PROPOSED DESIGN OF A 77,280 DRUMS OF SYNTHETIC RUBBER PLANT TO BE

LOCATED AT 191 BAGONG POOK, GULOD LEMERY BATANGAS

 CHAPTER I

INTRODUCTION

A plant layout study is an engineering study used to analyse different physical

configurations for a manufacturing plant. It is also known as Facilities Planning and

Layout .Plant layout is a “technique of locating different machines and plant services

within the factory so that the greatest possible output of high quality at the lowest

possible total cost can be available”.

IMPORTANCE OF PLANT LAYOUT

The importance of a layout would be better appreciated if one understands the

influence of an efficient layout on the manufacturing function: it makes it smooth and

efficient. Operating efficiencies, such as economies in the cost of handling materials,

minimization of production delays and avoidance of bottle necks all these depend on a

proper layout.

An ideally laid out plant reduces manufacturing costs through reduced materials

handling, reduced personnel and equipment requirements and reduced process

inventory.

OBJECTIVES OF PLANT LAYOUT

The objectives or advantages of an ideal layout are outlined in the

paragraphs that follow. The advantages are common to all the plants,

irrespective of age; and whether a plant employs 50 workers or 50,000 makes no

difference in so far as the applicability of the plant layout advantages is

concerned

Some of these advantages are

 Economies in Handling

Nearly 30% to 40% of the manufacturing cost is accounted for, by

materials handling. Every effort should, therefore, be made to cut down on

this cost. Long distance movements should be avoided and specific handling

operations must be eliminated. A cynic may say that the cheapest way to

handle materials is not to handle them at all. But, in a factory, materials have

to be handled; and therefore, it all depends on the layout.

 Effective Use of Available Area

Every inch of the plant area is valuable, especially in urban areas.

Efforts should therefore be made to make use of the available area by

planning the layout properly. Some steps for achieving this end are:

location of equipment and services in order that they may perform multiple

functions; development of up-to-date work areas and operator job

assignments for a full utilization of the labour force

 Minimization of Production Delays

Repeat orders and new customers will be the result of prompt

execution of orders. Every management should try to keep to the delivery

 schedules. Often, the deadline dates for delivery of production orders are a

bug-a-boo to the management.

 Improved Quality Control

Timely execution of orders will be meaningful when the quality of the

output is not below expectations. To ensure quality, inspection should be

conducted at different stages of manufacture. An ideal layout provides for

inspection to ensure better quality control.

 Minimum Equipment Investment

Investment on equipment can be minimized by planned machine

balance and location, minimum handling distances, by the installation of

general purpose machines and by planned machine loading. A good plant

layout provides all these advantages.

 Better Production Control

Production Control is concerned with the production of the product of

the right type, at the right time and at a reasonable cost. A good plant

layout is a requisite for good production control and provides the

production control officers with a systematic basis upon which to build

organization and procedures.

 Better Supervision

A good plant layout ensures better supervision in two ways:

 1. Determining the number of workers to be handled by a supervisor and

2.Enabling the supervisor to get a full view of the entire plant at one

glance.

 Improved Employee Morale

Employee morale is achieved when workers are cheerful and

confident. This state of mental condition is vital to the success of any

organization.

Morale depends on:

(a)Better working condition;

(b)Better employee facilities;

(c)Reduced number of accidents;

(d)Increased earnings.

SEENTHETIC RUBBER MANUFACTURING PLANT AND COMPANY( SRMPC)

A synthetic rubber is any artificial elastomer. These are mainly polymers

synthesized from petroleum by products. About fifteen billion kilograms (thirty-three billion

pounds) of rubbers are produced annually, and of that amount two thirds are synthetic.

Global revenues generated with synthetic rubbers are likely to rise to approximately

US$56 billion in 2020.Synthetic rubber, like natural rubber, has uses in the automotive

industry for tires, door and window profiles, hoses, belts, matting, and flooring.
 Rubber in its native form is basically useless. It is only when certain chemicals are

added, the rubber thus produced is used to make varied rubber products. Synthetic

rubber is used as a substitute for natural rubber in many cases. Depending on the

chemicals added and the properties associated with it, the synthetic rubber can be as

hard as a bowling ball or as resilient as a rubber band or as soft as a sponge. When

improved material properties are required, synthetic rubber is considered. Approximately

70% of all rubber used today are one from many synthetic rubber varieties.

HISTORY OF SYNTHETIC RUBBER

The expanded use of bicycles, and particularly their pneumatic tires, starting in the

1890s, created increased demand for rubber. In 1909, a team headed by Fritz Hofmann,

working at the Bayer laboratory in Elberfeld, Germany, succeeded in polymerizing

isoprene, the first synthetic rubber.

The first rubber polymer synthesized from butadiene was created in 1910 by the

Russian scientist Sergei Vasiljevich Lebedev. This form of synthetic rubber provided the

basis for the first large-scale commercial production by the tsarist empire, which occurred

during World War I as a result of shortages of natural rubber. This early form of synthetic

rubber was again replaced with natural rubber after the war ended, but investigations of

synthetic rubber continued. Russian American Ivan Ostromislensky who moved to New

York in 1922 did significant early research on synthetic rubber and a couple of monomers

in the early 20th century. Political problems that resulted from great fluctuations in the

cost of natural rubber led to the enactment of the Stevenson Act in 1921. This act

essentially created a cartel which supported rubber prices by regulating production, but
insufficient supply, especially due to wartime shortages, also led to a search for

alternative forms of synthetic rubber.

