TARRC - GMRT

Tun Abdul Razak Research Centre (TARRC)
A RESEARCH & PROMOTION CENTRE OF THE MALAYSIAN RUBBER BOARD
A comparison of the performance of
natural with synthetic rubbers
Dr Andy Chapman
Senior Research Fellow
www.tarrc.co.uk
Tun Abdul Razak Research Centre (TARRC)
A RESEARCH & PROMOTION CENTRE OF THE MALAYSIAN RUBBER BOARD
Tun Abdul Razak Research Centre (TARRC)
A RESEARCH & PROMOTION CENTRE OF THE MALAYSIAN RUBBER BOARD
•
Rubber research institute about 40 km North of London,
covering all aspects of rubber science and technology
•
Founded 1938, currently about 90 staff
•
About 75% funded by Malaysia,
25% generated internally through:
Consultancy work (www.rubberconsultants.com)
Collaborative research contracts, funded by EU, UK etc
www.tarrc.co.uk
INTRODUCTION
• Where does rubber come from?
• Strategic importance of Rubber
• Consumption of Rubber Natural Rubber (NR) and Synthetic Rubbers (SR)
• Comparison between NR and SR in 3 key areas.
• Tyres
• Fire retardant applications
• Vibration isolation applications
www.tarrc.co.uk
Where does rubber comes from?
NR - Renewable - Hevea brasiliensis
efficiently sequesters carbon using solar
energy to convert it into rubber and timber
Carbon Footprints:
NR Net sequestration = 22.5kg
CO2/kg SMR
SR: CO2 emission = 4.39kg CO2/kg
rubber
www.tarrc.co.uk
Sources of Rubber
Synthetic Rubbers (SR)
Natural Rubber (NR) and
rubbers based on NR
eg Epoxidized Natural Rubber (ENR)
CH3
H
C
CH3
C
~~
CH2
H
C
CH2
C
~~
CH2
CH2
HCOOOH
CH3
H
C
~~
CH2
CH3
C
H
C
CH2
CH2
C
O
CH2
~~
Manufactured in Malaysia:
2 grades: EKOPRENA™ 25 and EKOPRENA™ 50,
containing 25 and 50 mole % epoxidation
Acrylic Rubber (ACM)
Butadiene Rubber (BR)
Butyl Rubber (IIR)
Chlorobutyl Rubber (CIIR)
Chlorinated Polyethylene (CPE)
Chlorosulphonated Polyethylene (CSM)
Epichlorhydrin (CO)
Ethylene Acrylic (AEM)
Ethylene Propylene & Ethylene Propylene Diene Rubbers
(EPR, EPDM)
Fluoroelastomers (FKM, FEPM)
Nitrile & Hydrogenated Nitrile Rubbers (NBR, HNBR)
Isoprene Rubber (IR)
Perfluoro Elastomers (FFKM)
Chloroprene Rubber (CR)
Polynorbornene Rubber (PNB)
Polysulphide Rubber (TR)
Polyurethane Rubber (PU)
Silicone (and Fluorosilicone) Rubber (MQ, VMQ, PMQ, FMQ)
Styrene Butadiene Rubber (SBR)
www.tarrc.co.uk
Natural Rubber
Advantages:
Drawbacks:
Ø Strain crystallizes:
Very high tensile strength, even unfilled
Resistant to tearing and abrasion
Ø Limited resistance to heat, oils,
some chemicals
Ø Low hysteresis:
High resilience
Low heat build-up
Low tyre rolling resistance -->
Vehicle fuel economy
Ø Susceptibility to oxidation, ozonation;
protected using antidegradants
Ø Wet grip in tyres
Ø High green strength and tack
Ø High fatigue resistance
Ø Good creep and stress relaxation resistance
www.tarrc.co.uk
Strategic importance of Rubber
• Tyres consume about 75% of all NR and 50% of all SR
