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Economics of Process Aid use Asia Tyre

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Economics of Process Aid use Asia Tyre & Rubber Conference December 2 3, 2011 Hari Chandra Quantum Polymer Cleveland, Ohio ... – PowerPoint PPT presentation

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Title: Economics of Process Aid use Asia Tyre


1
Economics of Process Aid use Asia Tyre Rubber
Conference December 2 3, 2011
  • Hari Chandra
  • Quantum Polymer
  • Cleveland, Ohio

2
Contents
  • GDP growth of fast growing economies
  • Rubber output and price trends
  • Options to ease pressure on NR demand
  • Ecoreen and Ecorized Tire Rubber (ETR)
  • Ecoreen use to reduce cost and NR consumption
  • Findings and Recommendation

3
US GDP 1950 - 2010
4
GDP Growth China India
5
Exchange US1 6.4 RMB
6
Indian Rupee Conversion rate US1INR 50
7
China Automobile production by year China Automobile production by year
Year Production (in million units)
1992 1.0
1999 1.2
2000 2.07
2001 2.33
2002 3.25
2003 4.44
2004 5.07
2005 5.71
2006 7.28
2007 8.88
2008 9.35
2009 13.79
2010 18.06
8
Indian automotive production Indian automotive production
Year Car Production
1999 533,149
2000 517,957
2001 654,557
2002 703,948
2003 907,968
2004 1,178,354
2005 1,264,000
2006 1,473,000
2007 1,713,479
2008 1,846,051
2009 2,175,220
2010 2,814,584
9
World Auto Output
Year Units change
1999 56,258,892 6.20
2000 58,374,162 3.80
2001 56,304,925 -3.50
2002 58,994,318 4.80
2003 60,663,225 2.80
2004 64,496,220 6.30
2005 66,482,439 3.10
2006 69,222,975 4.10
2007 73,266,061 5.80
2008 70,520,493 -3.70
2009 61,791,868 -12.40
2010 77,857,705 26.00













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12
World Auto Output
13
Average Natural Rubber-SMR 20-Prices Average Natural Rubber-SMR 20-Prices
Year USCent/KG
2000 64.3
2001 54.5
2002 75.9
2003 100.5
2004 122.5
2005 139.4
2006 195.8
2007 216.7
2008 254.4
2009 183.8
2010 333.6
2011 470.7
14
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16
MRB FOB NOON PRICES FOR SMR 20 (US
Cents/Kg) January - October 2011
17
World Rubber Output in ( X 000) tons World Rubber Output in ( X 000) tons World Rubber Output in ( X 000) tons World Rubber Output in ( X 000) tons
Year NR SR Total
2000 6,762 870 17,632
2001 7,332 10,483 17,815
2002 7,326 10,877 18,203
2003 8,005 11,341 19,361
2004 8,774 11,961 20,707
2005 8,896 12,100 21,004
2006 9,706 12,653 22,444
2007 9,833 13,387 23,188
2008 10,042 12,743 22,779
2009 9,662 12,087 21,704
2010 10,291 14,002 24,293
18
Source Malaysian Rubber Board
19
Growth of China India Auto and NR SR sectors
for 2001 - 2010
Sector Growth Averages Average Annual Growth
China auto output 19
India auto output 16
Natural Rubber (NR) output 4
Synthetic Rubber (SR) output 2
NR plus SR output 3
NR SMR 20 price increase 19
China India combined auto 19
20
Demand trend and price hike
21
Options to resolve scarcity
  • Increase NR with planting Limits speed and
    growth-gestation / Land
  • Increase SR with investment in plants Limits due
    to fossil fuel raw material scarcity
  • Design lighter weight tires Possible
  • Recycled rubber Feasible

22
Recycled Rubber
  • Abundant source Used Tires

23
Used Tires in US
  • One tire per population per year
  • At 350 Million there are 350 Million Tire
  • The amount of Rubber compound 3.0 Million Tons
  • 60 Polymer mix of NR and SR 1.8 Million Tons