By 1925 the price of natural rubber had increased to the point that many companies

were exploring methods of producing synthetic rubber to compete with natural rubber. In

the United States, the investigation focused on different materials from those used in

Europe, building on the early laboratory work of Fr Julius Nieuwland, a professor of

chemistry at the University of Notre Dame, who developed the synthesis of neoprene.

Studies published in 1930 written independently by Lebedev, the American

Wallace Carothers and the German scientist Hermann Staudinger led in 1931 to one of

the first successful synthetic rubbers, known as neoprene, which was developed at

DuPont under the direction of E. K. Bolton. Neoprene is highly resistant to heat and

chemicals such as oil and gasoline, and is used in fuel hoses and as an insulating material

in machinery. The company Thiokol applied their name to a competing type of rubber

based on ethylene dichloride,[5] which was commercially available in 1930.

The first rubber plant in Europe SK-1 (from Russian "Synthetic Kauchuk", Russian:

СК-1) was established (Russia) by Sergei Lebedev in Yaroslavl under Joseph Stalin's

first five-year plan on July 7, 1932.

In 1935, German chemists synthesized the first of a series of synthetic rubbers

known as Buna rubbers. These were copolymers, meaning the polymers were made up

from two monomers in alternating sequence. Other brands included Koroseal, which

Waldo Semon developed in 1935, and Sovprene, which Russian researchers created in

1940.
World War II

Sheet of synthetic rubber coming off the rolling mill at the plant of Goodrich (1941)

B. F. Goodrich Company scientist Waldo Semon developed a new and cheaper version

of synthetic rubber known as Ameripol in 1940. Ameripol made synthetic rubber

production much more cost effective, helping to meet the United States' needs during

World War II.

Production of synthetic rubber in the United States expanded greatly during World

War II, since the Axis powers controlled nearly all the world's limited supplies of natural

rubber by mid-1942.[citation needed] Military trucks needed rubber for tires, and rubber

was used in almost every other war machine. The U.S. government launched a major

(and largely secret) effort to improve synthetic rubber production. A large team of

chemists from many institutions were involved, including Calvin Souther Fuller of Bell

Labs. The rubber designated GRS (Government Rubber Styrene), a copolymer of

butadiene and styrene, was the basis for U.S. synthetic rubber production during World

War II. By 1944, a total of 50 factories were manufacturing it, pouring out a volume of the

material twice that of the world's natural rubber production before the beginning of the

war. It still represents about half of total world production.

Operation Point-blank bombing targets of Nazi Germany included the Schkopau

(50,000 tons/yr) plant and the Hüls synthetic rubber plant near Recklinghausen (30,000,

17%),[7] and the Kölnische Gummifäden Fabrik tire and tube plant at Deutz on the east

bank of the Rhine.[8] The Ferrara, Italy, synthetic rubber factory (near a river bridge) was

bombed August 23, 1944.Three other synthetic rubber facilities were at

Ludwigshafen/Oppau (15,000), Hanover/Limmer (reclamation, 20,000), and Leverkusen

(5,000). A synthetic rubber plant at Oświęcim, in Nazi-occupied Poland, was under

construction on March 5, 1944[9] operated by IG Farben and supplied with slave labor,

by the SS, from the associated camp Auschwitz III (Monowitz).

Post-war

Solid-fuel rockets during World War II used nitrocellulose for propellants, but it was

impractical and dangerous to make such rockets very large. During the war, California

Institute of Technology (Caltech) researchers came up with a new solid fuel based on

asphalt mixed with an oxidizer (such as potassium or ammonium perchlorate), and

aluminium powder. This new solid fuel burned more slowly and evenly than nitrocellulose,

and was much less dangerous to store and use, but it tended to slowly flow out of the

rocket in storage and the rockets using it had to be stockpiled nose down.

After the war, Caltech researchers began to investigate the use of synthetic

rubbers to replace asphalt in their solid fuel rocket motors. By the mid-1950s, large

missiles were being built using solid fuels based on synthetic rubber, mixed with

ammonium perchlorate and high proportions of aluminium powder. Such solid fuels could

be cast into large, uniform blocks that had no cracks or other defects that would cause

non-uniform burning. Ultimately, all large solid-fuel military rockets and missiles would

use synthetic-rubber-based solid fuels, and they would also play a significant part in the

civilian space effort.

 Additional refinements to the process of creating synthetic rubber continued after

the war. The chemical synthesis of isoprene accelerated the reduced need for natural

rubber, and the peacetime quantity of synthetic rubber exceeded the production of natural

rubber by the early 1960s.

Synthetic rubber is used a great deal in printing on textiles, in which case it is called

rubber paste. In most cases titanium dioxide is used with copolymerization and volatile

matter in producing such synthetic rubber for textile use. Moreover, this kind of

preparation can be considered to be the pigment preparation based on titanium dioxide.

By the 1960s, most chewing gum companies had switched from using chicle to butadiene-

based synthetic rubber which was cheaper to manufacture.

Natural vs. synthetic rubber

Chemical structure of cis-polyisoprene, the main constituent of natural rubber.

Synthetic cis-polyisoprene and natural cis-polyisoprene are derived from different

precursors by different chemical pathways.

Natural rubber, coming from latex of Hevea brasiliensis, is mainly poly-cis-

isoprene containing traces of impurities like protein, dirt etc. Although it exhibits many

excellent properties in terms of mechanical performance, natural rubber is often inferior

to certain synthetic rubbers, especially with respect to its thermal stability and its

compatibility with petroleum products.

