PRATO 10 MARZO 2009 Franco Francalanci - Montefibre S.p.A

Transcription

1 FIBRE ACRILICHE. DALLA CRISI DI MERCATO A NUOVI SVILUPPI PRATO 1 MARZO 29 Franco Francalanci - Montefibre S.p.A

2 First impression: tons Synthetic Natural Artificial 1 5 Steady growth Natural fibers overtaken Good forecast of further increase SYNTHETIC FIBERS: A HEALTHY INDUSTRY

3 Steady growth Natural fibers overtaken Good forecast of further increase 1 tons Synthetic Natural Artificial SYNTHETIC FIBERS: A HEALTHY INDUSTRY IN A DREAM WORLD

4 PRODUCTION OF SYNTHETIC FIBRES IN DIFFERENT REGIONS ton Americas Europe Asia

5 PRODUCTION OF SYNTHETIC FIBRES IN DIFFERENT ASIAN COUNTRIES 1 ton China Japan South Korea Taiwan

6 WORLD PRODUCTION BY TYPE OF FIBER source CIRFS Acrylic Polyamide Polyester

7 WORLD MILL CONSUMPTION source PCI Acrylic Polyamide Polyester

8 PRODUCTION AND CONSUMPTION OF SYNTHETIC FIBRES IN CHINA 1 ton Production Consumption

9 MILL CONSUMPTION IN GREATER EUROPE source CIRFS Acrylic Polyamide Polyester

10 MILL CONSUMPTION IN WESTERN EUROPE source CIRFS Acrylic Polyamide Polyester

11 European Textile Production Index (source CIRFS) '85 '86 '87 '88 '89 '9 '91 '92 '93 '94 '95 '96 '97 '98 '99 ' '1 '2 '3 '4 '5 Seasonally adjusted index

12 PRODUCTION OF ACRYLIC FIBRE source CIRFS Europe USA Japan China

13 Acrylic production and consumption Western Europe Production WE Consumption WE

14 Acrylic production and consumption Western Europe and China Production WE Consumption WE Production China Consumption China

15 MAIN BURDENS ON INDUSTRY RAW MATERIALS ENERGY FINANCE On average: Raw materials account for % of production cost Energy accounts for 1 15 % of production cost Finance accounts for????

16 Cost Reduction Margin Increase Profit and Growh of Industry Process Innovation Product Innovation Lower impact of raw material (less pure monomers, polymer blends, higher efficiency) Lower impact of energy (integrated processes, higher efficiency) Health care Protective materials Post production modifications Side diversification (crutch)

17 POST PRODUCTION MODIFICATIONS FEEDSTOCKS MONOMERS POLYMERS FIBRE Low impact on consolidated processes Different products from the same precursor

18 POST PRODUCTION MODIFICATIONS A few examples - 1 ANTIPILLING POLYESTER => weakness due to low molecular weight polymer Classical approach: using a special crosslinked polymer of low polymer weight, but high melt viscosity. Melt Spinnable Need to synthesize a special polymer and develop a ad hoc process Alternative approach: getting a low viscosity polymer through controlled depolymerisation of melt STARTING FROM A STANDARD POLYMER (INVENTA FISCHER patent)

19 POST PRODUCTION MODIFICATIONS A few examples - 2 SUPERABSORBENT ACRYLIC FIBER => due to presence of COOH groups Classical : Polymerisation in water of acrylic acid and methyl acyilate Dry spinning with Water evaporation Stretching and drying Of resulting fibre Crosslinking 25 C of COOH Groups with functional groups Introduced during polymerisation Alternative : Commercial Acrylic fiber Crosslinking of 1-3 % of - CN groups Hydrolysis of remaining -CN to -COOH Drying of fibre CN CN CN CN + NH2 NH2 C==NH CN NH --NH C==NH CN Open problem: Alternative to hydrazine

20 POST PRODUCTION MODIFICATIONS A few examples - 3 LOTAN A SUPER FLAME RESISTANT FIBRE LOI % PANOX LOTAN PBI PPS Smokes: F1 (NF F 16-11) (ISO ) (ISO FTIR) PHENOLIC ARAMID PES (FR) MODACRYLIC VISCOSE PES ACRYLIC PP Fire: M1 (NF P 92-53/57) (UNI 9175) (ISO 566) CN CN CN CN + NH2 NH2 C==NH NH --NH CN LOTAN C==NH CN

