INDUSTRIAL TRAINING REPORT

PERFORMED AT

BANMORE TYRE PLANT

SUBMITTED BY

Mr. ANIKET CHAKI

 CONTENTS

 COMPANY OVERVIEW
 QUALITY CIRTIFICATIONS
 ACKNOWLEDGEMENT
 TYRE TERMINOLOGIES
 INTRODUCTION
 TYRE MANUFACTURING PROCESS
 PROCESSING OIL

 TYPES OF PROCESSING OILS

 COMPARISON OF AROMATIC OIL AND LOW PCA OIL

 MANUFACTURING OF PROCESS OILS

 POLYCYCLIC AROMATIC HYDROCARBONS (PAHs)

 REPLACEMENT OF HIGHLY AROMATIC OILS IN TYRES

 CASE STUDY

 CONCLUSION

COMPANY OVER VIEW

Jk Tyre and Industries is an Automotive Tyre,Tubes and Flaps
manufacturing company based in Delhi,India. A part of JK Organization
which ranks among top private groups in India. JK Tyre and Industries is
committed to self reliance and follows an ethic that views customer
satisfaction as an index of achievement. The manufacturing plants are
located at six centers in India,located at-
 Mysore - Karnataka (3)
 Banmore – Madhya Pradesh
 Kankroli - Rajasthan
 Chennai - Tamilnadu
 Lashkar - Uttarakhand
JK Tyre has also enhanced its global reach by taking over Tornel,A
Mexican company,which has 3 plants in Mexico.
Banmore Tyre Plant (BTP) set-up with a capacity of 57 lacks tyres
p.a. This division produces and market tyres and tubes under the brand
name “JK Tyre” for truck, buses, passenger cars, jeeps, light commercial
vehicles, multi utility vehicle and tractors.
The company pioneered “Steel Radial Technology” in India in 1977
and continues to be the industrial leader in Radial segment in India.
The company had a technical collaboration with M/s Continental AG,
Germany, which is among the top four tyre manufacturers in the world to
keep pace with latest technological developments. To stay at the forefront
of technological advancements a state of art Research & Development
Centre, HASETRI, was set up, which remains the nerve centre for
providing cutting edge technology. In a short span of time it has emerged as
the 17th largest tyre manufacturers in the world an achievement in itself.

QUALITY
ISO 9001
 JK Tyre India’s first tyre company to receive “ISO 9001” certification
for its entire operations in 1995 in one go. JK management system is
completely integrated into all aspects of their organization.
QS 9000
JK Tyre the world’s first company to receive Quality Management
System certification QS 9000, in 1998 for multi location operations. they
are using “QS 9000” system as a tool for continuous incremental
improvement.
Environmental Management System (ISO 14001)
JK Tyre recognizes the impact that their business has on the
environment and takes our responsibilities for maintaining harmony with
nature. JK are the first tyre company in India to receive ISO 14001
certification for multi location operations in 1999.
TS 16949
The company is accredited with TS 16949.The ISO/TS16949 is an ISO
technical specification aiming to the development of a quality management
system that provides for continual improvement, aiming on defect
prevention and the reduction of variation and waste in the supply chain. It is
based on the ISO 9001.
TPM
The company won TPM excellence category-A certification. It is a
Japanese concept of quality system. Main motto is “zero error, zero work
related accidents, zero loss”.

ACKNOWLEDGEMENT
 I commit this work before God Almighty for giving me the opportunity to take
up this project.

I would like to place on record my sincere gratitude towards management of M/S

J.K TYRE AND INDUSTRIES LIMITED, BANMORE TYRE PLANT for having
given me the permission for undergoing training and project in their esteemed
organization.

I express my deepest sense of gratitude to Dr. Josephine George Head of the

Department, polymer engineering, mahatma Gandhi University College of
engineering, Muttom.

I would like to express my deepest thanks to Mr.Shaji Varghese (G.M Technical),

Jk tyre and industries limited, Banmore tyre plant, for allowing me to conduct the
project and undergo the implant training.

I would like to express my deepest thanks to Mr. Rajesh kumar

(Chief manager,Technical) ,JK tyre and industries limited, Banmore tyre plant, for his
valuable co-operation throughout my work and his guidance, without which it would
have been difficult to me to contemplate this report. He was a constant inspiration
throughout my work and helped me a lot to complete my work in time.

I would also like to express my sincere thanks to Mr.Jagadhish Jana, Mr Debayan

basak and for his valuable help and guidance.

I would also like to express my thanks to my family, friends and fellow project
trainees who helped through the task technically and morally.

I thank all the people took part in the process directly or indirectly for their support
during my work.

INTRODUCTION
 According to ITTAC, tyre is an annular, flexible, toroidal shaped
inflatable envelope made up of elastic material, natural, synthetic or blend
reinforced with textile cord ply fabric carcass enclosing (steel) bead rings.
Tyre is a ring shaped covering that fits around a wheel rim to protect it and
enable better vehicle performance by providing a flexible cushion that
absorbs shock while keeping the wheel in close contact with the ground.

The fundamental materials of the modern tyres are synthetic natural, natural
rubber, fabric and wire, along with other compound chemicals. They consist
of a tread and body. The tread provides traction while the body ensures
support. Before rubber was invented the first version of tyres were simply
bands of metal that fitted around wooden wheels in order to prevent wear
and tear. Today the vast majorities of tyres are pneumatic inflatable
structures, comprising a dough nut shaped body of cords and wires encased
in rubber and generally filled with compressed air to form an inflatable
cushion. Pneumatic tyres are used on many types of vehicles, such as
bicycles, motorcycles, cars, trucks, and earthmovers Basic functions of a
tyre are

 Carry the load

 Transmit driving and breaking torque
 Develop adequate cornering force
 Cushion the vehicle ride
 Economic performance
 TYRE TERMINOLOGIES

Tread
Tread is the thick extruded profile that sorrounds the tyre carcass. It is the
outer portion of the tyre that comes in contact with the road surface.Tread
compounds include additives to impart wear resistance and traction . The
pattern of the thread depends upon the size of tyre, weather condition of the
place where the tyre is to be used, load which is to be carried and many
others. NR is generally for truck tyres to have good strength whereas the
blend of SBR and BR is used in LCV’s (Light Commercial Vehicles).
Sidewall
This is the flexing portion of the tyre that is run between the bead and the
tread. This has to be compounded in such a way to have better flex cracking
resistance and oxidation resistance.
Carcass
This is the skeleton of the tyre and gives shape to the tyre. This contains
rubberised fabric and /or rubberised wire. The fabric or wire that is coated
with the rubber is called ply or band. These plies are built to form carcass.
Bead assembly
The bead assembly contains a number of bead wires, bead filler and bead
flipper. The bead is used to seat the tyre on the rim firmly. The bead filler is
used to fill the gap that is formed between the bead and carcass ply turn up.
The bead flipper is a rubberised fabric to give extra protection to the tyre.
Cap strip/cap ply
The cap strip is the portion that runs from shoulder to shoulder below the
thread and above the carcass. The breaker has thick cords which can be
filled with more rubber compound. This provides extra stiffness to the
thread.
Inner Liner
The inner liner compounds are usually butyl or halo butyl based. It should
have very low air permeability.This is thin layer which is used to hold air in
the tubeless tyre. In tubed tyre, the inner liner serves to hold some air.
Chafer
This is a square woven rubberised fabric and is used to prevent the chaffing
of the carcass from rim in the bead area.
Belt
Belts are calendered sheets consisting of a layer of rubber ,a layer of closely
spaced steel cords and a second layer of rubber.This is used in radial tyres
and in bias belted tyres. This belt acts as a restricting member in the
tyre.passenger tyres are usually made with two or three belts.
1. RAW MATERIAL STORE
The raw material store is the area where all the raw materials
needed for the production of tyre is, recieved inspected and stored in, from
here the samples are collected as per the sampling plan and sent for the
testing in the chemical laboratory. The materials are weighed and sent to the
required area in the shop floor according to the daily requirement provided
by the production planning department.
The chemical lab performs various tests on the random samples
from the RMS and take usage decision. The vendor rating consistency and
processing capability of the material inspected with statistical data on
quarterly basis.