www.tarrc.co.uk
Natural rubber share of consumption
45
40
NR share,%
35
30
25
20
15
10
5
0
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
www.tarrc.co.uk
NR and SR in Tyres - The Desire for ‘Green Tyres’
• Growing concerns about climate change and oil price/availability
è demands for sustainable & renewable materials with low carbon footprints
• Tyre consumers and legislators are demanding
fuel economy and safety è tyre rolling resistance and wet grip
Japanese tyre manufacturers have voluntary
labelling for rolling resistance and wet grip
2010
South Korean
tyre label
2012
EU tyre label
2012
Proposed US tyre label
www.tarrc.co.uk
ENR - Ekoprena™ Properties
Strain-induced crystallization retained up to about ENR-50
12
400% extension
Crystallinity, %
10
8
6
4
2
0
0
25
50
75
100
Epoxide content, mole%
www.tarrc.co.uk
Ekoprena™ Properties
Epoxidation increases:
Glass transition temperature, Tg, influences dynamic properties:
Influences dynamic properties:
Decreasing low temperature resilience à damping
Tg of ENR-25* similar to sSBR used in tyre treads
Reducing gas permeability
Polarity:
Reducing oil swelling
Increasing compatibility with other polymers
Affecting partition of curatives and plasticizers in blends
Strong interaction with silica – silane coupling not required
www.tarrc.co.uk
Ekoprena™ silica- & black-filled vulcanizates
50 phr filler, 2 phr sulfur, 1.5 phr MBS
Polymer
Filler
NR
N330
black
ENR-25
N330
black
ENR-25
silica
(no silane)
Hardness (IRHD)
M300, MPa
65
11.9
69
12.4
67
12.8
Tensile strength, MPa
Elongation at break, %
29.4
495
25.5
435
21.0
405
Compression set, 1d/70°C, %
Akron abrasion, mm3/500rev
18
21
17
14
18
15
7
7
7
Goodrich HBU, 30min/100°C, ∆T°C
Carbon black and Silica are both reinforcing fillers in Ekoprena-25
www.tarrc.co.uk
Ekoprena™: Early Tyre work at TARRC
ENR-25 tyre tread compounds
Krol diagram: Wet Skid Pebble surface /Rolling Resistance (1985)
Wet Skid Index
120
ENR-25
silica
110
100
ENR-25 35/15
black/silica
ENR-25 black
OESBR black
ENR-25 15/35
ENR-30 black
black/silica
ENR-20 black
NR black
90
NR silica
80
80
90
100
110
120
Rolling Resistance Index
è Good vehicle fuel economy & safety
www.tarrc.co.uk
Ekoprena™ - Green Tyre Technology:
Early Tyre work at TARRC
Tyre companies were interested at the time, but did not take up the
technology
• Crude oil prices were low
• Environmental issues were not foremost
• Cost and large-scale production of ENR was uncertain
In 1990s Michelin introduced a synthetic rubber sSBR/BR/silica/silane
passenger car tread giving improved wet grip and lower rolling resistance
www.tarrc.co.uk
Dependence of Tan δ
Silica-filled sSBR/BR and ENR tread compounds
0.8
0.7
s-SBR/BR (Michelin Energy)
0.6
ENR-25/1165 MP silica
0.5
0.4
1Hz, 0.2% strain
0.3
0.2
High hysteresis –
