s bette r mol dflow , and Improve s lo w temperatur e quali ties . By

combinin g polybutadien e wit hnatura l rubber , a produc t 1 s obtaine d whic hha s highabrasio nresistance , a lowe r tendenc y t o fle xcracking , superio r agin g resistance , goo dresistanc e t o hea t buildup , andbette r resilienc e andtensil e strengt h[27] . Fou r stereostructura l polybutadiene s ar e possible : ds-1,4 ; trans-1,4 ; viny l 1sotact1c-l,2 ; an dviny l synd1otact1c-l,2 . Th e d s Isome r 1 s preferre d becaus e o f it s superio r processin g characteristic s and abilit y t o impar t greate r flexibilit y

i n endproducts . Generally , however , Isomeri c mixture s ar e produce d[27] . 2.3. 2 Manufacturin g Proces s Th e commercia l productio no f polybutadien e 1n th e Unite dState s date s bac k t o th e 1950s , whe na coordinatio ncatalys t wa s develope dwhic hpermitte d th e us e o f an ioni c proces s enablin g bette r contro l ove r polymerization . Polybutadien e ma y

b e produce db

y eithe r solutio no r emulsio npolymerization . Fo r th e mos t part , however , productio n1 s b y mean s o f th e solutio nprocess . Insolutio npolymerization , th e relativ e amount s o f th e variou s poly butadien e isomer s i n th e finishe dproduc t ar e controlle db y th e choic e o f catalysts . Amon g th e mor e commonly-use dcatalys t system s ar e th e cobal t complex , iodine-Ziegler , nicke l complex , andn-butyl-lithium . Diagramme di n Figur e 2- 3 i s a typica l proces s fo r th e manufactur e o f cis-l,4-polybutadiene . Th e proces s consist s o f fou r majo r stages : (1 ) purificatio no f the"butadien e an dsolvent ; (2 ) reactio nandconcentration ; (3 ) blendin g andsolven t removal ; and (4 ) dryin g andpackaging . I n th e firs t stage , th e butadien e 1 s pumpe dt o a purificatio nuni t wher e 1 t 1 s distille dan

ddrie dt o remov e Inhibito r andmoisture . Th e sam e procedur e 1 s use dt o remov e unwante dwate r fro m th e solvent . I n th e secondstage , th e catalyst , butadien e andsolven t ar e passe dthroug ha serie s o f reactor s wher e polymerizatio ntake s place . Th e polyme r strea m emergin g fro

m th e las t reacto r i s flas hevaporate dt o remov e unreacte dbutadien e andsolvent .

y 2-2 6 JACA CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER S 

# I IP.1 6

BUTADIEN E CAUSTI C

HAS H 

# r\

NAOH

HATE R 

# A 

# T

_

FRES H SOLVEN T 

# X

, SOLVEN T COOLAMT ^
FRACTIONATO R

BUTADIEN E & SOLVEN T

FRAaiONATO R CATALYS T 

# =^2 5 DECANTO R f

s 

### I \ 

### , / |

WAST E ORGANIC S

WATE R SOLVEN T REMOVA L 

### coo :



### ,LA 

# C! 3

SHORTSTO P CONCENTRATO R ( 

# I 7

ANTIOXIDAN T

BLEN D TAN K

SCREE N FILTE R POLYBUTADIEN E PRODUC T DRYE R 

# "FT BALE R| 

# ITT

Source : [39 ] Figur e 2- 3 PRODUCTIO N

O F CIS-POLYBUTADIEN E

? 1-21P.1 7 

# I 

# I

Th e unreacte dbutadien e andsolven t ar e recycle dbac k t o th e reactors . I n p th e thir dstage , th e thickene dpolyme r stream i s conveye dt o blendin g tank s wher e severa l batche s o f polyme r ar e blende dt o obtai na uniform mixture . fl Followin g this , stea m