2. RUBBER COMPOUNDING
COMPOUND

It is a homogeneous mixture of ingredients used in a particular product

manufacture such that the properties of most of the ingredients are
unchanged in the final product whereby providing a defined set of
mechanical properties.

COMPOUNDING

It is the science of selecting and combining elastomers and additives to

obtain an intimate mixture that will develop the necessary physical and
chemical properties for a finished product
OBJECTIVE

1. To secure certain properties in the finished product to satisfy the service

requirements.
2. To attain processing characteristics necessary for efficient utilisation of
available equipment.
3. To achieve desirable properties and processibility at the lowest possible
cost.
MAJOR OBJECTIVES OF COMPOUND DEVELOPMENT
Resistance to Degradation
• Heat, Oxygen, Ozone.
• Liquids
• Light
Miscellaneous property requirements
• Low temperature flexibility.
• Permeability.
• Bonding to metal & textiles.
• Abrasion resistance
• Flex fatigue resistance
• Tear resistance
• Low heat build up
• Other specific requirements
 CLASSIFICATION OF COMPOUNDING INGREDIENTS
1. Elastomer
2. Vulcanizing Agents (curatives)
3. Accelerators.
4. Activators and Retarders.
5. Antidegradants (Anti-oxidants, Antiozonants, Protective
waxes
6. Processing aids (Peptizers, Lubricants, Release Agents).
7. Fillers (carbon black, Non-Black materials).
8. Plasticizers, Softeners and Tackifiers.
9. Special Purpose Materials ( Eg:Blowing Agents)
POLYMER SELECTION CRITERIA
• Cost
• Ease of mixing
• Strength requirement
• Modulus or stiffness requirement.
• Abrasion resistance requirement.
• Elongation requirement.
• Oil resistance requirement.
• Low temperature requirement.
• Fatigue requirement.
• Tack.
 • Set or stress relaxation.
• Service temperature
• Dynamic properties (hysteresis, damping resistance)
• Chemical resistance
RUBBER:- Raw rubber (both synthetic & natural rubber) are semi solid
materials having properties like elasticity, strength, tear and flex resistance
etc. required for any tyre component.
The properties of rubber can be increased by adding various ingredients
at desired proportions in the process of mixing.
Raw rubber:- There are two type of rubber:
Natural rubber & Synthetic rubber.
Natural rubber:- Natural rubber is derived from latex of the rubber tree.
These are processed basically in two - Sheet rubber & Block rubber.
Various types of sheet rubbers are as follows:

 RSS 1
 RSS 2
 RSS 3
 RSS 4
 RSS 5

Block rubber : Block rubber are identified as TSR-X (Technically

Specified Rubber) and ‘X’ indicating Dirt content.
Various types are as follow:
 TSR20 (Technically Specified Rubber)
 SMR (Standard Malaysian Rubber)
 STR (Standard Taiwan Rubber)
 SIR (Standard Indonesian Rubber)

Synthetic Rubber : Synthetic rubbers are derived from petroleum product

and the selection based on the end application.
Various types of synthetic rubbers used in tyre industry are as follows:

1 SBR-1502 Use in treads for

2 SBR-1712 getting good wear
3 S-SBR resistance, low rolling
4 E-SBR resistance, low friction
etc.
5 PBD Mainly used in side
wall and tread for flex
resistance,tear
resistance
6 BIIR In tubeless inner liner
due to low air
permeability
7 CIIR

Reinforcing agents : Reinforcing agents added to rubber compound

for increasing the physical properties (like Tensile strength,
Elongation, Hardness, Abrasion resistance etc.) of compound.
 There are mainly two types of reinforcing agent.

 Carbon black
 Silica

Various types of Carbon black

Se. No. Carbon black Definition

1 ISAF-N220 Intermediate super abrasion furnace

black
2 ISAF-N234 Intermediate super abrasion furnace
black
3 HAF-N330 High abrasion furnace black

4 HAF LS-N326 High abrasion furnace black-Low

structure
5 HAF HS-N339 High abrasion furnace black-High
structure
6 FEF-N550 Fast extrusion furnace black

7 GPF-N660 General purpose furnace black

Types of Silica

1 VN3 Precipitated silica

2 7000GR Highly dispersible silica

Processing Aids : Processing aid is used to facilitate the processing.

Various types are given below:

S. No. Process Aids

1 Aromatic oil
2 VP1454
3 Peptizer
4 Paraffinic oil
5 Naphthenic oil

Vulcanization Agents : Vulcanization agents are used to make a

cross linking between the polymer chains for getting the desired
properties in the rubber compound. Commonly used vulcanizing
agents is Sulphur.

There are two types of Sulphur

1. Soluble sulphur
2. In soluble sulphur

In soluble sulphur is oil treated variety of sulphur and used in

compound having sulphur dosage more than 2 phr, to avoid
sulphur blooming. But in the process, special care must be taken to
control processing temperature below 1050C, insoluble sulphur will
lose its characteristic and turn to soluble sulphur.
Vulcanization Agents:-
 S. No. Vulcanization agent
1 Soluble Sulphur
2 Insoluble Sulphur (20% oil treated)
3 Insoluble Sulphur (33% oil treated)

Accelerators:- Accelerators are used to either increase or adjust the

speed of the vulcanization reaction. Accelerators are classified in to
various category. Such as slow, Medium, Fast, and Ultra fast
accelerator as per the reactivity.

Some of the commonly used accelerator are given below:

S. No. Name Types

1 DPG Slow/ Delayed accelerator

2 MBTS Medium fast accelerator

3 DCBS Medium fast accelerator

4 CBS Medium fast accelerator

5 MOR Medium fast accelerator

6 TBBS Medium fast accelerator

 7 TMTD Fast accelerator

Activator:- Activator are used to improve the efficiency of accelerators for getting the elasticity and
strength of vulcanizate.

S. No. Chemical Name

1 Zinc oxide
2 Stearic acid

Anti Degradant : Anti degradants are used in rubber compound to

avoid the degradation due to Flex, heat, ozone and oxygen during
service / storage.

