THE EFFECT OF OIL PALM TRUNK FILLER IN EPOXIED NATURAL RUBBER MOHD SAIFUL AFFENDI BIN ZABIDI A thesis submitted in fulfillment of the requirements for the award of the Degree of Bachelor of Chemical Engineering Faculty of Chemical Engineering & Natural Resources Universiti Malaysia Pahang NOVEMBER 2010
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THE EFFECT OF OIL PALM TRUNK FILLER IN EPOXIED NATURAL RUBBER
MOHD SAIFUL AFFENDI BIN ZABIDI
A thesis submitted in fulfillment
of the requirements for the award of the Degree of
Bachelor of Chemical Engineering
Faculty of Chemical Engineering & Natural Resources
Universiti Malaysia Pahang
NOVEMBER 2010
iv
ABSTRACT
The effect of loading oil palm trunk as filler in natural rubber was investigated in
this research. The testing that will be made on the reinforced fiber rubber are tensile
strength test and swelling test. The natural rubber is obtained from Rubber Research
Institute Malaysia (RRIM). There are three types of rubber in this research. They are
Epoxied Natural Rubber (ENR), Standard Malaysian Rubber (SMR), and Styrene-
Butadiene Rubber (SBR). The selected ENR will be milled on the two roll mill machine
and mix with filler after the milling process. The filler will be divided into five different
of parts per hundred rubbers (phr). The compounds will be vulcanized with sulfur and
ready to be molded. The molded rubber will be tested. The machines that will be used in
this research are two roll mill for compounding and hot press machine for molding. Two
roll mills will operate for 3 hours per compound. The hot press machine will be used for
25 minutes each molding sessions. Conventional filler is the carbon black filler. Oil
palm trunk is used as filler to compare with carbon black filler in terms of rubber
properties. It was found out that the higher the amount of oil palm trunk in rubber, the
lower the tensile strength of the rubber. The swelling of rubber product is higher in
kerosene compare with diesel. When the filler content increase, the mixing time will be
increased.
v
ABSTRAK
Pengaruh bebanan fiber batang pokok kelapa sawit diuji di dalam kajian ini.
Antara ujian yang dilakukan pada getah pencampuran fiber adalah ujian kekuatan
tegangan dan ujian pengembangan. Getah asli didapati dari Lembaga Getah Malaysia.
Terdapat tiga jenis getah yang terdapat di dalam kajian ini iaitu Getah asli epoxied
(ENR), Getah asli standard Malaysia (SMR) and Getah sintetik (SBR). ENR yang telah
dipilih akan dileperkan menggunakan two roll mill and dicampur dengan pengisi setelah
proses penleperan selesai. Pengisi dibahagikan kepada lima bahagian per seratus getah
(phr). Campuran tersebut akan divulknanisasi dengan sulfur dan bersedia untuk dibentuk
mengikut acuan. Campuran tersebut akan diuji. Peralatan yang digunakan adalah two
roll mill untuk pencampuran dan hot press machine untuk pembentukan. Two roll mill
akan beroperasi untuk 3 jam setiap sampel. Hot press machine pula beroperasi untuk 25
minut setiap sampel. Pengisi konventional ialah karbon hitam. Dari segi sifat getah, fiber
batang pokok kelapa sawit digunakan dan dibandingkan dengan pengisi karbon hitam.
Semakin tinggi fiber batang pokok kelapa sawit, semakin rendah kekuatan tegangan
getah tersebut. Dalam ujian pengembangan, getah yang direndam dalam minyak tanah
lebih kembang berbanding rendaman dalam minyak diesel. Semakin tinggi kandungan
fiber batang pokok kelapa sawit, semakin tinggi masa untuk pencampuran.