Synthetic rubber, like other polymers, is made from various petroleum-based

monomers. The most prevalent synthetic rubbers are styrene-butadiene rubbers (SBR)
derived from the copolymerization of styrene and 1,3-butadiene. Other synthetic rubbers

are prepared from isoprene (2-methyl-1,3-butadiene, yielding polyisoprene), chloroprene

(2-chloro-1,3-butadiene), and isobutylene (methylpropene) with a small percentage of

isoprene for cross-linking (this product is called butyl rubber). These and other monomers

can be mixed in various proportions to be copolymerized to produce products with a range

of physical, mechanical, and chemical properties. The monomers can be produced pure,

and the addition of impurities or additives can be controlled by design to give optimal

properties. Polymerization of pure monomers can be better controlled to give a desired

proportion of cis and trans double bonds.

Both natural rubber and synthetic rubber (IR) have high tear resistance, good low

temperature flexibility, and high tensile strength. An advantage natural rubber has over

synthetic rubber is that natural rubber has higher tensile strength, higher tear resistance,

and low odour compared to IR. Special properties can also be found in other synthetic

rubbers besides IR. These can include chemical resistances, fluid resistances, ozone

resistances, electrical resistances, and more. In addition, synthetic rubbers can have

excellent heat resistance, lower temperature resistance, and heat aging improvements.

Another consideration for choosing between natural rubbers vs. synthetic rubber is that

natural rubber contains natural proteins which may cause allergic reactions when in

placed in contact with human skin for prolonged periods. Despite these differences

between natural rubber and synthetic rubber, both natural rubber and synthetic rubber

are in high demand by manufacturers due to their low costs and satisfactory performance

for most applications. According to Statista, there were 15,189 thousand metric tons of

synthetic rubber and 13,225 thousand metric tons of natural rubber globally consumed in
2017. Indeed, although synthetic rubbers can provide a myriad of property improvements

not found in natural rubber, natural rubber is still valued for its high performance and low

cost.

https://www.coirubber.com/natural-rubber-vs-synthetic-rubber/

Uses of rubber

 The use of rubber is widespread, ranging from household to industrial products

 Tires and tubes are the largest consumers of rubber, accounting for around 56%

total consumption in 2005

 high performance, notably aircraft and truck tires

 The remaining 44% are taken up by the general rubber goods (GRG) sector, which

includes all products except tires and tubes

Other significant uses of rubber are:

 Door and window profiles, hoses, belts, matting, flooring and dampeners (anti-

vibration mounts) for the automotive industry in what is known as the "under the

bonnet" products

 gloves (medical, household and industrial), toy balloons, rubber bands

 adhesives in many manufacturing industries and products, although the two most

noticeable are the paper and the carpet industry

Raw materials in making Synthetic Rubber

 derived from petroleum, coal, oil, natural gas and naphtha

 has over a dozen major classes, many of them are copolymers ( polymers

consisting of more than one monomer)

 The earliest synthetic rubbers were the Styrene-butadiene copolymers (SBR)

which, to this day, is the most commonly used elastomer.

 Serves as a substitute for natural rubber in many cases, especially when

improved material properties are needed.

Demand of Rubber in the Philippines

The Philippines has been among the top ranking countries in rubber production

until the 80’s, when demand for car tires and other rubber-made products slowed down

following the decline in the Japanese and European economies. In recent times, however,

the Philippine market for rubber products has demonstrated new vitality shown by the

increasing demand for rubber-made goods.

 https://www.statista.com/statistics/752776/philippines-rubber-production/

The Philippines has been among the top ranking countries in rubber production

until the 80’s, when demand for car tires and other rubber-made products slowed down

following the decline in the Japanese and European economies. In recent times, however,

the Philippine market for rubber products has demonstrated new vitality shown by the

increasing demand for rubber-made goods.

The Philippine rubber industry is characterized by its expertise to manufacture a

wide array of rubber products, existing capacity to meet customer demands, technical

capability to satisfy customer needs, strong ability to adjust to customer requirements,

and highly-experienced direct labour.

 The main industry organization is the Philippine Rubber Industries Association,

Inc. (PRIA), formed in 1979 from the merger of the Philippine Rubber Manufacturers

Association (PHIRMA) and the Rubber Industries Association of the Philippines (RIAP).

PRIA today has 46 member firms, 26 of which are direct industry players, while the rest

are business development service providers (e.g. material suppliers and logistics

companies).The expected increase in global and domestic demand for natural rubber is

an opportune time to strengthen the rubber products industry in the country.

https://www.statista.com/statistics/752776/philippines-rubber-production/

PLANT SITE LOCATION

The location to where the plant will be established will be at 191 BAGONG POOK,

GULOD LEMERY BATANGAS. The location of the plant was determined by considering

different factors, these factors were the availability of raw materials, road accessibility,

the availability of water supply, distance from residential houses, and climate.

In other hands, the chosen location would mean that it would offer job opportunities

to those residents living in 191 BAGONG POOK, GULOD LEMERY BATANGAS. Since,

the plant location would be estimated 150 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.

 CHAPTER II

REVIEW OF RELATED LITERATURE

Production of Synthetic Rubber

Rubber is a collective term for macromolecular substances of natural (natural

rubber, NR) or synthetic (synthetic rubber, SR) origin. Natural rubber was already used

by the Mayas but was recognized as technical material first in 1851 when Charles Nelson

Goodyear presented a new material produced from the milk of rubber trees, which has

been treated with more or less amounts of sulfur and vulcanized. Years later, a number

of reasons including political events were responsible for the development of alternatives

for natural rubber.

Synthetic Rubber In 1920, the 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. In Germany, this was followed by a

patent for a synthetic rubber in 1929 and by the first large-scale industrial production

beginning in 1939. The respective product was called Buna, from Butadiene as raw

material and Natrium (sodium) as catalyst.

These days, process gas chromatographs are part of the standard instrumentation

of most production plants for 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.

