Keltan Eco. Marjan van Urk New Business Development Manager Keltan Eco. Philip Hough. Senior Technical Manager. Malmö, April 2013
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1 Keltan Eco Marjan van Urk New Business Development Manager Keltan Eco Philip Hough Senior Technical Manager Malmö, April 2013
2 Need for innovative products and technologies to enable sustainable mobility Requirements Solutions More sustainable car usage Fuel efficiency Emission reduction More sustainable car production process Reducing energy footprint Reducing carbon footprint Reduction of weight Using bio-based material Using recycled materials Keltan Eco part of the solution 2
3 Route to bio-based EPDM Keltan Eco compared to conventional EPDM Sugar cane Ethanol 100% bio based 50-70% bio based 15-20% bio based Ethylene EP(D)M 0% bio based 0% bio based Crude oil Raw materials End products 3
4 Keltan Eco commercially available First successful run took place in October
5 Keltan Eco First commercially available bio-based EPDM Benefits Reduced dependence on fossil resources Reduced carbon footprint due to sugar cane Truly sustainable & validated by Life Cycle Assessment Bio-based content can be measured by ASTM D6866 Carbon-14 test Achievements Keltan Eco made in Brazil 70% bio-based No compromise on quality Positive response in the market Testing at customers is ongoing Keltan Eco helps our customers to produce "greener" products 5
6 Ethanol productivity and land usage Source Sugarcane Corn Wheat Sugar beet Country Brazil USA EU EU GHG emissions reduction 90% 35% 34% 45% Energy balance Productivity (liters/hectares) 7,000 3,800 2,500 5,500 6 Source: Unica (Brazilian Association of sugar cane producers)
7 Impact on land usage if Keltan Eco grows big Assumptions All cars would be made out of Keltan Eco Approximately 7 kg of EPDM is used per car Car production 2011 globally: 78 million cars Ethanol yield per hectare: ~7,000 liters The ethylene yield per hectare: ~3 mt Impact on land usage > 600 cars per hectare < 130,000 hectares needed to cover global car production < 3% of the land currently used for sugarcane production for ethanol in Brazil < 2% of the land used for sugarcane production < 0.04% of all arable land in Brazil 7
8 Green C 2 has a favorable carbon footprint compared to petrochemical C 2 Carbon footprint from cradle to polymer factory gate (tons CO 2 / tons polymer) PS Gen. Purpose 1 Petrochemical PE 1 Petrochemical PP 1 PLA 2 Green PP 3 Green PE Source: Braskem Biopolymers 1 Plastics Europe; 2 Naturewors LLC CIT (Currently Implemented Technology) 3 Preliminary Ecoefficiency Analysis Espaҫo ECO Foundation
9 With Keltan Eco carbon footprint significantly lower than regular EPDM EPDM carbon footprint 100% Carbon footprint 15% Opportunity to reduce the carbon footprint up to 85% (for a polymer containing 70% C 2 ) 9 Source: Braskem LCA data + Life Cycle Assessment by PE International, cradle to gate CO2 footprint
10 Positioning Focus on Specialty high end applications Partners with sustainability on agenda Green applications Applications visible for end consumer Application opportunities bio based, outstanding flexibility, elastic, heat stable, weather resistant, durable, great surface aesthetics, excellent electrical properties mouldable, mixable, extrudable, compatible with other synthetic rubbers 10
11 Next steps Broaden portfolio of Keltan Eco grades 4 grades will be added to the Keltan Eco portfolio by the second half of 2013 These will be available in commercial quantities Keltan Eco Grade: Viscosity ML(1+4) (@ shown C) C 2 wt% ENB wt% Keltan Eco 3050 New! 51 (@ 100 C) 49 Co-polymer Keltan Eco 8550 New! 80 (@ 125 C) Keltan Eco 5470 Available 55 (@ 125 C) Keltan Eco 6950 New! 65 (@ 125 C) 48 9 Keltan Eco 9950 New! 60 (@ 150 C)
12 Application opportunities 12
13 Polymer Eval. Specifications Units Keltan 5470 Keltan Eco 5470 Test method Mooney Viscosity ML (1+4) 125 C MU ISO 289 Ethylene content wt% ASTM D 3900 Termonomer (ENB) wt% ASTM D 6047 Oil content wt% 0 0 LANXESS 14 C NMR wt% n.a. 70 ASTM D6866 IDENTICAL POLYMER SPECIFICATIONS (except for 14 C Content) Sugar Cane 13
14 Polymer Eval. 14 C Content Keltan Eco
15 Polymer Eval. C2/C3 and Crystallinity Keltan 5470 Keltan Eco 5470 Chemical composition (FTIR) C2 (wt%) C3 (wt%) ENB (wt%) Crystallinity (DSC) Tc ( C) dhc (J/g) Identical polymer composition and crystallinity ^endo Sample: K5508 Eco dd , mg Sample: K5508 ref dd , mg 2nd heating curve 0.5 Wg^-1 1st heating curve cooling curve C Lab: METTLER STA TAR e SW
16 Polymer Eval. Mol. Weight Distrib. Mol. Mass Distrib. (SEC) Keltan 5470 Keltan Eco 5470 Mn Mw Mz Mw/Mn Mz/Mw Instrinsic viscosity Keltan 5470 Keltan Eco 5470 Identical Molecular Weight and Molar Mass Distribution 16
17 Polymer Eval. Branching level Unit Keltan 5470 Keltan Eco 5470 ML (1+4) 125ºC MU Delta -delta Same Mooney Viscosity and Branching level Frequency vs Loss Angle plot of Keltan 5508 Reference and Keltan ECO Delta ( ) Keltan Keltan ECO Frequency (rad/s)
