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Distillate aromatic extracts (DAE) are currently used as aromatic process oils for
the manufacture of oil extended natural
or synthetic rubber and also tire compounds. These oils contain high levels
of polycyclic aromatic hydrocarbons
(PAH) and are identified to cause tumours
in various mice skin painting tests [1, 2, 3].
Therefore process oils of the distillate aromatic extract type have consequently
been classified as carcinogenic according to the European legislation (EU Substance Directive 67/548/EEC) and must
be labelled with the risk phrase R 45
(may cause cancer) and the label T
(toxic, skull & crossbones) in Europe [4].
A debate about the environmental impact of aromatic process oils on the emissions from passenger cars tires was initiated by the Swedish Kemi study
(1994), which estimated 14 t/year of polycyclic aromatic hydrocarbons from
10 000 t/year tire wear in Sweden [5]. A
1998 research project sponsored by
the German Umweltbundesamt focused
on the environmental pollution from tire
wear and came to slightly different PAH
estimates. The analysis of individual polycyclic aromatic hydrocarbons from commercial aromatic process oils included
determination of individual carcinogenic
PAHs such as benzo[a]pyrene, benzo[a]anthracene, benzo[b]fluoranthene,
benzo[j]fluoranthene and benzo[k]fluoranthene, and resulted in PAH concentrations between 100 and 1400 mg/kg. This
corresponds to a emission of PAH from
tire wear up to 1.7 t/year for Sweden
[6]. The inconsistency between the two
studies can be explained by the fact
that the authors used different concentrations of polycyclic aromatic hydrocarbons
in aromatic process oils for their calculations [7]. For Germany the Umweltbundesamt study expected the annual
tire wear to grow to 65 000 t/year in
799
oils were evaluated in typical tire tread formulations based on carbon black and silica compounds with typical current DAE
as a benchmark.
TDAE might require substantial capital investments where suitable hardware is not
available.
MES and the severely processed
naphthenic process oils (NAP) are
made from the corresponding paraffinic
or naphthenic distillates, either via solvent
extraction or hydrotreating. MES type
products have already been manufactured on a commercial scale at different
refineries and are available world-wide,
e. g. as Shell Catenex SNR. The availability of naphthenic process oils is
much higher in the USA than in Europe.
These oils are already commercially available, e. g. outside USA as Shell Gravex
181 or in USA as Shellflex 794 respectively [12, 13]. The PCA contents of these
oils are carefully controlled to stay below
the 3 %m threshold of the EU Substance
Directive and hence not classified and
free of labelling constraints [19].
800
DAE
TDAE
NAP
MES 1
MES 2
D8.0
1002
1.570
260
30
1500
31
0.957
41/31/28
D8.0
939
1.520
264
27
210
14.5
0.880
19/23/58
5.5
938
1.512
252
15
785
25.0
0.863
11/43/46
2.0
909
1.501
266
15
175
14.2
0.840
12/30/58
7.0
914
1.504
250
6
179
14.4
0.846
13/31/56
4
50
10/70/20
2.8
74
2/43/55
1.0
85
2/51/47
0.4
99
1/42/57
1.4
95
1/50/49
IP 346
Bayer ELA 601
20
43
1.3
58
1.2
43
1.4
64
1.1
66
801
802
Grimmer DAE
Fluoranthene
Pyrene
Benzo[a]fluorene
Benzo[b c]fluorene
Benzo[b]naphtho[2,1-d]thiophene
Benzo[g]fluoranthene, -[h]-, -[i]Benzo[a]anthracene
Chrysene Triphenylene
1 2 3 4 5 6-Methylchrysenes
Benzo[b j k]fluoranthen
Benzo[e]pyrene
Benzo[a]pyrene
Perylene
Dibenz[aj]anthracene
Indeno[1,2,3-c,d]pyrene
Dibenz[a,h]anthracene, -[a,c]Benzo[b]chrysene
Dibenzo[g,h,i]perylene
Anthanthrene
Coronene
Total sum of PAH
Sum of Grimmer PAH (x)
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Compounding
The influence of different process oil
types in the rubber mixtures has been
tested in a series of experimental tire
tread compounds based on typical carbon black and silica formulations backto-back with DAE. The full recipes are
shown in Tables 3 and 4.
Table 3: Carbon black compound
NAP
MES 1
MES 2
1
7
26
15
15
6
6
48
73
< 0.1
0.1
0.1
0.3
0.1
0.4
0.1
0.1
0.4
0.1
< 0.1
< 0.1
< 0.1
0.1
0.2
0.4
0.4
1.7
< 0.1
< 0.1
< 0.1
< 0.1
< 0.1
< 0.1
< 0.1
0.2
0.9
0.1
0.3
0.2
< 0.1
0.3
0.1
0.1
< 0.1
0.3
64
45
12
49
1
8
8
0.1
0.1
< 0.1
< 0.1
< 0.1
< 0.1
< 0.1
0.1
< 0.1
< 0.1
< 0.1
2
1
< 0.1
0.5
0.2
0.3
< 0.1
< 0.1
0.5
< 0.1
0.8
< 0.1
2.8
6
5
< 0.1
0.1
0.1
< 0.1
< 0.1
< 0.1
< 0.1
0.1
< 0.1
< 0.1
< 0.1
2
1
49
6
4
443
279
to all non-carcinogenic process oils. Replacing DAE by non-carcinogenic process oils will reduce the PAH emissions
from tires by more than 98 %.