24
Current Used Tire Disposal
Use Percent
Ground Rubber 26.2
Tire Derived Fuel 40.3
Used Tire 7.2
Civil Engineering 5.5
Reclaimed 2.5
Others 5.7
Land Fill 12.6
25
Current Used Tire Disposal
Use Percent Rubber/Carbon Tons
Ground Rubber 26.2 786,000 Tons
Tire Derived Fuel 40.3 1,209,120 Tons
Used Tire 7.2
Civil Engineering 5.5
Reclaimed 2.5
Others 5.7
Land Fill 12.6
26
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27
Devulcanization Set backs
  • Low green strength
  • Poor Tack
  • Increased Viscosity
  • Inability to hold fillers
  • Possible solution Use of Liquid (Depolymerized)
    NR

28
Depolymerized Natural Rubber DPR applications
  • Rubber Process Aid ML4 drops by 5- 20 units
  • Rubber Performance Improvement
  • Rheology modifier for lubricants
  • Asphalt additive
  • Has ability to bind large volumes (10X)
    of fillers

29
Impediments to use of DPR
  • Liquid and difficult to handle
  • Limited supply source
  • High cost When Natural Rubber was at 1.50 per
    LB DPR was at 3.50 / LB

30
.
Ecoreen Process Aids DPR Substitute
  • Composed of Virgin polymers Pre cross-linked
    rubber (vulcanized Rubber)
  • Types Tire Rubber (T), Butyl Rubber (B), EPDM
    (EP), NR (N) and others
  • .

31
Ecoreen T for Tire Compounds
  • Free Flowing Pellets Versus Liquid DPR
  • Function Plasticizer to reduce mix cycle time
    and increases filler holding capacity
  • Reactive Cures with the rest of polymer matrix
    and non migrating

32
Ecoreen T -Tire Rubber DP Applications
  • Rubber Process Aid ML4 drops by 20 units.
  • Improves tack Green Strength
  • Rubber Performance Improvement
  • Rheology modifier for lubricants
  • Asphalt additive
  • Thermoplastic Rubber base
  • Has ability to bind large volumes of fillers

33
Ecorized Tire Rubber (ETR)
  • Tire Rubber Powder (Tire Crumb) is ecorized to
    different levels for use in various applications
    by treating ground tire powder with Ecoreen T
    process aid

34
Tire Crumb after milling (Ecorized) with 10 PHR
Ecoreen T Curatives
35
Devulcanized Tire Crumb with Curatives, no
Ecoreen
36
Clay Versus Ecorized Tire Rubber (ETR)
  • Comparison

37
SG of Clay and Tire Filled Mixes
Mix Clay Level Clay Mix SG Clay Mix Weight / Cu Ft. ETR Level Tire Crumb Mix SG
1 100 1.28 80 LB 100 1.12
2 200 1.44 90 LB 200 1.12
3 300 1.57 98 LB 300 1.12
4 400 1.68 105 LB 400 1.12
5 500 1.75 109 LB 500 1.12
6 600 1.82 114 LB 600 1.12
7 700 1.89 118 LB 700 1.12
8 800 1.95 122 LB 800 1.12
9 900 2.00 125 LB 900 1.12
10 1000 2.04 127 LB 1000 1.12
Weight of ETR filled at all levels SG 1.12,
weight 70 LB / Cu Ft
38
SG of Ecoreen TC Vs Clay
Clay
Ecoreen TR
39
Cost of weight Vs Volume Fillers Clay and E.
Tire Crumb Weight per LB, Volume per Cu Ft 6 X
4 X ½ Mat
Filler Level Clay Filler Cost /LB E.Tire Crumb Cost / LB Clay Filler per Cu Ft E.Tire Crumb per Cu.Ft
100 0.70 0.76 55.94 53.14
200 0.57 0.64 51.24 44.75
300 0.48 0.57 47.05 39.86
400 0.42 0.52 44.05 36.36
500 0.38 0.49 41.52 34.26
600 0.34 0.46 38.63 32.16
700 0.31 0.44 36.58 30.77
800 0.29 0.43 35.30 30.07
900 0.27 0.41 33.71 28.67
1000 0.26 0.40 33.11 27.97
40
Cost per LB Ecoreen TC Vs Clay
Ecoreen TR
Clay
41
Cost by Volume ECoreen TC Vs Clay per Cu Ft (6
X 4 X ½)
Clay
Ecoreen TR
42
RHC Content in Clay and ETR Filled N 110 Black Mix
 Filler PHR Mix with Clay Mix with ETR
0 63 63
100 38 60
200 28 58
300 22 58
400 18 57
500 15 57
600 13 57
700 12 56
800 10 56
900 9 56
1000 9 56
43
RHC Rubber Hydro Carbon
44
Advantages of ETR based Mix
  • Lighter weight constant SG at 1.12 at all
    levels
  • Higher recycled content
  • Releases pressure on demand for NR and SR
  • Able to reduce costs substantially while meeting
    quality standard