High wet grip
0.1
0
-40
-20
0
20
40
60
Low hysteresis –
low rolling resistance
Temperature, °C
www.tarrc.co.uk
Ekoprena®-25 in Passenger Tyres – Rolling resistance
175/70 R13 Tyre – Michelin casing, E3B1 tread pattern
80km/h at 380kg load: corrected to 2m drum
Rolling Resistance Coefficient
12
sSBR/BR silica/silane
control
ENR-silica
10
Contribution to tyre
rolling resistance:
Tread 40%
Casing 60%
8
6
13% lower
contribution from
tread
Retreaded
www.tarrc.co.uk
Ekoprena™ - Truck tyres
Ro llin g Re sistan ce Co e fficie n t
Rolling resistance to UN ECE Regulation 117
9
Contribution to tyre
rolling resistance:
8
7
17%
lower
6
5
4
3
Tread 55%
Casing 45%
27% lower
contribution from
tread
2
1
0
NR/BR control
Ekoprena
www.tarrc.co.uk
British Portable Skid Resistance Tester
Test piece
Smooth concrete slab
or asphalt tarmac
www.tarrc.co.uk
Ekoprena™ - Passenger tyres
Wet /ice grip on tarmac
British Pendulum Skid Testing - BPSRT number
80
70
60
50
40
30
20
10
0
22°C
15°C
11°C
sol-SBR/BR
8°C
Ekoprena
Ice
www.tarrc.co.uk
Ekoprena™-25 in Truck/Bus Tyres:
Wet/Ice Grip
British Pendulum Skid Testing - BPSRT number
80
70
17%
27%
60
50
40
31%
30
20
10
0
Wet concrete
Wet tarmac
NR/ BR control
Ice
Ekoprena Bus
www.tarrc.co.uk
Tyre Testing at TARRC
Friction and grip – Track testing
www.tarrc.co.uk
Ekoprena™ - Passenger tyres
Wet track testing: Locked wheel skid from 40kph
Stopping distance, m
70
60
50
6.4 m
40
30
3.2 m
20
10
0
Tarmac
Michelin Energy
Bridport pebble
ENR 25
www.tarrc.co.uk
Silica-filled Ekoprena™-25 tyre tread compounds
Advantages of silica-filled Ekoprena-25
•
Use of renewable resources - non-petroleum based
•
Rubber trees efficiently sequester carbon dioxide è
ENR has a large negative carbon footprint
•
Exceptionally high wet grip è improved safety
•
Significantly improved ice grip
•
Very low rolling resistance è reduced fuel consumption
www.tarrc.co.uk
ENR in tyres: Commercial uptake
•
2008: Introduction of ENASAVE 97 tyre by SRI
Ø
Ø
Materials are 97% non-petroleum based
Targeted for ‘Green’ Hybrid Vehicles (Toyota Prius)
ENR-based Tyre (ENASAVE 97)
Typical fuel-efficient Tyre
Silica
Carbon
Black
Natural
Rubber
Silica
Steel
Steel
Natural
Rubber
Fibre
Chemicals
Carbon Black
Oil
Synthetic
Rubber
ENR
Natural Fibre
Vegetable oil
Chemicals
Chemicals (Enasave 100)
www.tarrc.co.uk
Ekoprena™ in tyres: Commercial uptake
• 2008: ENASAVE 97 - 35% less rolling resistance:
Ø Over life-time of car, 1.75 tonnes CO2 saved
Ø Over lifetime of tyres (50,000 km) –
175 litres fuel saving ≡ £240
Passenger tyre structure:
(ENR-25/silica tread)
Tread ribs
& blocks
Grooves
Cap plies
Belts
Bead
Shoulder
Undertread
Carcass
Sidewall (ENR/NR)
Liner (ENR)
Chafer
www.tarrc.co.uk
Ekoprena™ in tyres: Commercial uptake
• 2008:
• 2013:
100% fossil fuel free tyre.
Launched at 43rd Tokyo Motor Show.