These are classified in to two types:

1. Antioxidant
2. Antiozonant

S. No. Name Type

1 TMQ Antioxidant
2 6PPD Antioxidant
3 DPPD Antioxidant
4 WAX Antiozonant

Tackifiers:- The tackifiers are used to increase the tackiness of the

green component to facilitate sufficient tackiness to individual
component during tyre building and to avoid air entrapment
between components.
Various tackifiers and type in use are

S. No. Name
1 Phenol formaldehyde (PF) resin
2 Aliphatic resin
3 Gum rosin
4 Thermosetting P.F. resin

Retarder:- Retarder or pre vulcanization inhibitors are mainly use to

avoid premature scorch /cure (lumpy) of compound during
processing stage to certain level of dosage.

This will not have any impact on cure rate of the vulcanizate.

Commonly used retarder is N-cyclohexyl Thio Pthalamide (CTP)

Special additives:- In addition to the above rubber ingredients, for

getting some special properties, certain chemical are added in
mixing process.

These chemicals are called as special additives.

They are as follows:

1. Bonding agent
2. Silane coupling agent
3.
1. Bonding agents:- Bonding agents are mainly used to increase
the bonding strength between the rubber and fabric as well
steel.
Bonding agents used are shown below
S. No. Chemical Name
1 Resorcinol formaldehyde
2 Resorcinol stearic acid melt
3 Resorcinol
4 Cobalt-borate adhesion promoter
5 Cobalt stearate

2.Silane coupling agent:- Used in silica based compounds to facilitate

better linkage between the silica and polymer to get desired property in the
compound.

S. No. Chemical Name

1 X-50s

2 X-266s

MIXING

Mixing is the process of applying mechanical work to the

ingredients in order to blend them into a homogeneous substance. Internal
mixers are often equipped with two counter-rotating rotors in a large
housing that shear the rubber charge along with the additives. The mixing is
done in three or four stages to incorporate the ingredients in the desired
order. The shearing action generates considerable heat, so both rotors and
housing are water-cooled to maintain a temperature low enough to assure
that vulcanization does not begin.

After mixing, the rubber charge is dropped into a chute and fed by
an extruding screw into a roller die. Alternatively, the batch can be dropped
 onto an open rubber mill batch off system. A mill consists of twin counter-
rotating rolls, one serrated, that provide additional mechanical working to
the rubber and produce a thick rubber sheet. The sheet is pulled off the
rollers in the form of a strip. The strip is cooled, dusted with talc, and laid
down into a pallet bin.

The ideal compound at this point would have a highly uniform

material dispersion; however in practice there is considerable non-
uniformity to the dispersion. This is due to several causes, including hot and
cold spots in the mixer housing and rotors, excessive rotor clearance, rotor
wear, and poorly circulating flow paths. As a result, there can be a little
more carbon black here, and a little less there, along with a few clumps of
carbon black elsewhere, that are not well mixed with the rubber or the
additives.
FLOW CHART OF COMPOUND MIXING(MASTER/FINAL)

Polymer
+ Carbon
+ Oil
banbury
+ Chemicals

Mixing
Mixing mode
mode Mixer
Master
Master Compound
Compound Dump
Dump temp
temp
Time
Time ,, Temp
Temp &
& Energy
Energy RPM
RPM ,, Ram
Ram Pressure
Pressure ,, Batch
Batch maintain
maintain 150
150 -160◦C
-160◦C
weight
weight

Dump Mill
R
For
For compound
compound sheeting
sheeting

R
Batch off mill

Soap Solution

Anti sticking agent

Cooling conveyor

To prevent scorching during storage

 Lay down

Lay down temp ≤45◦C

THE THREE STAGES IN THE MIXING PROCESS ARE

Storage
1. Feeding the ingredients to the mixer in the correct quantities, at
the correct times, and at the correct temperature.
2. The actual mixing of the ingredients.
3. Discharge of the mixed compound from the mixer, and its shaping,
cooling, and packaging for the next process.

OBJECTIVE:- The objective of mixing is to produce a compound with its

ingredients sufficiently thoroughly incorporated and dispersed so that it will
process easily in the subsequent forming operation, cure efficiently and
develop the necessary properties for end-use, all with the minimum
expenditure of machine, energy and time.
The four main component of the mixing process:-
1. Incorporation
2. Dispersion
3.distribution
4.plasticization or viscosity reduction
 INCORPORATION: Sometimes called wetting, is the first stage in
mixing during which the previously separate ingredients from a coherent
mass.

 DISPERSION: Dispersion is the process during which filler

agglomerates are fractured and reduced to their ultimate size

 DISTRIBUTION: Distribution is simple homogenization, during which

the various ingredients are randomly distributed throughout the mass of
the mix

 VISCOSITY REDUCTION:- During plasticization, the mix reaches it’s

final viscosity as plasticizers effectively internally lubricate the mix
These four processes are not entirely distinct.
They all, especially distributive mixing, take place through out the
mixing cycle. However, incorporation predominates in the early stages,
dispersion in the middle, and plasticization towards the end.

MIXING EQUIPMENTS
The equipment used for mixing or processing rubber and its ingredients are
called as “mixer”.

TYPE OF MIXERS : There are basically two types of mixers

1. Continuous Mixer
2. Batch Mixer
1. CONTINUOUS MIXER : In continuous mixer, material are fed in to
hopper continuously and steadily and discharged from other end after
thoroughly blending the mix. Here the feeding & discharging operations
are continuous.
2. BATCH MIXER : In Batch mixer loads are put in the machine is run
for the specified time and is then stopped and unloaded the mix. While
mixing one batch load, another batch material must wait for its turn.

According to the body construction and its salient features batch type
Mixers are categorized as follows:
1. Open Mill
2. Internal Mixer

1. OPEN MILL:- The open Two roll mill consist of two parallel,
horizontal rolls rotating in opposite direction. The back roll is usually
rotating faster than the front roll. The roll are consist of cast Iron. The
friction ratio of both roll is 1:1.1 to 1:1.3

2. INTERNAL MIXER:- Internal Mixer is a batch type mixer capable of

mixing, thick, viscous, & hard to mix materials in a very short period of
time. Internal mixers are most versatile mixer.
Common feature of Internal mixer:-

 A chamber with a feed hopper and discharge door.

 Rotors which can exert both a high localized shear stress (a nip
action) and a lower shear rate (a stirring or homogenisation action) to the
material being mixed. It is the combination of these two effects, high shear
stress plus large shear deformation, that is effective in producing both good
dispersive and distributive mixing

 A ram which exerts pressure on the mix in the chamber

 A heating / cooling system, which controls the temperature of the

chamber walls, drop door, ram and rotors.
TYPES OF INTERNAL MIXER:- According to the chamber and rotor
design there are two types of Internal Mixer.
1. Intermix
2.Banbury

1. INTERMIX

Mixing is done between the rotors only. The thicker portion of

one rotors produces kneading action to the thinner portion of the other rotor,
which creates friction while mixing. Rotor runs at even speed.
Intermeshing rotor are presence. This rotors generally have a large volume
and take up more of the chamber space.
That is for two mixers of the same chamber volume, the batch size is
greater for tangential mixer.
Intermeshing machine, because of the more intensive mixing action,
can achieve a better degree of dispersion in a given mixing time & better
control of the batch temperature. This is used where difficult to mix
compounds, typical of the industrial good sector.
2. BANBURY

In Banbury, Mixing is done between rotor, rotor and chamber.