45
Ref 9340 9340 9340
Material per LB Parts / LB Mix
Rubber 2.00 100 53 1.07
N 330 Black 0.45 60 32 0.14
Zinc Oxide 0.93 5 3 0.02
Stearic Acid 0.63 2 1 0.01
Wax 0.45 2.5 1 0.01
Antioxidant TQ 1.85 1 1 0.01
6PPD 2.30 1.5 1 0.02
N. Oil 0.53 15 8 0.04
Ecoreen TR 0.43 0 0 -
Total 187 1 1.32
Tire Tread Mix No Ecoreen TC
46
Ref 9340 9340 9340
Material per LB Parts / LB Mix
Rubber 2.00 100 26 0.52
N 330 Black 0.45 60 16 0.07
Zinc Oxide 0.93 5 1 0.01
Stearic Acid 0.63 2 1 0.00
Wax 0.45 2.5 1 0.00
Antioxidant TQ 1.85 1 0 0.00
6PPD 2.30 1.5 0 0.01
N. Oil 0.53 15 4 0.02
Ecoreen TR 0.43 200 52 0.22
Total 387 1 0.86
Tire Tread Mix with 200 PHR Ecoreen TC
47
Premium Tread Mixes
Ref   9338 / N 110 9338 / N 110 9338 / N 110 9339 / N 220 9339 / N 220 9339 / N 220 9340 / N 330 9340 / N 330 9340 / N 330
Material / LB Material Parts / LB Mix Parts / LB Mix Parts / LB Mix
Polymer 2.00 100 63 1.25 100 57 1.15 100 53 1.07
Black and Oil 0.68 48 30 0.20 62 36 0.19 75 40 0.19
Activators 0.84 7 4 0.04 7 4 0.03 7 4 0.03
Anti Degradants 1.29 5 3 0.04 5 3 0.04 5 3 0.03
ETR   0 0 - 0 0 - 0 0 -
Total   160 100 1.53 174 100 1.42 187   1.32
48
Ecorized Tire Rubber costs 0.43 per LB
49
ETR at loadings from 0 to 100
ETR cost 0.43 per LB
50
Ecoreen 2.0 costs 0.65 per LB
51
Three Products
  1. Ecoreen T Process Aid (0.65) Not made into
    product by itself
  2. Ecoreen Master Batch For blending and making
    products by itself (0.80)
  3. Ecorized Tire Rubber (ETR) Polymer filler to
    reduce cost and improve process /
    product (0.43)

52
9345
9343
9344
9342
Ecoreen 50
Ecoreen 25
Ecoreen TR 500 PHR
Ecoreen TR 100 PHR
1.40/LB
1.20 /LB
1.14 / LB
0.95 / LB
Control 9346
1.60 / LB
53
Examples of poor flow in spider test
54
Findings
  • Ecorized Tire Rubber decreases cost of product
    through loading high levels in tire mixes and
    molded products while improving processing
    characteristics and final product performance

55
Recommendation
  • Ecorized Tire Rubber / Crumb can be used at high
    loadings (100 to 500 PHR) in tire tread and
    retread formulations.

Quantum will provide anyone masterbatch samples
upon request with specification
56

Mix 2 Masterbatch
57
Final compound with cure
58
Mix 2 Tire
59
Mix 1 Tire
60
Mix 223 Tire
Mix 2 Tire
61
Thanks to Asia Tyre Rubber Conference 2011
Organizers for this opportunity
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