vi
TABLE OF CONTENTS
CHAPTER TITLE PAGE
TITLE PAGE i
DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
ABSTRAK v
TABLE OF CONTENT vi
LIST OF FIGURES x
LIST OF TABLES xii
LIST OF APPENDICES xiii
LIST OF ABBREVIATIONS xiv
1 INTRODUCTION
1.0 Background 1
1.1 Problem Statement 3
1.2 Objective 3
1.3 Scope of study 4
1.4 Rational & Significance 4
2 LITERATURE REVIEW
2.1 Introduction 5
2.1.1 History 5
2.2 Types of Rubber 6
2.2.1 Natural Rubber 6
vii
2.2.2 Epoxied Natural Rubber 7
2.2.3 Styrene Butadiene Rubber 8
2.2.4 Cross-linked rubber 9
2.2.5 Polybutadiene Rubber 10
2.2.6 Ethylene-Propylene-Diene 11
2.3 Filler 12
2.3.1 Particle Size 13
2.3.2 Surface Area 13
2.3.3 Structure 13
2.4 Types of Fillers 14
2.4.1 Carbon Black 14
2.4.1.1 N550 17
2.4.1.2 N660 17
2.4.2 Oil Palm Fibre 18
2.4.3 Coconut Fibre 19
2.5 Rubber Processing 20
2.5.1 Masticating 20
2.5.2 Compounding 21
2.5.3 Vulcanization 22
2.5.4 Molding 23
2.5.4.1 Extrusion 23
2.5.4.2 Compression Molding 24
2.5.5 Testing 25
2.5.5.1 Tear strength 25
2.5.5.2 Tensile strength 26
2.5.5.3 Hardness 28
2.5.5.4 Scanning Electron Microscope 29
2.5.5.5 Swelling test 29
viii
3 RESEARCH METHODOLOGY
3.1 Introduction 30
3.2 Raw Material & Chemical Used 32
3.2.1 Epoxied Natural Rubber 34
3.2.2 Oil Palm Trunk Filler 35
3.2.3 Sulphur 36
3.2.4 Zinc Oxide and Stearic Acid 37
3.2.5 CBS 38
3.2.6 6PPD 39
3.3 Rubber Formulation 40
3.4 Equipment Used 42
3.4.1 Two Roll Mill 42
3.4.2 Hot Press Machine 43
3.4.3 Universal Tensile Machine 44
3.5 Experimental preparation 45
3.6 Testing 45
3.6.1 Swelling Test 46
3.6.2 Tensile Test 47
4 RESULT & DISCUSSIONS
4.1 Introduction 48
4.2 Tensile test 49
4.2.1 0 phr of filler loading 49
4.2.2 15 phr of filler loading 50
4.2.3 30 phr of filler loading 51
4.2.4 40 phr of filler loading 52
4.2.5 50 phr of filler loading 53
4.2.6 Ultimate Tensile Strength 54
4.2.7 % Elongation 55
4.2.8 Young’s Modulus 56
ix
4.3 Swelling Test 57
4.3.1 % swelling of ENR in diesel 57
4.3.2 % swelling of ENR in kerosene 58
4.3.3 Comparison between ENR’s swellings in each
solvent
59
4.4 Mixing Process 60
4.4.1 Mixing Time 60
5 CONCLUSION & RECOMMENDATIONS
5.1 Conclusion 61
5.2 Recommendations 62
REFERNCES 63
APPENDIX A 67
APPENDIX B 70
x
LIST OF FIGURE
FIGURE NO TITLE PAGE
Figure 2.1 Structure of natural rubber 7
Figure 2.2 Structure of SBR 8
Figure 2.3 Cross-linked Reaction 9
Figure 2.4 Chemical structure of PBR 10
Figure 2.5 Structure of EPDM containing ENB 11
Figure 2.6 Categories of Fillers 12
Figure 2.7 Production of Carbon Black 16
Figure 2.8 Mechanical Properties of Oil Palm Fibre 18
Figure 2.9 SEM of Coir Fibre 19
Figure 2.10 Example of Rubber Compounding 21
Figure 2.11 Schematic diagram of an extruder 23
Figure 2.12 Schematic diagram of compression molding 24
Figure 2.13 Example of tear strength result 26
Figure 2.14 Typical tensile test machine 27
Figure 2.15 Example of natural rubber tensile test result 27
Figure 2.16 Hardness test 28
Figure 2.17 Schematic presentations of rubber vulcanizates 29
Figure 3.1 Process flow of producing rubber products 31
Figure 3.2 Chemicals in Stage 1 33
Figure 3.3 Chemicals in Stage 2 33
Figure 3.4 Natural Rubber in bulk size 34
xi
Figure 3.5 Oil Palm Trunk filler 35
Figure 3.6 Sulphur photo 36
Figure 3.7 Chemical structure of sulphur 36
Figure 3.8 Chemical structure of Zinc Oxide 37
Figure 3.9 Chemical structure of Stearic Acid 37
Figure 3.10 Chemical structure of CBS 38
Figure 3.11 Chemical Structure of 6PPD 39
Figure 3.12 Laboratory Two Roll Mill 42
Figure 3.13 Hot & Cold Molding Press Machine 43
Figure 3.14 Universal Tensile Machine 44
Figure 3.15 Swelling test 46
Figure 3.16 Sample at initial of testing 47
Figure 3.17 Sample at during of testing 47
Figure 3.18 Sample at after of testing 47
Figure 4.1 Graph of stress vs. strain for 0 phr of filler loading 49
Figure 4.2 Graph of stress vs. strain for 15 phr of filler loading 50
Figure 4.3 Graph of stress vs. strain for 30 phr of filler loading 51
Figure 4.4 Graph of stress vs. strain for 40 phr of filler loading 52
Figure 4.5 Graph of stress vs. strain for 50 phr of filler loading 53
Figure 4.6 Graph of tensile strength vs. filler content 54
Figure 4.7 Graph of % elongation vs. filler content 55
Figure 4.8 Graph of Young’s modulus vs. filler content 56
Figure 4.9 Graph of % Swelling vs Filler Content (diesel) 57
Figure 4.10 Graph of % Swelling vs Filler Content (kerosene) 58
Figure 4.11 Graph of % Swelling vs Filler Content in each solvent 59
Figure 4.12 Graph of mixing time vs. filler content 60
xii
LIST OF TABLE
TABLE NO TITLE PAGE
Table 2.1 Types of carbon black used 15
Table 3.1 Additives and its function 32
Table 3.2 Formulation of rubber product by parts 40
Table 3.3 Formulation of rubber product by weight 41