strippin g i s employe dt o recove r toluen e fo r reuse . Th e strippin g proces s leave s behin da polymeri c crum bslurry . I n th e fourt handfina l stage , th e slurr y 1 s passe dove r dewaterin g screens , drie d b y extrusion , baled , the nwrappe d 1 n polyethylen e fil m [27] , 2.3. 3 Producers , Capacitie s andOutpu t Currently , solution-polymerizatio npolybutadien e i s produce d b y fou r companie s a t fou r facilities . Th e combine dannua l productio ncapacit y o f thes e unit s i s 83 8 millio npounds . Tabl e 2-1 2 list s th e producers , th e plan t locations , andth e plan t capacities . Th e larges t produce r 1 s Goodyear , whos e Beaumont , Texa s facilit y account s fo r 3 6 percen t o f th e tota l Industr y

capacity . Th e onl y produce r o f emulsion-polymerizatio npolybutadien e i s Synpol , whic hmanufacturer s thi s produc t alon g wit hSB Ra t a facilit y i n Por t Neches , Texa s [19] . A s allude dt o earlier , th e productio no f solutio n polymerize dpolybutadien e fa r exceed s th e productio no f emulsion-polymer ize dproduct . I n 197 9 (the mos t recen t yea r fo r whic hdat a ar e available) , onl y 4 3 millio npound s o f emulsion-polymerize dpolybutadien e wer e manufac ture dcompare dt o 87 5 millio npound s o f solutio npolymerize dproduc t [59] . I n1984 , ther e wa s a closur e o f a 141-million-pound-a-yea r facilit y jointl y owne db y Phillips , Armstron g Rubber , an dGenera l Tire . Othe r tha n this , industr y

capacit y

ha s change dvery

littl e in recen t years . Capacit y utilizatio ni s estimate dt o b e abov e 7 8 percen t a t presen t [29] . Domestic productio no f polybutadien e fo r th e perio d1976-8 6 i s show n inTabl e 2-13 . Traditionally , th e productio no f polybutadien e ha s followe d th e genera l busines s cycle . However , despit e a relativel y stron g econom

y 1n1986 , productio no f polybutadien e slippe d1. 5 percen t t o 71 6 millio n pounds . Productio no f polybutadiene , lik e tha t o f othe r syntheti c rubbers , ha s bee nhur t b

y importe dcar s an

dimprove dtir e life . Change s i n th e marke t fo r syntheti c rubbe r wil l limi t polybutadien e productio nt o slow growt hove r th e nex t 5 years . 

### y 2-2 8 JACA CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER S 

# fP.1 8



# 1 I



# J I I fl fl fl fl fl A Tabl e 2-1 2 PRODUCER S O F POLYBUTADIEN E RUBBE R

Compan y
America n Syntheti c Rubbe r Corp . Fireston e Tir e an d Rubbe r Co . Genera l Tir e an d Rubbe r Co . Polysa r Grou p Synpo l Inc . Locatio n
Louisville , IC

Y
Orange , T X

Beaumont , T X
Orange , T X Por t Neches , T X Proces s Typ e
Solutio n
Solutio n
Solutio n
Solutio n Emulsio n TOTA L Annua l Capacit y (Million s o f Pounds )


### 13 9
24 3
30 2
15 4 

### a 83 8

a No t available . Source : [16 ]

s 2-2 9

JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP.1 9

Tabl e 2-1 3 U.S . PRODUCTION

AND CONSUMPTION O F POLYBUTADIENE , 1976-86 a (Figure s 1

n Million s o f Pounds )

Yea r
198 6 198 5 198 4 198 3 198 2 198 1 198 0 197 9 197 8 197 7 197 6 Production



### 71 6 727 792 73 4 63 5 75 4 68 6 87 5 83 3 79 6 776 Consumptio n



### b 83 5 90 4 79 5 58 5 763 68 3 91 0 88 3 887 793

a Indude s latex . b No t available . Sources : [4 , 4 5 t o 56 ]