Rotor run at different speed to create friction ratio. This mixer are all of
tangential rotor design. Tangential rotor machine accept ingredients faster
and discharge mixed compound faster. As total cycle time is from dump to
dump, this means that unproductive time in the cycle is less.
Parts of Banbury : A Banbury consist of different parts.
1. Body : Chamber sides are made out of heavy cast iron fabrication. End
frames are the main supports that carry the chamber sides and in which
rotor bearings are based. The bearing are sealed against dust & packed
with grease or oil lubrication system.

2. Doors : According to the system of closing operation there are two types
of discharge door in Banbury.
a) Drop door
b) Sliding door

(a)Drop door : It is hinged parallel to the rotors and operates by means of a

hydraulic system.

(b) Sliding door : The door comprises of an air cylinder carried on side
rails of the bottom part of the body of the mixer. The door apex is
 mounted on top of the cylinder and slides pneumatically to open and
close the bottom of the chamber.

3. Dust ring or dust seals:- Helps preventing of material leakage from the
chamber due to the high internal pressure exerted while mixing.
Lubricating oil is forced between the moving metal faces to reduce
friction that would cause over heating and destroy the seal.

4. Feed Hopper:- This is the entrance, through which all the ingredients
are fed in to the mixer.

5. Ram : Ram is also called as float. This works pneumatically moves up

and down through a vertical cylinder above the feed hopper.
Design are of two types:
a) Flat
b) V-bottom

6. Rotors:- Rotors are the mixing blades and are supported at the end
frames by the bearings rotated towards opposite direction at slightly
different speeds (Friction ratio).
Both the rotor are drilled at centre for water cooling system and rotor
surfaces are coated with hard chromium plating to resist the wear.
Two types:
(a) 2 Wing
(b) 4 Wing

7. Drive system:- The internal mixer are powered by a heavy- duty motors
and reduction gear units.

Parameter of Banbury
1. Temperature control unit (TCU):- TCU is the main parameter of
Banbury. The energy that produces the shearing action is largely
converted in to heat, and this results in temperature rise during mixing.
Rubber is an inherently poor conductor of heat, and heat can be removed
from the mass of rubber only if fresh surfaces are generated and brought
in to contact with cooler metal surface, that is the surface of the rotor and
the inside of the chamber &discharge door. TCU is controlled by
temperate water.

2. Rotor speed:- Total shear deformation is the criterion of mixing and

increasing the rotor speed will achieve this in a short time. However, it
must be remembered that an increased rotor speed will result inevitably
in a rise of temperature in the mixer with which the cooling facilities
may be unable to cope. If, scorch can be avoided, mixing time may
generally be regarded as being inversely proportional to rotor speed.

3. If the rotor speed be increased of a 250 litre machine from 40 to 60 rpm,

the mixing time is reduced by 18% and the peak power requirement is
doubled.

4. Ram pressure:- The main function of the ram is to keep ingredients in

the mixing chamber. As ram pressure is increased, voids within the
mixture are reduced, and slippage between the rubber and rotor surface
is reduced, and cycle time is reduced. This is because as pressure
increases, the contact force between the rubber and the rotor surface
increases, and the flow beings at a lower temperature. This is especially
true for high viscosity polymer, which reduce a higher effective batch
pressure.

5. Batch size : Batch size must also be optimized. It the mixer is under
loaded, or over loaded, poor mixing and longer mixing time may result.
If the batch is too small, the ram can seat right down and acts merely as
 part of the chamber wall, exerting no pressure on the materials in the
mixer.
If the batch is too large, then the ram never seats down, and
material, especially powders, accumulates in the throat and never enters the
mixing chamber, and is not incorporated in to the mix. This has two adverse
effects. Firstly, the batch is not homogeneous, nor does its composition
agree with the formulation. Secondly, when the unincorporated powders are
dumped with the batch they can cause a hygiene problem.
The optimum weight for any particular batch depends on the type
and level of rubber, filler, and plasticizer. The specific gravity of the
finished compound is only a rough guide to the required volume.
Formula of Batch size :-

B=CSL

B = Batch size in Kilogram or pounds

C = Capacity of mixer in Kilogram or pound of water
S = Specific gravity of the compound
L = Loading factor (% of total mixing capacity occupied by the complete
batch)

6. Dump criteria : In the initial stages after introduction of the internal

mixers, noise, or ram vibration were taken as indication of completion
of mixing. But these criteria are too subjective. Power curve is too
complicated for the operator to understand and utilize. Hence based on
the power curve data on experimental batches, criteria like constant time
or constant temperature are selected as dumping criteria. However, some
variations in the operating conditions do occur in practice e.g. cool
 Banbury after weekend , variation in cooling water temperature,
fluctuations in ram pressure etc. with constant time or constant
temperature as the dump criteria, there will be variation in quality of the
compound produced. The better criterion is the constant energy criterion.
All modern industrial internal mixer are worked on constant energy as
the dump criteria.

7. Cycle time:- It is considered that, to carry out a mixing, a certain

number of rotor revolutions are needed. The mixing time in the machine
is directly proportional to rotor speed. The loading and discharge time
will normally be approximately a constant for any given machine, so it
can be deduced that

3. EXTRUSION
Extrusion is the process by which the tread, sidewall
components are manufactured. Here the un vulcanised rubber compound
batches are plasticized by high temperature and shear between the screw
and barrel arrangements. The batches are cracked and warmed up in cracker
and warm up mills respectively, before feeding on to the hot feed extruder
as feed strips. The tread so extruded is then passed through conveyors and
linear balance and marking conveyor to the cooling tank of 107m, where
the tread is cooled to ambient temperature before booking.
The tread is immersed and processed through a continuously
supplied chilled water tank. The temperature of chilled water being 19±3°C.
The tread so cooled is then passed on to sponge roll to remove water from
the surface and then to an auto-skiver arrangement to cut it into desired set
length. The tread is then booked in leaf trucks and placed for sufficient
ageing before building with proper identifications.
 The main two classification of extruders are;
1. Hot feed extruder
Here the material is fed as hot and the main type of hot feed
extruder is Dual extruder.

2. Cold feed extruder

Here in this type of extruder the material is heated inside the
extruder. The main types of cold feed extruder used are Triplex
extruder and Duplex extruder.
The extruder used in bias tread production is a dual extruder in
which each extruder facilitates the base and cap plasticization. The extruder
for the cap is a 10” extruder while for the base is an 8.5” extruder.
It is used for the production of treads and sidewall for tractors,
trucks, OTRs. The process of tread extrusion involves major machineries
and accessories like:
1. Cracker and warm up mills
2. Feed mills
3. Dual extruder
4. Initial conveyors
5. Cooling conveyors
6. Auto-skivers
7. Final balance

1. Cracker and warm up mills:

The cap and base compounds have different arrangements for
the cracking and warm up. The 10” cap extruder compound has a cracker, a
warm up and feed mill while the 8.5” extruder has only cracker feed mill.
The primary objectives of using cracker mills are to reduce
the tread compound viscosity from 65 to 60. Cracker mills are similar to
ordinary roll mills but with a serrated back roll.
 There are two warm up mills. They are used primarily to
reduce the compound viscosity, homogenization and better filler dispersion.