Siemens Process Analytics is well known worldwide for its excellent process

analyzer technique, application know how, service competence and expertise in

engineering and manufacturing turnkey solutions including those for synthetic rubber

production.

Synthetic Rubbers

Synthetic rubbers are complex chemical compounds built by means of

polymerization of monomers. Synthetic rubber production (fig. 1) starts with the refining

process of oil, coal or other hydrocarbons with naphtha as one of the resulting products.

The naphtha is then combined with natural gas to produce monomers. As feed material,

typically monomers such as butadiene, styrene, isoprene, chloroprene, acrylonitrile,

ethylene or propylene are used

These are then treated by polymerization using catalyst and process steam to form

chains of polymers which finally results in rubber substances.

 These substances are then processed to rubber products by vulcanization. In

integrated plants, naphta or even the monomers and process steam are delivered as raw

materials from other production facilities which are located close to the rubber plant.

The synthetic rubber industry provides a high number of different synthetic rubbers

which are produced in chemical plants worldwide to reflect the different applications and

the wide range of requirements from the market.

The use of rubber is widespread, as the characteristics and properties of these

elastomers make them useful in almost all economic sectors such as automobiles, civil

construction, footwear or plastics so that they are of crucial importance in the daily life of

society.

As they are most widely used to produce tires, the SBR and BR varieties are the

most widely consumed type of synthetic rubber.

According to “International Rubber Study Group”, world production of synthetic

rubber grew from 12.8 to 13.6 million tons in 2006-2007.

As massive investments were required to develop these different varieties, the

production technology was heavily concentrated in long-established global major

chemical companies such as BASF, Lanxess (formerly Bayer), DOW, Shell, Exxon,

DuPont or major players in the tire industry like Goodyear, Firestone or Michelin. Leading

world manufacturers are located in Asia and Europe, followed by Northern America and

Russia.

Butyl Rubber
 Butyl Rubber (IIR) production Butyl Rubber is a solution copolymer of Isobutylene

with some percent of Isoprene (Isobutylene Isoprene Rubber, IIR). Polyisobutylene by

itself is fully saturated; therefore, isoprene is added to provide sufficient double bonds to

allow vulcanization with sulphur. The outstanding property of IIR is the very low

permeability to air and other gases why it is used for tire inner tubes. Other specialities

include very good resistance to sunlight, ozone and aging and, when used in tires,

reduced rolling resistance and thus reduced fuel consumption for “green mobility”.

Production process

https://www.google.com/search?q=flow+diagram+of+making+synthetic+rubber&tbm=isc

h&ved=2ahUKEwjBtcWY097lAhULfpQKHWN9Br4Q2-cCegQIABAA&oq=flow+diag
 • Feed blending (fi g. 2, section 1) Butyl Rubber typically consists of about 98%

Isobutylene with 2% Isoprene distributed randomly in the polymer chain. The most

commonly used polymerization process uses methyl chloride as reaction diluent. Chillers

are used to cool the blended feed stream before it is fed to the reactor

• Polymerization and stripping unreacted monomers (Section 2) Butyl rubber is

produced by co-polymerizing isobutylene with a small amount of isoprene, in a solution

with methylchloride and a chilled catalyst. To achieve high molecular weight, the

exothermic reaction must be controlled at low temperatures close to -100 °C. A slurry of

fi ne particles of butyl rubber dispersed in ethyl chloride is formed in the reactor. The

methyl chloride and unreacted monomers are fl ashed and stripped overhead in a

sequence of distillation columns by addition of steam and hot water.

• Recycle compression and purifi cation (section 3 and 4) Solvent and isobutylene

are recovered and dried and recycled to the polymerization section, while impurities are

purged out.

• Finishing (section 5) Slurry aid and antioxidant are introduced to the hot

water/polymer slurry to stabilize the polymer and prevent agglomeration. Then the

polymer is screened from the hot water slurry and dried in a series of extrusion dewatering

and drying steps. Fluid bed conveyors are used to cool the product to acceptable

packaging temperature.

General objective

In production plants to produce synthetic rubber material process gas

chromatographs play a dominant role to control various process sections. They provide
key data about the composition of the feed, intermediates or the final products. This

enables the control system to increase the productivity, reliability and availability of the

production plant, to cut maintenance costs and to minimize potential risks.

Top technology ensures optimal process control

Siemens Plant Reliability Solutions aims to detect potential plant faults early on

and safeguard availability as well as productivity. Process Gas Chromatography (PGC)

has been used for decades in the chemical industry. Typically, a PGC will be running for

multiple component analyses of various hydrocarbons (from low boiling point up to high

boiling fractions) but also inert gases such as hydrogen. MAXUM edition II represents the

top technology in process gas chromatography for analysing liquids and vapor process

samples. Unparalleled product features deliver high versatility and the best possible

analytical results at the lowest cost.

These are:

• Multiple analytical tools such as injectors, ovens, detectors or columns to adapt

the hardware perfectly to the analytical needs

• Liquid injection modules to optimize the evaporation of liquid samples

• Broad range of column types and columns switching technologies available to

provide perfect customized solutions

• Sensitive detectors to determine trace components

• Single and independent dual oven concept for minimizing the number of

analyzers
 • Airless oven to reduce utility costs

Measuring tasks Details of measuring tasks

https://www.google.com/search?q=measuring+task&tbm=isch&ved=2ahUKEwiHvarK0t

7lAhVQEqYKHYR_AUEQ2-

cCegQIABAA&oq=measuring+task&gs_l=img.3...86998.89823..90467...0

Sampling locations and concentration values of the components differ from plant

to plant according to process type and specific plant design. But the measuring

components themselves will be very similar in all cases. Fig. 7 shows a typical list with

reference to the flow chart of fig. 2. Most of the components are determined by gas

chromatography, but continuous gas analyzers are also used in applications like

combustion optimization and exhaust gas emission control at different locations of the

plant.