2-3 0 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP.2 0

I n1985 , th e Unite dState s Importe d 14 7 millio npound s o f polybuta diene . Foreig npolybutadien e represente d1 8 percen t o f domesti c demand . A s show n1 n Tabl e 2-14 , Import s o f polybutadien e hav e fluctuate dyea r t o yea r dependin g o

n genera l economi c conditions . Currently , Import s ar e a t thei r highes t leve l fo r any o f th e year s shown . Export s o f polybutadien e hav e bee nsubjec t t o wid e fluctuation s a s well . I n 1985 , U.S . producer s exporte d5 3 millio npound s o f polybutadiene . 2.3. 4 Use s an

dConsumptio nTrend s Th e curren t patter no f en duse s fo r polybutadien e i s show nin Tabl e 2-15 . O f tota l domesti c consumption , 8 0 percen t i s use di n th e manufactur e o f automobile , truck , an dbu s tires . Combine dwit hnatura l rubbe r and SBR , polybutadien e i s use di n th e productio no f tir e tread s t o increas e resistanc e t o abrasio nan dcracking . A s muc ha s 3 0 percen t o f th e rubbe r use din carcas s compound s andsidewal l stock s ma y b e polybutadiene . I t i s use di n thi s applicatio nt o improv e resistanc e t o hea t degradatio nand blowout s [32] . Non-tir e use s capitaliz e upo npolybutadiene' s resistanc e t o abrasio n andfle xcracking , resilience , and lo w temperatur e flexibility . Amon g thes e miscellaneou s use s ar e conveyo r belts , gol f balls , hoses , seals , gaskets , sho e soles , moto r mounts , furniture , toys , case s fo r electrica l appliances , and floo r til e [27,31,42] . Domesti c consumptio no f polybutadien e 1 s show ni n Tabl e 2-13 . Th e 198 5 leve l o f 83 5 millio npound s represent s a n 8 percen t declin e fro m th e previou s year . Th e deman dfo r polybutadien e ha s Increase d sinc e 198 2 b y nearl y 2 0 percent ; however , futur e growt hfo r polybutadien e wil l b e slow . Industr y expert s predic t tha t th e us e o f polybutadien e 1 n tire s wil l even tuall y giv e wa y

t o ne w solutio npolymers . Th e Rubbe r Manufacturer s Asso ciatio npredict s a n annua l growt hrat e o f 1. 4 percen t 1 n polybutadien e deman dthroug h199 1 [9] .

2-3 1

JAC A CORP

. • MANAGEMEN T CONSULTANTS & ENGINEER STabl e 2-1 4 IMPORT S AND EXPORT S O F POLYBUTADIENE : 1975-8 5

(Million s o f Pounds ) P.2 1



# I f 

# t

Yea r Import s Import s a s a Percen t o f Consumptio n Export s Export s a s a Percen t o f Productio n 198 5 198 4 198 3 198 2 198 1 198 0 197 9 197 8 197 7 197 6 197 5 

### 14

7 14 3 10 7 6 6 6 6 6 9 97 98 12 4 5 9 4 4 17. 6

15. 8 13. 5 11. 3 

### 8. 6 10. 1 10. 7 11. 0 14. 0 

### 7. 4 6. 3 5

3 5 4 3 6 32 62 7 7 60 3 4 27 4 7 27 7. 3

6. 8 4. 9 5. 0 8. 2 11. 2 

### 6. 9 4. 1 3. 4 6. 1 4. 2

Sources : [4 5 t o 56 ]

2-3 2

JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER SP.2 2

Tabl e 2-1 5 EN D USE S FO

R POLYBUTADIEN E

Product s Breakdow nb y En d Us e (% )
Automobile , truc k and bu s tire s 8 0 High-impac t resin s (mainl y polystyrene ) 1 6 Othe r use s 4 TOTAL 10 0

Source : Develope d b

y JACA fro m dat a containe d 1

n [16 ]

' 2-3 3 JAC A CORP

. • MANAGEMEN T CONSULTANT S & ENGINEER S