2. Feed mills
The feed mill used for the feeding of the cracked and
warmed up compound into the respective extruders at sufficient
temperature. The temperature of feed mills is almost 105°c. There are three
feed mills all together. It is provided with a stock blender for further
homogenization of the feed, guide roll to supply the feed at correct width to
the extruder.

4.DIPPING
The latex components in RFL may be the layer of the adhesive
flexible and combine it firmly with the rubber layer by means of secondary
bonds and co-vulcanization. The RF components react with active hydrogen
of nylon and forming primary bonds or hydrogen bonds with the fiber. This
forms a network structure.
If the RF components are simply dried in the drier after the dipping
only an adhesion is formed by hydrogen bond. Strong hydrogen bonds are
formed only if the components are baked at high temperature.

DIP SOLUTION MAKING PROCEDURE&INGREDIENTS

 Resorcinol
 Formalin
 Vinyl Pyridine Latex
 Sodium Hydroxide
 Ammonium Hydroxide
PROCESS
STEP 1 (COMPOUND.1)

 Take water from condensate storage tank in to master batch tank

 Start chiller and TCU
 Start stirrer
 Bring down the temperature of the water to 22-23°c
 Add NaOH and dissolve
 Add resorcinol and dissolve
 Keep stirrer on
STEP 2

 Take vinyl pyridine latex into final batch tank

 Rinse each drum with 5 liters of water
 Transfer compound.1 into final batch tank
 Add water into final batch tank
 Add ammonium hydroxide and stir well
Ph and TSC are tested and controlled

5. CALENDERING
The calendaring department produces rubber coated fabric
plies and squeegee and inner liner components of the tyre which are used
in the tyre manufacturing process. These components are produced using
two calendars.
a) 3 Roll calendar
b) 4 Roll calendar
The 3 roll calendar is used for making squeegee and the inner
liner which are thin rubber sheets of 0.5-1.5 mm thickness. This is
calendared from a 3 vertically arranged rolls in which the calendared
sheets passes in a z path between the rolls, finally cutting in to desired
widths and rolling on to liners.
The 4 roll calendar comprises of the following machineries
along with the cracker and feed mills for the softening of the batch. The
4 roll calendar is used for rubberizing dipped nylon fabric which are
suitably cut and sent for the band building department.
Dual let off stand:
This contains the RFL treated (Nylon 6). This is operated by
disc brake system for adjusting let off fabric tension. The specified dual
let off tension is 32psi. The two let off units provide continuous
operation of the unit
Splice press:
This pres joins ends of a let off roll. Joining of these two
ends is done by putting a green rubber strip between two ends and then
curing it under temperature and pressure.
Pull off rolls:
After splice unit, there are set of five rolls, called pull off
rolls. These rolls provide the required tension to the fabric. During roll
change over, the fabric is locked between two rubber rollers and pull
rolls feed the fabric under tension.
Centering device:
A light source ensuring the centering of the fabric entering the
let off accumulator which is placed across the width of the fabric. A
sensor is placed on the other side of the fabric. According to the intensity
of the light falling on the sensor, it send electromagnetic signals which
make the cylinder to move left or right accordingly.
 Let off accumulator:
This acts as a fabric reservoir. It provides the fabric to the
calendar when one let off roll ends and other does not start. It prevents
the starving of the calendar. It consists of two set of rolls. The number
of rolls in upper and lower are 14 and 15 respectively. The upper set
of rolls can move upward or downward.
Calender
The temperature of 1st and 2nd rolls is 80°c where as that of the
2nd and 3rd is 75°c. For adjusting the temperature , heat exchangers are used.
The rubber gauge varies from 0.2-0.4mm. When rubber strip is fed to the
calendar, it causes the roll to bend. The bending of the rolls lead to non
uniform thickness of the rubber later. To compensate these following
adjustments are made;

 Rolls are crowned

 Bending of the roll
 Making use cross axis devices
Cooling drum
The fabric from calendar passes over a set of 12 drums called
cooling drums. These are hollow drums through which chilled water is
circulated
Wind up accumulator
This unit receives the fabric after calendaring. It has two
sets of rolls each composed of 10 rolls each. The working principle of this
accumulator
Pricker roll
The function of this roll is to eliminate entrapped air. The rolls have a
number of blunt needles on its surface.

Wind up roll
The calendared fabric is then winded up after passing through a spreader
roll that relieves of it any creases. The winding is done under tension to
avoid the crease formation.

6. LTBC & HTBC

The calendered fabric is cut at a certain angle( 90° for Radial
ply ) . this process is called Bias cutting. Cut plies are flexible and
improves the impact resistance of the tyre. There are mainly two types
of cutting machine for radial ply, LTBC and HTBC
There are two important parameters which need to be
considered while cutting the fabric. One is the angle of the ply , second
is the width of the plies and Splicing of Cut plies. The angle and width
changes with size of the tyre. Width of the plies is important to achieve
correct turn up and ending of the plies. The machine used for bias cutting
(bias cutter) are equipped with belt, chain drive and limit switches for
adjusting the conveyor belt. To measure the width of the ply, there is a
scale equipped with photocell to achieve correct width. The required
angle is obtained with the help of a hand wheel attach screw shaft on the
machine. Machine is equipped with auto splicing in specified splicing
width.
Fabric from a let off is passed through a self levelling festoonery
unit mounted between the stripper and the bias cutter. And cutting in 90
degree angle for radial ply.
 After cutting the fabric, the dancer roll tips the top limiting switch
which starts the let off motor. The cut fabric plies are spliced on a table
and wound up in liners.
Based on the Cutting table arrangement textile cutter are classified as
HTBC ( High Table Bias Cutter ) and LTBC ( Low Table Bias Cutter )

BEAD WINDING

A bead is a coil of rubber coated high tensile copper coated steel wire.
Before coating with rubber these wires are coated with copper. The
functions of bead are to hold the tyre on the rim, to prevent air and moisture
penetration into the tyre and in tubeless tyre it prevents the leakage of air
from the tyre. It is as important as the carcass of the tyre.
These are reels of copper coated high tensile steel wires. The
copper coating is done to improve the bonding between rubber and steel
wires. The no of reels depend on the no of wires required which in turn
depend on the size strength requirement. Guide rolls help in proper
movement of wires to the T-Head extruder. Before entering the wires in to
the extruder, they are passed through heating rollers. While passing through
these rollers the wires are heated to 40°c. Heating of these wires helps in
the bonding between the wires and the rubber.