21 LOTAN BY MONTEFIBRE General Properties Tenacity cn/tex Elongation % Density 1.5 g/cm 3 Autoignition Temperature (1% O2) 435 C L.O. I. > 38% (typically 39-42) Reaction to Fire Class M1 (NF P ) Smoke & Gas evolution CO2 - H2O with negligible amounts of HCN,HCl, SOx Toxicity and Opacity Smoke Class F F1 (NF F 16-11) Water Regain ~ 12 % Water Imbibition ~ 45 % Shrinkage in boiling water ~ % Alkali & Acids resistance Good / Very Good Common solvents resisistance Not soluble U.V. Stability Good

22 LOTAN BY MONTEFIBRE Before Flame Exposure After Flame Exposure Char Barrier No Melting No Shrinking No Flaming Drops

23 LOTAN BY MONTEFIBRE Effect of Dry Heat Time Exposure : 24 h Breaking Tenacity (cn/tex) Temperature ( C) Breaking Elongation (%)

24 LOTAN BY MONTEFIBRE Effect of Acid Solution on tensile properties Tenacity (cn/tex) LOTAN ARAMIDES POLYACRYLONITRILE (1%) 12 Treatment Time (hours) Time Exposure: 12 h Temperature: 6 C Acid Solution: HCl - 4%

25 LOTAN BY MONTEFIBRE POSSIBLE END USES????:. Protective Clothings Liquid Filtration at temperature Barrier Fabrics No Limits to Product Design in the Firefighting Area both in NONWOVEN And in SPINNING SECTORS Fire blankets Hot gas Filtration Wall Coverings Mattresses construction Extreme Sport Clothing For additional information, please visit:

26 SIDE DIVERSIFICATION (CRATCH FOR BUSINESS) POLYESTER POLYAMIDE ACRYLIC RESIN FOR BOTTLES HIGH PERFORMANCE PLASTIC CARBON FIBERS

27 ACRYLIC CARBON FIBERS Processo di produzione della fibra di carbonio da PAN Trattamento superficiale Sizing bobinatura Precursore PAN Ossidazione in aria ( 2 3 C 3 6 min.) Carbonizzazione (Pirolisi in azoto 7 15 C 2-1 min) - HS Grafitizzazione (Pirolisi in azoto oltre 2 C 1-2 min) - HM PAN C C C C C C N C N C N Fibra ossidata O C C C C C C C N C N C N Fibra di carbonio N N

28 Consumi mondiali di fibra di carbonio ,4 3 26,5 Migliaia di ton ,7 1, , ,6 17,1 19,1 2,9 23, Anno - Forecast consumi mondiali di fibra di carbonio 6 Migliaia di ton , ,4 38,8 41,9 44,4 48, Anno

29 Consumi fibra di carbonio per settore 6 5 Migliaia di ton ,9 16,6 12,9 6,5 15,4 7,6 8,3 3,5 5,2 3 3,3 4,8 5,9 6, Industrial Aerospace Sport Anno Recipienti pressione 18,5% Ripartizione consumi industriali Fuel cell 2,3% Altro 6,2% Nautica 7,7% Eolico 9,2% Trasporti 4,2% P etrolio 3,9% Compositi 12,3% Cilindri 12,3% Medicale 3,9% Edilizia 11,6% Cuscinetti 1,% Alberi trasmissione 6,9%

30 SVILUPPO FIBRE DI CARBONIO PER AREA GEOGRAFICA 24 > tons 27 > 32.2 tons 21 > tons /Taiwan /Corea Cina 14% Altri 14% Giappone 15% Europa 27% USA 3% /Taiwan /Corea Cina 15% Giappon e 13% Altri 12% USA 29% Europa 31% /Taiwan /Corea Cina 16% Giappone 13% Altri 5% USA 31% Europa 35%

31 CONCLUSIONS Synthetic Fibers Industry in big troubles (mainly in industrialized Countries) Main problem: Costs (raw materials),weak market Solution will come from Innovation (both Process and Product) Post modification and side productions (CRUTCH) may help