TDAE
0.3
0.4
0.2
0.4
< 0.1
< 0.1
< 0.1
0.1
0.2
< 0.1
0.1
5
2
Component
phr
Component
phr
50
25
25
37,5
55
3
1,5
1
1
1
1,6
0,3
1,6
70
30
37,5
10
70
5,6
3
1
2
1
1,4
2,0
1,6
Compound properties
The experimental carbon black and silica
compounds were vulcanised and analysed for Mooney viscosity, scorch time
TS3/130 8C, t90 (170 8C) and delta torque (S'max S'min). The data are shown
as standardised spider diagrams with the
results of the DAE compound set as 100
(Figure 1). Results greater than 100 indicate a better performance, results lower
than 100 indicate a poorer performance.
Overall no drastic differences have
been observed during vulcanisation of
the carbon black or the silica filled compounds. The compound Mooney viscosity decrease more by the use of MES oil. A
possibly improved compatibility of DAE
with styrene butadiene rubbers might
cause a reduction of the delta torque
(S'max S'min) during vulcanisation.
Vulcanisate properties
The impact of the different process oils on
the performance in finished tires was
evaluated in selected laboratory tests.
All results are summarised in Figure 2
as separate spider diagrams each for carbon black and silica vulcanisates with
DAE as reference. Results greater than
100 indicate a better performance and results less than 100 indicate a poorer performance. No significant impact of the
process oils was observed on properties
such as tensile strength, elongation,
modulus and hardness for both the carbon black and the silica filled vulcanisates. For the carbon black filled vulcanisates the tear resistance for all safe process oils was lower compared to that of
DAE. For the silica filled vulcanisates the
differences in tear resistance were only
marginal with NAP and TDAE showing
a slight improvement and MES slightly
poorer results. A significant improvement
for all safe process oils was observed in
DIN abrasion tests for both vulcanisate
types. Overall, the effects of the oil types
were more significant for the carbon
black filled compound, which presumably may caused by different interactions
between the carbon black or silica filler
and the process oils.
Modern passenger car tires are expected to perform best in wet grip handling to guarantee high driving safety
and to reduce fuel consumption. The
damping characteristics at 0 8C are
Figure 1: Effect of process oil type on compound properties of carbon black and silica compounds (data standardised, DAE reference 100, greater than 100: better, lower than 100:
worse)
used to indicate the wet grip performance. Low rolling resistance, indicated
by the tan d at 60 8C value is directly
correlated to low fuel consumption. The
tan d curves were analysed at a frequency
of 10 Hz (Roehlig) and the tan d versus
temperature curves are shown in Figure 3
for carbon black and in Figure 4 for silica
filled vulcanisates over the temperature
range from 30 to 70 8C.
At higher temperatures, the tan d for all
safe process oils are on a comparable
level and significantly lower than the
tan d for DAE. At lower temperatures, a
different behaviour was observed be-
Figure 2: Effect of process oil type on vulcanised properties of carbon black and silica compounds (data standardised, DAE reference 100, greater than 100: better, lower than 100:
worse)
803
A 1:1 substitution of DAE by safe process oils in typical tire tread formulations
based on E-SBR with carbon black and
S-SBR with silica results in some
changes in rubber performance for all
types of alternative oils when compared
with DAE. The tan d 60 8C was at a comparable level for all oils and significantly
below DAE. This was expected from
the lower glass transition points (Tg) of
the oils resulting in lower tan d at higher
temperatures for the corresponding vulcanisates. This observation is also in
line with the reduced heat built up during
vulcanisation. The wet grip performance
indicated by the tan d 0 8C is slightly
poorer for MES and TDAE. With some
modifications in tire formulations the expected wet grip and wet brake performance can also be met with non-carcinogenic oils.
The evaluation of different MES type
oils made to the same specification
from different refineries and different
crude oils shows no differences during
vulcanisation or in the finished tread compounds. This proves the full interchangeability of MES in rubber and tire formulations.
Conclusion
The environmental impact and the performance in typical tire tread formulations of
medium extracted solvates (MES) from
different refineries, a naphthenic process
oil (NAP) and a treated distillate aromatic
extract (TDAE) have been evaluated
back-to-back with DAE.
804
These test results are intended to support the rubber and tire industries in their
environmental challenge to replace the
classified aromatic oils. Further extensive
compounding and evaluation work will be
required by each company using its proprietary tire formulation technology. Demand for these oils is expected to rise
as car manufacturers realise that carcinogenic emissions from tires can hereby be
greatly reduced. It has already been demonstrated on a commercial scale that
this challenge can be met by a change
to safer alternatives such as MES. The
production of Shell Catenex SNR began in 1997 and the first tires with this
safe oil are already on the market.
Acknowledgement
The author would like to thank Jurgen
Trimbach, Bayer AG, Leverkusen, for
his excellent cooperation, extensive evaluations and discussions.
References
[1] International Agency for Research on Cancer
Monographs Evaluation of Carcinogenic
Risk. Vol. 32, Lyon, France (1983).
[2] International Agency for Research on Cancer:
Mineral oils. In: IARC Monographs on the Evaluation of the Carcinogenic Risk of Chemicals
to Humans Vol. 33, Lyon, France, April (1984)
148.
[3] S.M.A. Doak et al., Br. J. Cancer 48 (1983) 429.
[4] Commission Directive 93/72/EEC of 1 September 1993, 19th ATP of Council Directive 67/548/
EEC, O.J. L258 (1993) 29.
[5] U. Duus, J. Ahlbom, I. Anderson, Toxic oil in
rubber tires, KEMI National Chemicals Inspectorate, 6 (1994), Solna.
[6] W. Baumann, M. Ismeier, Kautsch. Gummi,
Kunstst. 51 (1998) 182.
The author
Dr. V. Null works at Shell Global Solutions as Technology Manager for Industrial Specialities
Correspondence
Dr. V. Null, Shell Research and Technology Centre
Hamburg, PAE Labor, Hohe-Schaar-Strae 36
21107 Hamburg, Germany
805