Cooling drum
As the name indicates, these drums are used to cool the
rubber coated wire.
Festooner
Their job is to accumulate the coated bead wire. The diameter
of winding wheel is in accordance with the bead core internal diameter. The
winded wheel is provided with a gripper, which grips one end of the wire. A
timer controls the number of turn. After the required number of turns is
over, a cutter cuts the wires.
Bead cementing
A rubber solution called rubber cement is applied on the
bead to facilitate good adhesion between filler and flipper.

7 TYRE BUILDING
Tire building is a process of assembling the different component
to form a green tyre. The tire building machine consists of a rotating
drum, on which the components are assembled. The drum is mounted on
a shaft. The design is such that it collapses radially for removing the
green tire. The drum is expanded and collapsed by locking a quick shaft
with an air clutched rotating the drum by drive motor.
The other important assemblies and arrangements that facilitate
the tire building are bead setter, bead stitcher, tread stitcher, guide lights,
bottom roller stitcher etc…

The green tyre consist of two parts

 Carcass
 Package
The components of carcass are
• Innerliner
• Ply
• Bead filler (bead +filler)
• Sidewall
The components of package are
 Belt
 Cap strip (cap ply)
 Tread
Carcass + package =green tyre
Parts are assembled in building machine.two types of building
machines are mainly used .they are
 Unistage building machine and
 Two stage building machine
In unistage building machine, all the components are assembled
in a single stage operation .This is the modern method used for
tyre building.compared to two stage machine it consumes lesser
time for green tyre building.
In two stage building machine ,there are two stages for
building.In first stage bead,inner liner,ply,sidewall etc are
assembled.Belt ,cap strip and tread are assembled in the second
stage
 Tyre building process

BEAD
+ INNER LINER
+ PLY
+ CHAFER

SIDEWALL
+ BELT
+ CAP STRIP
+ TREAD

BUILDING MACHINE

UNISTAGE MACHINE TWO STAGE MACHINE

GREEN TYRE
 8. PAINTING
There are two different types of paints. They are
1. Inner paint
2. Outer paint

Inner paint
This is applied inside the green tyre. This is applied to avoid sticking of the
bladder with inner liner during curing and it also helps to bleed out the air
between the carcass and bladder. the paints are oil based and water based.
Outer paint
This is applied on the sidewall portion. This is applied to improve the flow
of sidewall compound inside the mould and to improve the cure properties
of the sidewall. The paint used mainly rubber based and these paints mixed
with curatives.

9.AWLING
When a green tire is loaded in the mould for curing, there occurs air
entrapment. This entrapped air may cause a severe damage to the tire. To
avoid this fine holes are made in the tire all over its surface. This is called
poking. This is done by an automatic machine which contains specially
designed needles. Awling is done after making sure that inner paint has
been dried completely.
The tyre is loaded into the machine manually but unloading is done
automatically. The machine consists of two vertical posts, a piston with
number of needles and a tyre holder. The piston will move up and down,
and it will pierce the tyre. The whole is produced by which the air inside the
green tyre will escape. The number of wholes depend on the size of the
green tyre. The pressure of piston and the sharpness of the needles should
be sufficient to pierce the green tyre.

10) TYRE CURING

Curing is a process which gives the final shape and strength to the
green tire, different tyre components are joined by physical bonding.

SELECTION OF CURING METHOD

All steam cure

Hot water cure
Conventional cure
Gas cure

All steam cure

The temperature of the steam is maintained high. So the heat input in from
the mould to the rubber compound will be very high. Due to which the
rubber compound can be cured within Short time and hence the
productivity will be high.
The defects in the products cannot be identified easily as the products per
unit time produced will be very high.

Hot water cure

The temperature of the hot water will be low when compared to the steam
used above. So the heat input will be less. Hence using the hot water as an
agent for heating, the productivity will be less. Due to low productivity, the
defects in the product can identified easily.

Conventional cure
The heat input range will between the all steam cure and hot water cure.
Here the time consumption for the curing and the defect identification can
be optimized.

Gas cure
Here instead of water or steam, the nitrogen gas is used as agent for curing.
This gas is used because it is inert. The only disadvantage with this cure is
that N2 absorbs O2 from the atmosphere nitrogen. Nitrogen absorbs the heat
from the high pressure steam and retains it for a long time. So the cure time
will be low and hence productivity will be high. Defects cannot be
identified easily due to high productivity.

b)UTILITY SERVICES
Utility services are nothing but the agents that are required to heat the green
tyre for curing. the agents used for the cooling of cured tyre from its cure
temperature are also called utility services. The following are the utility
services used in tyre industry.

High pressure steam : pressure depends upon the pressure required to

inflate the green tyre and is greater than 14 kg/cm2
Medium pressure steam : temperature of the steam is around 191 deg
Celsius and the pressure maintained is about 12 kg/cm2
Low pressure steam : the temperature of steam is around 100 deg Celsius
and pressure maintained is low in the order of about 5 kg/cm2
Hot water : temperature of the hot water depends upon the time required to
cool the cured tyre from its cure temperature.

Cold water : the cold water is also used to cool the cured tyre from its cure
temperature.

Air : in some cases, instead of using the cold water, the air is used for
cooling of the green tyre.

c)TYRE CURING METHODS

The green tyres are cured in the tyre curing presses. There are two types of
curing presses
1. Dome press
2. Platen press
Dome press : this press is used to cure the bias tyres. The mould region has
top part and bottom part. The top part in this press resembles the shape of
dome and hence it is called as ‛dome press’. The mould is fitted inside these
parts. Hence the mould is directly heated up by steam.
Platen press : this press is used to cure radial tyres. In this case there are
platens in which the mould is fitted. Here the mould is not heated up
directly by steam. Instead it is heated up by platens. The platens will
receive the heat from steam continuously. So mould will retain high
temperature for a very long time.
11. TYRE UNIFORMITY

Radial tyres are tested for tyre uniformity. This test is done to check the
forces that are acting on the tyre. The forces such as radial forces,
circumferencial forces, vertical forces, and other small forces acting on the
tyre during function should be uniform throughout. If there is any non
uniformity of forces in tyre, then there will be no balancing of forces on the
tyre. It will there by affect comfortable travelling of the vehicle. The tyre is
inflated to working pressure and is rotated at a specified speed. Then the
uniformity is tested automatically by the machine. The instrument will shoe
the point where the forces are not balanced. This is the point where the
mouth of the tube is fit to avoid the non uniformity. The extra weights
maybe added to the rim (opposite to the point where forces acting
minimum) of tyre to balance the uneven forces. This test is not done for
bias tyres.

POST CURE INFLATION

Tyre with nylon or polyester casing requires to be under pressure. This can
be done by cooling in press by circulating cold water or by mounting tyre
on a rim immediately after removal from the mould and cooled under air
inflation pressure. This process is known us “post cure inflation (PCI)”.

12.FINAL INSPECTION

Following curing, finishing operation and inspection remain to be

performed before the tire is stored or shipped. The finishing operation trims
flash or excess rubber from the tire. This excess rubber remains on the tire
from vents in the curing mould. Additionally, excess layer of rubber may
need to be ground from the side walls or raised lettering on the tire. The tire
with defects such as flow crack, blister, foreign matter and buckle are
buffed and the defects are removed.

