Styrene-butadiene rubber: Production route
Emulsion or solution: cheap workhorse versus tuned rubber
What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.SBR is made in two ways. Emulsion polymerisation (ESBR) uses free-radical chemistry in water and gives a random copolymer at low cost; it is the larger volume. Solution polymerisation (SSBR) uses anionic chemistry with butyllithium in hydrocarbon solvent, so producers can control the vinyl content, molecular weight and chain-end chemistry. Functionalised SSBR bonds to silica and is the basis of 'green' low-rolling-resistance tyres. Both depend on butadiene, which is about three-quarters of the polymer.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Emulsion SBR (ESBR, 1500 and 1700 series) | about 60-65% (indicative) | about 0.76 t butadiene and 0.24 t styrene per t of rubber (indicative); oil-extended grades contain about 27% oil | 60-200 kt/yr; Indian Synthetic Rubber 120 kt/yr ESBR (butadiene tile) | about 97-98% on monomers after recycle (indicative) | waste water with salts and soap residues | monomer cost about $1,080/t at Sep 2025 to Mar 2026 Asian prices (0.76 x $1,095 butadiene + 0.24 x $1,030 styrene), plus about $200-250/t conversion (indicative) |
| Solution SBR (SSBR, including functionalised grades) | about 35-40% and rising (indicative) | about 0.65-0.75 t butadiene and 0.25-0.35 t styrene (indicative) | 50-150 kt/yr lines | near complete conversion (indicative) | solvent losses (VOC) | about $200-400/t above ESBR (indicative) |
| SB latex and high-styrene resins (related products) | SB latex is reported separately from solid SBR (indicative) | higher styrene share (indicative) | 50-300 kt/yr latex | not published | none | not published |
How each route works
Emulsion SBR (ESBR, 1500 and 1700 series)Butadiene and styrene are emulsified in water with soap and polymerised by a redox initiator at about 5 C to about 60-70% conversion. Unreacted monomers are stripped and recycled; the latex is coagulated with acid and salt, washed, dried and baled. 1700 grades are oil-extended.
Cheap and robust; limited control over microstructure.
butadiene and styrene tiles; indicative Solution SBR (SSBR, including functionalised grades)Butadiene and styrene are polymerised in cyclohexane or hexane with butyllithium and polar modifiers that control vinyl content. Chain ends can be functionalised to bond with silica. The solvent is stripped by steam and recycled.
Tunable for EU tyre labels and EVs; higher capital and energy cost.
indicative SB latex and high-styrene resins (related products)Carboxylated SB latex is used for paper coating and carpet backing; high-styrene SBR (about 50-85% styrene) for shoe soles. Made in emulsion plants.
Different markets from tyres.
indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.