Leading in process analytics

Siemens is a leading provider of process chromatographs, process analyzers and

process analysis systems and solutions. We offer our global customers the best solutions

for their applications based on innovative analysis technologies, customized system

engineering, sound knowledge of customer applications and professional support. From

applications in the chemical and petrochemical industry to emission monitoring in waste

incinerators and power plants, the highly accurate and reliable Siemens analyzers and

chromatographs will always do a perfect job. The chromatographs and analyzers are

easily integrated into the Totally Integrated Automation (TIA) concept making Siemens

Process Analytics your qualified partner for efficient solutions that integrate process

analyzers into automation systems.

Global presence

The global presence of the Siemens service organization permits optimum

support for our customers through fast response times onsite. Furthermore, our service

specialists are acquainted with the local and regional requirements, standards and

directives. We can offer our customers tailored service products based on our specific

knowledge of the processes involved in the oil & gas, chemical, power, cement and other

industries.

Plant life-cycle support

 https://www.google.com/search?q=+industrial+plant+life+cycle&tbm=isch&ved=2

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cCegQIABAA&oq=+industrial+plant+life+cycle&gs_l=img.3

As a result of our large service portfolio we are able to support our customers

throughout the complete product life cycle (fig. 10). We already develop cost-efficient and

reliable analytical concepts during plant planning. Using customized service contracts and

competent service onsite we can help to reduce downtimes while simultaneously ensuring

optimum operation of the analytical equipment. Our range of services is extended with

technical support from experts over the hotline and a comprehensive selection of on-site

training courses for service personnel and operators

https://pdfs.semanticscholar.org/ede2/eccc10fd23aaf1dd7a11a1d83a18abe683d

5.pdf

CHAPTER III

METHODOLOGY

PROCESS OVERVIEW

Background

Rubber products permeate our world. They are used extensively in automobiles,

from tires to gaskets. They are used in industrial machinery and household appliances.

Rubber is used in production of some articles of clothing and footwear. There are two

major types of rubber: natural rubber and synthetic rubber. However, there are a variety
of subordinate rubber materials, usually denoted by degrees of hardness, which can be

produced from either type. Natural rubber was first discovered in the Amazon and for a

time, Brazil experienced a boom from rubber production. Seeds from the rubber tree were

eventually smuggled to Britain and exported to British colonies in Asia. Since the late 20th

century, the majority of natural rubber has been produced in Asia, where there are vast

rubber plantations. Synthetic rubber is produced across the globe.

PROCESS DIAGRAM
SYNTHETIC RUBBER PRODUCTION PROCESS

Synthetic rubbers are complex chemical compounds built by means of

polymerization of monomers. Synthetic rubber production starts with the refining process

of oil, coal or other hydrocarbons with naphtha as one of the resulting products.

The naphtha is then combined with natural gas to produce monomers. As feed material,

typically monomers such as butadiene, styrene, isoprene, chloroprene, acrylonitrile,

ethylene or propylene are used.

These are then treated by polymerization using catalyst and process steam to form

chains of polymers which finally results in rubber substances.

These substances are then processed to rubber products by vulcanization. In

integrated plants, naphta or even the monomers and process steam are delivered as raw

materials from other production facilities which are located close to the rubber plant.

The synthetic rubber industry provides a high number of different synthetic rubbers which

are produced in chemical plants world wide to reflect the different applications and the

wide range of requirements from the market.

Examples are

• Styrene-Butadiene Rubber (SBR),

Benefits offered by SBR such as low rolling resistance, high traction during

braking, low abrasion etc. makes it an ideal material for tire applications. Cold SBR is

used for lighter duty tires and other mechanical goods

• Polybutadiene Rubber (BR)

 Polybutadiene rubber is a polymer formed from the polymerization of the monomer 1,3-

butadiene. Polybutadiene has a high resistance to wear and is used especially in the manufacture

of tires, which consumes about 70% of the production

• Polyisoprene Rubber (IR)

Gum polyisoprene compounds are used in rubber bands, cut thread, baby bottle

nipples, and extruded hoses, and other such items. Mineral-

filled polyisoprene finds applications in footwear, sponges, and sporting goods. Other

important uses include medical applications and adhesives and sealants.

• Butyl Rubber (IIR)

Is great for applications that need vibration damping, sound damping, and age

resistance It is resistant to phosphate ester based hydraulic fluids, and has excellent

electrical insulation performance. Butyl is not recommended for use when in contact with

petroleum oils and fluids.

• Nitrile Rubber (NBR)

The uses of nitrile rubber include disposable non-latex gloves, automotive

transmission belts, hoses, O-rings, gaskets, oil seals, V belts, synthetic leather, printer's

form rollers, and as cable jacketing; NBR latex can also be used in the preparation of

adhesives and as a pigment binder.

• Halobutyl Rubber (HIIR)

 It is also suitable for pharmaceutical stoppers and rubber articles needing good

resistance to chemicals, weathering, and ozone, such as tank linings, conveyor belts, and

protective clothing.

• Ethylene Propylene Diene Monomer (EPDM)

EPDM rubber (Ethylene Propylene Diene Monomer rubber) is a high-density

synthetic rubber primarily used for outdoor applications like rubber roofing. It has

dynamic and mechanical properties between natural rubber and synthetic rubber.

The use of rubber is widespread, as the characteristics and properties of these

elastomers make them useful in almost all economic sectors such as automobiles, civil

construction, footwear or plastics so that they are of crucial importance in the daily life of

society.