PROJECT ON

EFFECT OF DIFFERENT PROCESSING

OIL ON COMPOUND PROPERTIES
OBJECTIVE

The objective of this project is to compare the effect of Aromatic oil and
the low PCA oil on the PCR compound properties. Because of high Aromatic content
in conventional Aromatic oil, the Europe market and most of the OEM’s are preferred
an Eco Friendly oil which is not toxic.

In present scenario, modern countries like Europe , America aromatic oil is banned.
Because of highly aromatic content leads to health issues . in India , aromatic oils are
gradually replaced by the low PCA oil under REACH compliance.

To study the effect oil in compound properties ,different compounds are mixed with
aromatic oil and low PCA oil.The compound details mentioned below.

Following compounds to be Mixed with basic formulation except only change in Oil
type.

1. PCR Tread cap : A

2. PCR Tread cap : B

3. PCR Side Wall

4. PCR Casing compound

The presence of polycyclic aromatic hydrocarbons (PAHs) in the environment is

primarily due to human activity but can also have a natural origin (forest fires,
volcanoes and other combustion of organic materials in nature)
The utilisation of PAHs free extender oils for the tyre compounds should reduce the
harmfulness of PAHs to health and environment and give the tyre characteristics to
meet the technical requirements for tyre.

NOTE ON VARIOUS PROCESSING OILS

Rubbers both synthetic and natural are commercially used to

convert into the final products ,from a toy to the tyre of a vehicle. Rubber process oils
are used during the processing and production of rubber compounds. Extender oils are
also often referred to as “process or softening oil”. The conventionally widely used
oils in tyre compounds are highly aromatic oils. Because they provide good
compatibility with both natural and some synthetic rubbers as used in tyres
Highly aromatic oils are also reffered to as distillate aromatic extract (DAE). Which
contain a high concentration of polycyclic aromatic hydrocarbons (PAH). Or also
called the poly nuclear aromatics (PNA) . PAHs are organic compound possessing two
or more aromatic rings, of which eight types are identified as carcinogens. These are
benzo[a]pyrene , benzo[e]pyrene , benzo[a]anthracene ,benzo[b]fluoranthene ,
benzo[j]fluoranthene , benzo[k]fluoranthene , dibenzo[a,h]anthracene and chrysene
many other PAHs are harmful to health and environment. Non carcinogenic oils are
need to replace HA oils in tyre compounds.
Process oils in rubber compounds serve three main purposes
 To aid processing of rubber during milling , mixing , extrusion and injection
moulding by providing lubrication of the rubber molecules by reducing its
viscosity
  To improve the physical properties of natural and synthetic rubbers such as flex
life and low temperature performance and also aid the dispersion of fillers
resulting in physical and mechanical properties such as tensile strength and
abrasion resistance. yet retaining the desirable physical properties of the high
molecular weight polymer
 To extend the rubber giving a larger volume of elastomer , thus reducing the
cost of rubber compounds and of the finished rubber goods . presence of oils
also permits the incorporation of dry compounding ingredients into finished
rubber articles

TYPES OF PROCESSING OILS

The rubber processing oils are high boiling petroleum fractions obtained in refining
after gasoline , fuel oil , and other low boiling compounds are removed by distillation.
process oils are made up largely of ring structures. The oil molecules typically
contains the unsaturated rings (aromatic), saturated rngs (naphthenic) and saturated
side chains (paraffinic)

Depending on the type of rubber and the end product applications , various types of
rubber process oils are used.

 Aromatic type
 Naphthenic type
 Paraffinic type

AROMATIC OILS

The primary characteristics of aromatic hydrocarbons is the presence of

the double bonded mix ring carbon structure. Aromatic extracts procured from selected
refineries and suitably blended to meet stringent specifications are used for
compounding batches to manufacture tyres,tubes,hoses,calendar sheets,etc. highly
aromatic (HA) oils also referred to as distillate aromatic extract oils.and these are oils
with a high amount of aromatic carbon structures .These oils contain an increased
polycyclic aromatic hydrocarbon content and can thus also called PAH rich oils.
Aromatic oils are added to the tyre , additionally the tread rubber compound achieves
improved performance characteristics, mainly wet grip but also other characteristics
like wear and endurance.

Aroamatic oils contain high levels of unsaturated single and multiple ring
compounds,stronger odour lower oxidation stability and higher reactivity compared yo
paraffinic and naphthenic oils.Highly aromatic oils are conventionally widely used as
process oils for rubber and tyre compounds because they have good compatibility with
both natural and diene based synthetic elastomers in addition they have low
price.Highly aromatic oils are also often reffered to as distillate aromatic extracts

NAPHTHENIC OILS

Naphthens are a class of hydrocarbons also referred to as “cycloparaffins”. Though

their structure is similar to the aromatic ring. These are single bonded thus having a
stable structure . several such hydrocarbon rings may be linked indicating a variety of
available grades.naphthenic oils derived from naphthenic crude are very available and
inexpensive.

Their unique colour stability ,solubility and good thermal stability makes them ideal
for moulded articles like slippers,LPG tubes floor tiles,etc

Napthenic oils contain a higher level of saturated rings than aromatic and paraffinic
process oils.They have similar odour to paraffinic oils.

PARAFINIC OILS

This class of hydrocarbons constitutes branched chain or straight linked

hydrocarbon molecules of various viscosities.as the chain length increases ,the
viscosity increases and the rubber process oils becomes more viscous.they find
extensive usage in ethylene-propylene rubbers. These are most stable and have the
highest flash point for a given viscosity.paraffinic oils are prepared by solvent
separation technique from paraffinic crude oils paraffinic have good thermal and
oxidative stability and good high temperature viscosity characteristics.
Paraffinic oils contain the high levels of paraffinic molecules. They have less odour
and more oxidative stability than naphthenic and aromatic oils.these oils have similar
levels of monoaromatics,but much lower levels of multi ring aromatics compared to
aromatic oils.

Different kind of low aromatic content oil available for replace highly aromatic
oils
 TDAE ( treated distillate aromatic extract )(treated DAE)
 T-RAE (Treated residual aromatic extract )(treated RAE)
 Naphthenic blends
 MES (mild extraction solvate )
 HND (hydrotreated naphthenic distillate )
 HPD (hydrotreated paraffinic distillate )

Comparison of different types of oil

DAE MES TDAE HND NAP

Oil type Aromat Paraffinic Aromatic Naphthenic Naphthenic
ic
Density 1 0.915 0.95 0.94 0.91
@15°C g/cm
Viscosity@ --- 210 410 438 92
40°C mm/s
Viscosity @ 27 16 19 19 8
100°C mm/s
Aniline point 43.8 97 68 88 97
°C
Ring CP 35 14 25 16.5 1
analysis %
 CN 32 29 30 39.5 52
%
CP 33 57 45 44 47
%
PCA % 13.7 1.2 2.5 2.6 3