www.tarrc.co.uk
Fire-retardant Applications:
Low-Smoke Low-Toxic Halogen-free formulations
• Aiming to develop halogen-free formulations based on a
renewable rubber
• Current fire-retardant formulations often based on
halogen-containing synthetic rubber (CR) or chemicals
www.tarrc.co.uk
Fire-retardant Applications
In 1996, a fire in the London Underground killed 31 people and injured 60
This led to stringent requirements for materials used in the rail sector
Fire-retardant Applications
Approach to Testing
Material testing involves the following;
F- Flame spread
BS476-Part 7, ISO 5658-2
I- Ignitability
BS ISO 4589-2 or BS EN ISO 4589-3:1996
R- Rate of heat release
BS476-Part 6, ISO5660-1
S- Smoke density
BS6853 Annex D, ISO 5659-2
T- Toxicity
BS6853 Annex B, ISO 5659-2
Current BS Standard to be withdrawn in December 2015
www.tarrc.co.uk
Cone Calorimetry Heat Release Rate Data:
ISO5660-1 @ 50kw/m2
Cone Data: Smoke Release Rate
Comparison:
TARRC vs Current Commercial Compound
Test
Units
Commercial
Compound
(35kW/m2)
TARRC
Compound
(50kW/m2)
seconds
49
97
Total heat evolved
MJm-2
136
147
Average Heat Release
Rate
KWm-2
251
110
Peak Heat Release Rate
KWm-2
481
171
MAHRE
KWm-2
102
98
Time to ignition
(Maximum average rate of
heat emission)
www.tarrc.co.uk
Fire-retardant Applications:
Low-Smoke Low-Toxic Halogen-free formulations
Conclusions
• Fire-retardant compounds developed based on
renewable rubber
• Meets the EN requirement for low smoke
• Potential for meeting the heat-release rate and toxicity
requirements of EN standard
• Development ongoing to meet stringent BS requirements
for Category 1a vehicles for London Underground
www.tarrc.co.uk
Vibration isolation applications
Melbourne Viaduct, 1889
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Pelham Bridge built in 1956 in Lincoln, England
Bridge bearings allow the deck to expand and contract
The world’s first bridge with
bonded laminated rubber bearings,
in good condition after 58 years service
Albany Court above St James Park underground station
in London, constructed in 1966
The first building in the world on laminated rubber bearings for vibration mitigation
17-21 NORTHWOLD ROAD,
N16
HIGHBURY COAL YARD,
LIVERPOOL ROAD, N7
MARRIOTT HOTEL
ST PANCRAS CHAMBERS
BARBICAN ARTS CENTRE
WELLINGTON HOSPITAL
ALEXANDRA RD
BROADGATE TOWER
IDEA STORE, EC1
11-13 HOLBORN VIADUCT
HILTON METROPOLE
105-109 PARK ROAD
CARR STREET, EC14
PARK HOUSE
PROCESSION HOUSE
1 POULTRY LANE
LANGHAM HOTEL
LLOYDS AVENUE
DEVELOPMENT
ROYAL OPERA HOUSE
1 AMERICA SQUARE
ALBANY COURT APARTMENTS
(1966)
LION PLAZA
PLAZA
101 QUEEN VICTORIA ST
THAMES BARRIER
ESSO GLEN, VICTORIA
ROYAL FESTIVAL HALL
BLACKFRIARS STATION
30 QUEEN STREET
DOCKLANDS LIGHT RAILWAY
www.tarrc.co.uk
ParkHouse, Oxford Street, London, 2012
isolated from underground railway
Earthquake protection
Foothill Communities Law and Justice Center,
San Bernardino County, California, USA
Ø First building in the world to use High-Damping Natural Rubber bearings
Ø Completed in 1985 at a cost of $38 million, mounted on 98 bearings
www.tarrc.co.uk
Applications for Earthquake Protection
USC Hospital
www.tarrc.co.uk
Comparison between the University of Southern California hospital (USC)
and the LA County General Hospital Complex (1 km away)
225% increase in force
1.30g
70% reduction in force
7
6
5
4
3
2
1
B
0.11g
0.49g
0.13g
0.40g
0.40g
0.37g
Using Rubber Isolators
USC required no repair and
operational during and after the
Northridge earthquake
Conventional LA County General
Hospital suffered $400 million
damage
Artist’s Impression of the 24km
Second Penang Crossing
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Installed bearings with preset locking plates
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Bearing with locking plates removed
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Other vibration isolation applications
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Vibration isolation applications
Natural rubber works in many vibration isolation applications:
•
Isolating bridge vibrations
•
Isolating buildings
•
Seismic isolation of buildings and bridges
•
Automotive applications
www.tarrc.co.uk
Tun Abdul Razak Research Centre (TARRC)
A RESEARCH & PROMOTION CENTRE OF THE MALAYSIAN RUBBER BOARD
Thank you
www.tarrc.co.uk

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