As they are most widely used to produce tires, the SBR and BR varieties are the

most widely consumed type of synthetic rubber. According to “International Rubber Study

Group”, world production of synthetic rubber grew from 12.8 to 13.6 million tons in 2006-

2007.

As massive investments were required to develop these different varieties, the

production technology was heavily concentrated in long-established global major

chemical companies such as BASF, Lanxess (formerly Bayer), DOW, Shell, Exxon,

DuPont or major players in the tire industry like Goodyear, Firestone or Michelin. Leading

world manufacturers are located in Asia and Europe, followed by Northern America and

Russia.
Equipment for Rubber Manufacturing Applications

French designs, manufactures and supports an array of equipment used in rubber

component manufacturing from mixing to rubber molding and curing.

Rubber Mixer Group offers tilt style intensive mixers, from 5 to 110 liters, for all

types of rubber and plastic compounds.

Hydraulic Press Group manufactures and supports hydraulic presses, from 5 to

3,000 tons, with various platen sizes, for compression, transfer, lamination or vacuum

molding. Presses can be equipped with or retrofitted with our Isobar & Isoplaten Thermal

Solutions and our advanced microprocessor-based recipe and data collection control

systems.

In addition, Polymer Group produces dewatering and drying screw presses for all

types of synthetic rubber and thermoplastic production, upstream of the mixing and

moulding processes.

TMP Rubber Mixer Designs

TMP offers a variety of batch sizes for every application, from a 5 liter laboratory

mixer to the larger 35, 55, 75 and 110 liter models. Mixing in an adaptable tilt mixer

reduces cycle time, improves quality, facilitates ease of cleaning and reduces total

processing costs

Each Techni-Mix HD Series tilt-body intensive rubber mixer from TMP provides the

highest quality mixing of your precise rubber, silicone and plastic formulations at an initial
cost that is about 50% less than traditional rubber mixing equipment. Each Techni-Mix

rubber mixer is designed and built to meet your specific needs

55 Liter Techni-Mix Rubber Mixer

https://frenchoil.com/industries/rubber-manufacturing-applications/

Hydraulic Presses

French designs, manufactures and supports custom hydraulic presses for rubber

molding, composite molding, laminating, forming, bonding and various additional

applications. Hydraulic presses can be designed with capacities generally ranging from20

tons to 2,000 tons, with various heated platen sizes, for compression, transfer, lamination

or vacuum molding. French hydraulic press engineering designs are continually being

improved by quality driven programs and with enhancements in automation and

advanced electrical control systems.

 Automated 350 Ton Sideplate Hydraulic Press System for Rubber and

Composite Molding

https://frenchoil.com/products/hydraulic-presses

Dewatering Screw Press

French Dewatering Screw Press models are designed to accept a free-drained

feed material in a 40-60% water content range and dewater the material by expression to

a discharge moisture in the 6-12% range.

Our commercial size dewatering equipment is designed to meet the unique

process requirements of the customer. Many models are available; and the particular

model best suited for the job will depend on capacity and type of material and amount of

water to be removed:

 The capacity determines the diameter (7”, 10.25”, 14”, 16”, and 18” diameters are

available). Capacity ranges of 500 kg/hr to 12 metric tons/hr. Gearbox and

machine designs range from 150 hp to 1,500 hp.

  The type of material and amount of water to be removed determines the length to

diameter ratio. Our machines can range from 3:1 to 6:1.

1500Hp/1118.55KW

https://frenchoil.com/products/polymer-equipment/designs/dewatering-screw-

press/

Extruder Dryer

Extruder dryers and mechanical dryers are used for many synthetic rubber

materials. Extruder dryers and mechanical dryers normally will dry material that has been

first dewatered to an 8-12% moisture by a mechanical screw press or expeller. Drying is

accomplished by heating the polymer under pressure and then subjecting it to a flashing

stage where the water is evaporated. Some residence time in a following conveyor will

allow specification moistures and temperatures to be reduced

French R-120 Extruder Dryer

This machine is a solid barrel extruder type dryer. Flashing takes place upon the

material exiting from a die plate. The discharge material is in a porous pellet form that is

easily final dried and cooled.

Our Model R-120 is a 10.25” diameter unit and has a capacity range of 2 tons/hr.

to 8 tons/hr., depending on material. Our larger size 14” machine is available for even

higher capacities.

Our R-120 was designed with the customer’s input. We met with many synthetic

rubber producers around the world to obtain their input on what features are desired in

an expansion type dryer. We received excellent input, and our Model R-120 includes

many features for low maintenance and flexible operation.

French R-120 Extruder Dryer

https://frenchoil.com/products/polymer-equipment/designs/drying-press/
 CHAPTER IV

COMPUTATION AND EQUIPMENTS

Water tank capacity

Average water consumption per person per day in the Philippines

For instance, research says that on average, a person needs only 54 liters of water a

day for drinking, hygiene, sanitation, food preparation and laundry. But the actual water use by

Filipinos in 2014 was pegged at 98 liters per person per day

https://www.pressreader.com › Philippines › philippine-daily-inquirer-1109

Total liter/week
7𝑑𝑎𝑦
98 L/person/day x𝑤𝑒𝑒𝑘=686 L/person/week

Total employees=57 persons

686 L X 57 persons = 39,102 L/person≈40,000 L/person

TOTAL CAPACITY OF WATER

40,000L
WP=Q𝛿𝑇𝐷𝐻
TDH=36 m
Q=4Hrs(40,000L)=160,000L/hr =0.04444 m3/s
WP=0.4444 (9.81) (36)
WP=15.6944304𝐾𝑊 ≈ 16 Kw
𝑊𝑃
Pmotor = .85
16𝐾𝑊
Pmotor = .85

Pmotor =18.82 KW ≈ 19 KW
Water Tank (80,000 liters/week)

The stainless steel storage tanks above ground suitable for field as edible oil, juice,
beverage, medicine chemical or bio-engineering project,etc. We manufacture tanks for
the petroleum, chemical, and water storage. Our product includes carbon steel, stainless
steel, and fiberglass storage oil tanks. We offer a complete range of above ground oil
tanks including: gasoline and diesel tank systems, potable water tanks, and a variety of
customize oil storage tanks for your specific requirement.