COMPARISON OF AROMATIC AND Low PCA OIL

AROMATIC OIL LOW PCA OIL

PARAMETERS TEST TEST RESULTS TEST TEST RESULTS

SPECIFICATIONS SPECIFICATIONS

Aniline point 25-55 deg.c 46.2 90-110deg.c 100.4

Specific gravity 0.98-1.02 1.001 0.90-0.96 0.930
@15.5deg.c
Kinematic viscosity 30 cst (max) 28.3 30 cst( max) 24.1
Flash point 210 deg.c 225.2 200 240
(min) deg.c(min)
 MANUFACTURING OF PROCESSS OILS

The process oils are manufactured from two general types of crude petroleum
ie,paraffinic and naphthenic.these paraffinic and naphthenic crudes are complicated
mixtures of the same type of molecules.paraffinic crude petroleum has a higher level
of paraffinic or saturated long chain molecules.It tends to have higher levels of
petroleum wax which consist of straight chained paraffinic molecules.Naphthenic
crude petroleum has higher levels of saturated ring compounds and tends to be low in
wax content.There are several methods applied for producing process oils from
different crudes,eg naphthenic oils is produced from naphtenic feed by a hydrotreating
process or by a two stages method involving hydrotreating and solvent extracting
steps.Process oils have also been made by hydrotreating process from a mixture of
aromatic and paraffinic rich feeds and a mixture if aromatic extract oil and naphthenic
rich feed.
The production of process oils is generally conducted via two different
processes .The first process is an extraction-hydrotreating-solvent dewaxing process
which is a popular method for producing process oils.Crude petroleum is first distilled
into steams.The oil steams are next extracted with a solvent such as phenol to remove
the highly aromatic molecules ( 3 or more rings) these highly aromatic oils are used as
process oils.The oil steams are further hydrotreated to improve colour and oxidation
stability and are then dewaxed to improve the low temperature handling properties and
improve compatibility with the rubber.
The second process is a newer hydro cracking-isodewaxing process.The crude
petroleum is distilled and then goes into a hydrocracker that breaks up the larger
molecules into smaller molecules.This process converts the aromatic molecules rather
than removing them.The oil streams then go to a hydro isomerization processing
step,which branches the normal paraffins,making them no longer wax type
molecules.This process has a higher yield of process oils than conventional processing
because the aromatic molecules and wax molecules are converted to process oils rather
than being removed
Oil Refining - process diagram

Crude Light oil

oil Hydrotreatment “Hydrotreated MES”
Kerosene
distillate

Diesel Mild Solvent

Dewaxing MES
De salt Gas oil Extraction

Heavy Solvent Dewaxing S-RND

( > 345℃) Extraction
(Solvent Refined heavy
S
Naphthenic Distillate)
Vacuum Distillation

(HND)
Distillate Solvent Base Oil
(HPD)
Extraction
Solvent
DAE TDAE
Extraction

Solvent Dewaxing Brightstock

deasphalting Extraction
Solvent S-RAE
Extraction (T-RAE)
RAE
(solvent refined Residual
Asphalt (Residual Aromatic Extraction)
Aromatic Extraction)

POLYCYCLIC AROMATIC HYDROCARBONS (PAHs)

The presence of polycyclic aromatic hydrocarbons (PAHs) in the environment

is primarily due to human activity but can also have a natural origin (forest fires,
volcanoes and other combustion of organic materials in nature)

PAHs are produced by all combustion phenomena like waste incineration,

iron and steel production , home barbecues , motor vehicle exhaust , open chimney
fires , tobacco smoking gas cooking cigarette smoke etc.

PAHs are also present in aromatic oils produced by oil refining including in
extender oils , and thus also end up as a consequence in tyres.PAHs as such are not a
purposeful addition to tyres.PAHs are present in the air , water and ground. Emission
of PAHs coming from abraded tyre particulates are minor (2%)realative to total PAHs
emission in air , water and ground.

Hydrocarbon molecular with poly aromatic structure .PAHs are also present in the
aromatic oils produced by oil refining which are used in tyres .
Emission of PAHs coming from abraded tyre particulates pollute the environment
Example :

(naphthalene) (anthracene) (phenanthrene)

(diphenyl) (o-diphenylbenzene)

REPLACEMENT OF HIGHLY AROMATIC OILS IN TYRES

Today, alternative oils are produced by many petroleum companies

however still problem with availability of these oils. The use of these alternative oil is
technically possible in some tyre segment.

But in some others , the industry has still to invest substantial

development to compensate for the loss of performance mainly wet skid performance
this means that some extensive testing is still required before broad use is possible.
Some technical adjustments are definitely needed in order to safeguard tyre
performance we have concerns regarding the wet grip , tyre durability and breaking
strength.
 DETAILS OF TYPICAL COMPOUND RECIPE
AND COMPOUND PROPERTIES MIXED WITH
AROMATIC AND LOW PCA OIL
Typical Compound Specification for Casing compound
PHR
WITH WITH LOW
Ingredients AROMATIC PCA

RSS4 55.00 55.00

SBR 35.00 35.00

PBR 10.00 10.00

Carbon Black - N339 60.00 60.00

9.00
Aromatic Oil
9.00
Low PCA oil

Zinc Oxide 10.00 10.00

Stearic Acid 1.00 1.00

Anti Ozonent 0.50 0.50

Processing Aid 1.00 1.00

Resin 2.00 2.00

Anti Oxidant 1.50 1.50

Sulphur 3.00 3.00

Primary Accelarator 0.70 0.70

Secondary Accelarator 0.20 0.20

Retarder 0.15 0.15

Total 189.05 189.05

Typical Compound Specification for Side wall compound

PHR
WITH
Ingredients AROMATIC WITH LOW PCA

SMR 20 60.00 60.00

PBR 40.00 40.00

Carbon Black - N339 50.00 50.00

7.00
Aromatic Oil
7.00
Low PCA oil

Zinc Oxide 5.00 5.00

Stearic Acid 3.00 3.00

Anti Ozonent 1.00 1.00

Processing Aid 2.00 2.00

Anti Oxidant 1.50 1.50

Sulphur 2.00 2.00

Primary Accelarator 0.50 0.50

Secondary Accelarator 0.50 0.50

Retarder 0.15 0.15

Total 172.65 172.65

Typical Compound Specification for Tread Cap compound
PHR
WITH
Ingrediants AROMATIC WITH LOW PCA

SBR 90.00 90.00

PBR 10.00 10.00

Carbon Black - N339 70.00 70.00

8.00
Aromatic Oil
8.00
Low PCA oil

Zinc Oxide 4.50 4.50

Stearic Acid 3.00 3.00

Anti Ozonent 1.25 1.25

Processing Aid 2.00 2.00

Anti Oxidant 1.00 1.00

Sulphur 2.30 2.30

Primary Accelarator 1.20 1.20

Secondary Accelarator 0.30 0.30

Retarder 0.15 0.15

Total 193.70 193.70

CONCLUSION

Raw Material :
There is a difference in Aniline point , In Low PCA oil Aniline point
is higher than Aromatic Oil.
Aromatic content in Aromatic oil is more than 80% , where as in low
PCA the aromatic content is less than 3.5 %.

Compound Test Properties :

The compounds are mixed without change in recipe except oil .The
mixed compound properties are found comparable with each other.
There is no major variation in Cure and Physical properties.
Based on test results, Aromatic oil Can be replaced with low PCA
oil.