18 Compound Eval. Stand. Form. 70/40/70 Keltan 5470 Keltan Eco 5470 EPDM ZnO-active 5 5 Stearic acid 1 1 Carbon black N Carbon black N Paraffinic oil MBTS ZBEC ZDBP Vulkalent E/C S Total PHR
19 Compound Eval. Mixing & extrusion Keltan 5470 Keltan Eco 5470 Keltan 5470 Keltan Eco 5470 Identical Mixing and Processing behavior Mixing Properties (Shaw K1 Intermixer) Load factor (%) Mixing time (s) Power max (kw) Dump temp ( C) Compound Mooney Viscosity ML (1+4) 100 C (MU) Extrusion Properties (Garvey Die, 50 rpm) Output (g/min) Die Swell (%) Head pressure (bar) Rating Garvey Die Swell & porosity edge 3 3 Surface 4 4 Corners
20 Compound Eval. Branching level Compound RPA analysis Keltan 5470 Keltan Eco 5470 δ Identical Branching Frequency vs Loss Angle plot of compounds with Keltan 5508 Reference and Keltan ECO Delta ( ) Keltan 5508 Keltan ECO Frequency (rad/s) 20
21 Compound Eval. Vulcanization (MDR) Keltan 5470 Keltan Eco 5470 Identical vulcanization behavior and delta torque (crosslink density) MDR (180 C, 20 min) Unit Keltan 5470 Keltan Eco 5470 ML dnm MH-ML dnm Ts2 Min tc(90) Min
22 Compound Eval. (Mooney Scorch) Keltan 5470 Keltan Eco 5470 Same vulcanization/scorch behavior Mooney Scorch (125 C, 60 min) Unit Keltan 5470 Keltan Eco 5470 Initial MU t2 Min t5 Min t35 Min
23 Compound Eval. Physical Properties Vulcanizate Properties Unit Keltan 5470 Keltan Eco 5470 Hardness IRHD Hardness after ageing (100C, 168 Hrs) IRHD Tensile Strength MPa Modulus 100% MPa Modulus 300% MPa 10 9 Elongation at Break % Tensile Strength after ageing (100C, 168 Hrs) MPa Modulus 100% after ageing MPa Modulus 300% after ageing MPa Elongation at Break after ageing % Tear Strength Delft (N) N Tear Strength after ageing (100C, 168 Hrs) N CS 24h/-25 C % CS 24h/70 C % 9 9 CS 24h/100 C % Identical behavior w.r.t. physical properties
24 Application Recipe 24 Keltan Eco/N550 Keltan Eco/BBC500 EPDM Carbon Black FEF N BlackBear Carbon BBC Whiting Paraffinic Oil ZnO-active 5 5 Stearic Acid 1 1 PEG CaO CBS TMTD ZDMC ZDBC Sulphur Total PHR Automotive solid seal recipe using carbon black from pyrolized tyres supplied by BlackBear Carbon
25 Application Recipe; Mixing and Viscosity Keltan Eco 5470/N550 Keltan Eco 5470/BBC 500 Non-pelletized BBC 500 required 3 additions to the mixer due to low bulk density, otherwise mixed well. Similar Mooney viscosities Keltan Eco/N550 Keltan Eco/BBC500 Mixing properties Load factor (%) Mixing time (s) Power max (kw) Dump Temp ( C) Mooney viscosity ML (1+4) 100 C MU
26 Application Recipe; Cure Behavior BBC 500 gives longer tc(90), but MH is good. Keltan Eco 5470/N550 Keltan Eco 5470/BBC MDR (180 C, 20 min) Unit Keltan Eco/N550 Keltan Eco/BBC500 ML dnm MH-ML dnm Ts2 Min tc(90) Min
27 Application Recipe; Physical Properties Property Unit Keltan Eco/N550 Keltan Eco/BBC Hardness IRHD Hardness after ageing (100 C, 168 Hrs) IRHD Tensile Strength MPa Modulus 100% MPa Modulus 300% MPa 8 6 Elongation at Break % Aged Tensile (100 C, 168 Hrs) MPa Aged Modulus 100% MPa Aged Modulus 300% MPa 0 0 Aged Elongation at Break % Rebound Resilience (Schob) % CS 24 Hrs, 100 C % BBC 500 gives comparable physical properties. Estimated CO 2 reduction per tonne of compound approx. 5 tonnes.
28 Innovative bio-based rubber for more sustainable solutions First green synthetic rubber on the market True technical drop-in for Keltan 5470 (ex. Keltan 5508) Contribution to a significantly reduced carbon footprint Offers customers a unique opportunity to develop more sustainable Green products Broader portfolio available by H2 2013: Keltan Eco 3050, 5470, 6950, 8550,
29 Disclaimer Lanxess Buna GmbH The manner in which you use and the purpose to which you put and utilize our products, technical assistance and information (whether verbal, written or by way of production evaluations), including any suggested formulations and recommendations are beyond our control. Therefore, it is imperative that you test our products, technical assistance and information to determine to your own satisfaction whether they are suitable for your intended uses and applications. This application-specific analysis must at least include testing to determine suitability from a technical as well as health, safety, and environmental standpoint. Such testing has not necessarily been done by us. Unless we otherwise agree in writing, all products are sold strictly pursuant to the terms of our standard conditions of sale. All information and technical assistance is given without warranty or guarantee and is subject to change without notice. It is expressly understood and agreed that you assume and hereby expressly release us from all liability, in tort, contract or otherwise, incurred in connection with the use of our products, technical assistance, and information. Any statement or recommendation not contained herein is unauthorized and shall not bind us. Nothing herein shall be construed as a recommendation to use any product in conflict with patents covering any material or its use. No license is implied or in fact granted under the claims of any patent 29
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