WATER PUMP
 A submersible pump (or sub pump, electric submersible pump (ESP)) is a

device which has a hermetically sealed motor close-coupled to the pump body. The

whole assembly is submerged in the fluid to be pumped. The main advantage of this type

of pump is that it prevents pump cavitation, a problem associated with a high elevation

difference between pump and the fluid surface. Submersible pumps push fluid to the

surface as opposed to jet pumps which create a vacuum and rely upon atmospheric

pressure. Submersibles are more efficient than jet pumps. Hydraulic submersible pumps

(HSP's) use pressurised fluid from the surface to drive a hydraulic motor downhole, rather

than an electric motor, and are used in heavy oil applications with heated water as the

motive fluid. (PRIZE OF THE PUMP WILL RANGE IN US$580.00 - US$1,800.00)

PRIZE WILL BE $801.595 ( PHP.40,079.75)

LIGHTS (400 W) (PHP 558 x 6= PHP 3,348 )

Air conditioning for canteen and locker room (USD 1,408= PHP 70,400x4= PHP
281,600) (5,276 W)

Air conditioning for office (USD 500= PHP 25,000) (2,600 W)

LIGHT FOR OFFICE, WAREHOUSE, CANTEEN, LOCKER ROOM, AND FACTORY
(65W), (USD 36=PHP 1,800), (20 PCS)

VENTILATOR (20 PCS) FOR FACTORY AND WAREHOUSE (3,230 x 20=PHP 64,600)

Delivery truck (USD 32,300X2=PHP3,230,000)

Forklift ($7,000x2=$14,000) ( PHP 700,000)

Conveyor ($5000=PHP 250,000)(550w)

200 Liters Steel Drum For Sale Metal Drum

FOR WAREHOUSE SHOP(LAZADA)

TOOLS QUANTITY POWER Unit PRICE Total price
(W) (PESOS) (PESOS)
GRINDER 2 840 1,300 2,600
DRILL 2 350 2,149 4,298

ELECTRIC 2 1050 1,699 3,398

CIRCULAR SAW
BLOWER 2 620 2,519 5,038

Welding machine 2 66,000 5,699 11,398

https://www.lazada.com.ph/products/powerhouse-angle-grinder-w-back-switch-800w-phm9553hd-
free-safety-goggles-i278542283-
s418691840.html?spm=a2o4l.searchlist.list.1.3add76c7yIWyVl&search=1

https://www.lazada.com.ph/products/bosch-gbm-350-rotary-drill-power-tool-350w-with-protective-
spectacles-gloves-with-rubberized-palm-and-free-1pc-double-ended-ph2-screw-bit-i117523787-
s121857236.html?spm=a2o4l.searchlist.list.13.179864a6tOw8uT&search=1

https://www.lazada.com.ph/products/bosch-gbl-620-blower-620w-i295986410-
s496260909.html?spm=a2o4l.searchlist.list.1.427c2b71Nec1VN&search=1

https://www.lazada.com.ph/products/kawasaki-inverter-welding-machine-300amp-i216541296-
s281784731.html?spm=a2o4l.searchlist.list.13.66607039WwEniU&search=1

https://www.lazada.com.ph/products/new-mailtank-7-14-professional-circular-saw-machine-900w-
i289002787-s465680021.html?spm=a2o4l.searchlist.list.19.2fbc74b2H2PgXs&search=1

https://www.alibaba.com/product-detail/200-Liter-Steel-Drums-For-
Sale_62043982007.html?spm=a2700.7724838.2017203.3.42a44c59kN0R8e&s=p

TOTAL CAPACITY OF POWER

PUMP+ +CONVEYOR+ LIGHTS+ AIR CONDITIONING+WAREHOUSE ELECTRIC
TOOLS.

PLANT CAPACITY

Rubber in its native form is basically useless. It is only when certain chemicals are

added, the rubber thus produced is used to make varied rubber products. Synthetic

rubber is used as a substitute for natural rubber in many cases. Depending on the

chemicals added and the properties associated with it, the synthetic rubber can be as

hard as a bowling ball or as resilient as a rubber band or as soft as a sponge. When

improved material properties are required, synthetic rubber is considered. Approximately

70% of all rubber used today are one from many synthetic rubber varieties
DEMAND OF THE SYNTHETIC RUBBER IN PAST 8 YEARS AS OF 2011-2018:

425.7+443+444.8+453.1+398.1+362.6+407+423.4=3357.7 thousand metric ton

3357.7 Thousand metric ton÷ 8 year = 419.7125 thousand metric ton/year

Demand of rubber in the Philippines

Year Demand each year Percent of demand Rating of demand each
(Thousand metric tons) each year (%) year (%)

2011 425.7 85.14% 0

2012 443 88.6% Increased by 3.46%
2013 444.8 88.96% Increased by 0.36%
2014 453.1 90.62% Increased by 1.66%
2015 398.1 79.62% Decreased by 11%
2016 362.6 72.52% Decreased by 7.1%
2017 407 81.4% Increased by 8.88%
2018 423.4 84.68% Increased by 3.2%

TOTAL 419.7125 83.9425% 5.09%≈5%

FOR THE DEMAND OF SYNTHETIC RUBBER PER YEAR

SINCE 419.7125 THOUSAND METRIC TONS IS THE DEMAND OF RUBBER IN THE
PHILIPPINES AND RUBBER HAS A TWO TYPES WHICH ARE THE NATURAL AND
SYNTHETIC RUBBER
(419,712.5 METRIC TONS PER YEAR) X ( .70) = 293,798.75METRIC TONS/YEAR

FOR THE RATE OF DEMAND EACH YEAR IN PERCENT(5%)

(293,798.75METRIC TONS/YEAR) x(0.05)=14,689.9375 METRIC
TONS/YEAR≈15,000 METRIC TONS/YEAR
1000𝐾𝑔
15,000 METRIC TONS X 1 𝑀𝐸𝑇𝑅𝐼𝐶 𝑇𝑂𝑁
=15,000,000 Kg/YEAR
ACCORDING TO THE RESEARCH THAT I GATHERED 1 LITER OF SYNTHETIC
RUBBER IS EQUAL TO 1 KILOGRAM
1 DRUM =200 LITERS=200Kg/DRUM
46 COMPANIES TO BE SUPPLIED BY SYNTHETIC RUBBER
15,000,000 KG/YEAR / 46 COMPANY FIRMS =326,086.95192 Kg/YEAR/COMPANY
326,086.95192 Kg/YEAR/COMPANY / 240 DAYS/YEAR=1358.695652 Kg/DAY/
COMPANY≈1400 Kg/DAY/ COMPANY

FOR THE DISTRIBUTION OF SYNTHETIC RUBBER PER COMPANY PER DAY

1400Kg PER DAY PER COMPANY / 200 Kg PER DRUM = 7 DRUMS PER COMPANY
PER DAY
7 DRUMS PER COMPANY PER DAY X 5DAYS/WEEK =35 DRUMS PER COMPANY
PER WEEK

FOR THE OUTPUT OF SYNTHETIC RUBBER PER DAY FOR 46 COMPANIES

7 DRUMS PER COMPANY PER DAY X 46 COMPANIES =322 DRUMS PER DAY

322 DRUMS PER DAY X 240 WORKING DAYS PER YEAR =77,280 DRUMS PER
YEAR

FOR THE PRICE OF SYNTHETIC RUBBER PER DRUM

SYNTHETIC RUBBER PRICE IN THE MARKET = 99.98 PESO/Kg≈100 PESO/Kg
(200Kg/DRUM ) X (100 PESOS/Kg)=20,000 PESOS/ DRUM
 ECONOMIC ANALYSIS

INITIAL COST
United States Dollar exchange rate to Philippine Peso

1 USD = 50.00 PHP

PRICE OF LAND IN GULOD LEMERY, BATANGAS

3100 PER SQUARE METER
41,971.82 SQ METER X 3100 SQ/METER=P130, 112, 642

COST FOR THE EQUIPMENT

Equipment No. of units Price/ unit (PHP) Total cost (PHP)
WATER TANK (80,000 L) 1 1,500,000 1,500,000.00
TOTAL CAPACITY
WATER PUMP 1 40,079.75 40,079.75
AIRCONDITIONING FOR 4 70,400 281,600.00
CANTEEN AND LOCKER
ROOM
AIRCONDITIONING FOR 1 25,000 25,000.00
OFFICE
LED 60 1,800 36,000.00
VENTILATOR 20 3,230 64,600.00
DELIVERY TRUCK 10 1,615,000 16,150,000.00
FORKLIFT 10 350,000 3,500,000.00
GRINDER 2 1,300 2,600.00
DRILL 2 2,149 4,298.00
ELECTRIC CIRCULAR 2 1,699 3,398.00
SAW
BLOWER 3 2,519 5,038.00
WELDING MACHINE 2 5,699 11,398.00
GENERATOR 1 1,891,250 1,881,250.00
COMPUTER 10 10,499 104990.00
XEROX MACHINE 2 122,500.00 245,000.00

TOTAL

CIVIL WORKS

PLACE SQ METER
ADMIN 2,000
WAREHOUSE/FACTORY 8,000
SHOP WAREHOUSE 500
POWER HOUSE 50

TOTAL SQ METER 10,550

ORGANIZATION CHART
 Chairman

Board of
Plant Manager
director

Secretary Accountant HR Process Engr.

Driver Chemist Operator Maintance

Certified
Helper Plant Mechanic

Electrician

QCQA

Machine
Maintenance

Utilities

MANPOWER REQUIREMENT AND ANNUAL LABOUR COST (PHP)

Sr. Description Req. Monthly Annual

No. No. Salary Salary
 A. Administration
1 Chairman 1
2 Board of Director 2 30,000 720,000
3 Accountant 2 17,000 408,000
4 Secretary 1 15,000 180,000
5 Human Resource 2 13,000 312,000
6 General service/Utility 10 10,000 1,200,000
7 Driver 5 18,000 1,080,000
8 Helper 4 10,000 480,000
Sub-Total 27 4,380,000
B. Production
1 Plant Manager 1 70,000 840,000
2 Process Engineering 1 30,000 360,000
3 Operators 6 18,000 1,296,000
4 Chemist 5 20,000 1,200,000
5 PME 1 50,000 600,000
6 Electrician 2 14,000 336,000
7 Mechanical Maintenance 3 15,000 540,000
8 QCQA 4 25,000 1,200,000
Sub-Total 23 6,372,000

Total 50 10,752,000
13-month pay 900,000
Grand Total 57 11,652,000