Keltan Eco Marjan van Urk New Business Development Manager Keltan Eco Philip Hough Senior Technical Manager Malmö, April 2013
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
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
Keltan Eco commercially available First successful run took place in October 2011 4
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
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 9.3 1.4 2.0 2.0 Productivity (liters/hectares) 7,000 3,800 2,500 5,500 6 Source: Unica (Brazilian Association of sugar cane producers)
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
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) 3.4 2.1 2 1.3 PS Gen. Purpose 1 Petrochemical PE 1 Petrochemical PP 1 PLA 2 Green PP 3 Green PE 3-2.3-2.5 8 Source: Braskem Biopolymers 1 Plastics Europe; 2 Naturewors LLC CIT (Currently Implemented Technology) 3 Preliminary Ecoefficiency Analysis Espaҫo ECO Foundation
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
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
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) 55 5.5 Keltan Eco 5470 Available 55 (@ 125 C) 70 4.6 Keltan Eco 6950 New! 65 (@ 125 C) 48 9 Keltan Eco 9950 New! 60 (@ 150 C) 48 9 11
Application opportunities 12
Polymer Eval. Specifications Units Keltan 5470 Keltan Eco 5470 Test method Mooney Viscosity ML (1+4) 125 C MU 55 55 ISO 289 Ethylene content wt% 70 70 ASTM D 3900 Termonomer (ENB) wt% 4.6 4.6 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
Polymer Eval. 14 C Content Keltan Eco 5470 14
Polymer Eval. C2/C3 and Crystallinity Keltan 5470 Keltan Eco 5470 Chemical composition (FTIR) C2 (wt%) 70 70 C3 (wt%) 25 25 ENB (wt%) 4.6 4.6 Crystallinity (DSC) Tc ( C) 18 19 dhc (J/g) 39 39 Identical polymer composition and crystallinity ^endo Sample: 20111100821-2 K5508 Eco dd 23-10-2011, 21.6210 mg Sample: 20111100821-1 K5508 ref dd03-11-2011, 24.2060 mg 2nd heating curve 0.5 Wg^-1 1st heating curve cooling curve -100-80 -60-40 -20 0 20 40 60 80 100 120 140 C Lab: METTLER STA TAR e SW 10.00 15
Polymer Eval. Mol. Weight Distrib. Mol. Mass Distrib. (SEC) Keltan 5470 Keltan Eco 5470 Mn 70 71 Mw 185 190 Mz 460 470 Mw/Mn 2.7 2.6 Mz/Mw 2.5 2.5 Instrinsic viscosity 1.85 1.87 Keltan 5470 Keltan Eco 5470 Identical Molecular Weight and Molar Mass Distribution 16
Polymer Eval. Branching level Unit Keltan 5470 Keltan Eco 5470 ML (1+4) 125ºC MU 55 57 Delta -delta - 22 23 Same Mooney Viscosity and Branching level Frequency vs Loss Angle plot of Keltan 5508 Reference and Keltan ECO 5508 60 45 Delta ( ) 30 15 Keltan 5508 17 Keltan ECO 5508 0 0.01 0.1 1 10 100 1000 Frequency (rad/s)
Compound Eval. Stand. Form. 70/40/70 Keltan 5470 Keltan Eco 5470 EPDM 100 100 ZnO-active 5 5 Stearic acid 1 1 Carbon black N-550 70 70 Carbon black N-772 40 40 Paraffinic oil 70 70 MBTS-80 1.31 1.31 ZBEC-70 0.7 0.7 ZDBP-50 3.5 3.5 Vulkalent E/C 0.5 0.5 S-80 1.25 1.25 Total PHR 293.26 293.26 18
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 (%) 54 54 Mixing time (s) 249 251 Power max (kw) 51 51 Dump temp ( C) 117 118 Compound Mooney Viscosity ML (1+4) 100 C (MU) 55 54 Extrusion Properties (Garvey Die, 50 rpm) Output (g/min) 503 505 Die Swell (%) 37 38 Head pressure (bar) 53 51 Rating Garvey Die Swell & porosity 4 4 30 edge 3 3 Surface 4 4 Corners 4 4 19
Compound Eval. Branching level Compound RPA analysis Keltan 5470 Keltan Eco 5470 δ 16 16 Identical Branching Frequency vs Loss Angle plot of compounds with Keltan 5508 Reference and Keltan ECO 5508 60 45 Delta ( ) 30 15 Keltan 5508 Keltan ECO 5508 0 0.01 0.1 1 10 100 1000 Frequency (rad/s) 20
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 1.1 1.1 MH-ML dnm 17 17 Ts2 Min 1.2 1.2 tc(90) Min 4.7 4.8 21
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 55 53 t2 Min 23 24 t5 Min 31 31 t35 Min 45 46 22
Compound Eval. Physical Properties Vulcanizate Properties Unit Keltan 5470 Keltan Eco 5470 Hardness IRHD 68 68 Hardness after ageing (100C, 168 Hrs) IRHD 71 70 Tensile Strength MPa 15 15 Modulus 100% MPa 2.8 2.6 Modulus 300% MPa 10 9 Elongation at Break % 486 507 Tensile Strength after ageing (100C, 168 Hrs) MPa 15 15 Modulus 100% after ageing MPa 3.7 3.5 Modulus 300% after ageing MPa 12 12 Elongation at Break after ageing % 386 409 Tear Strength Delft (N) N 51 49 Tear Strength after ageing (100C, 168 Hrs) N 51 51 CS 24h/-25 C % 97 98 CS 24h/70 C % 9 9 CS 24h/100 C % 25 26 23 Identical behavior w.r.t. physical properties
Application Recipe 24 Keltan Eco/N550 Keltan Eco/BBC500 EPDM 100 100 Carbon Black FEF N550 120 0 BlackBear Carbon BBC 500 0 135 Whiting 85 85 Paraffinic Oil 80 80 ZnO-active 5 5 Stearic Acid 1 1 PEG 4000 2 2 CaO-80 10 10 CBS-80 2.1 2.1 TMTD-80 0.5 0.5 ZDMC-80 1.2 1.2 ZDBC-80 2.5 2.5 Sulphur-80 1.8 1.8 Total PHR 411.1 426.1 Automotive solid seal recipe using carbon black from pyrolized tyres supplied by BlackBear Carbon
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 54 54 (%) Mixing time 251 418 (s) Power max 57 46 (kw) Dump Temp ( C) 110 115 Mooney viscosity ML (1+4) 100 C MU 52 53 25
Application Recipe; Cure Behavior BBC 500 gives longer tc(90), but MH is good. Keltan Eco 5470/N550 Keltan Eco 5470/BBC 500 26 MDR (180 C, 20 min) Unit Keltan Eco/N550 Keltan Eco/BBC500 ML dnm 1.1 1.6 MH-ML dnm 18 17 Ts2 Min 0.6 0.7 tc(90) Min 1.7 3.7
Application Recipe; Physical Properties Property Unit Keltan Eco/N550 Keltan Eco/BBC500 27 Hardness IRHD 68 68 Hardness after ageing (100 C, 168 Hrs) IRHD 78 78 Tensile Strength MPa 11 10 Modulus 100% MPa 2.8 2 Modulus 300% MPa 8 6 Elongation at Break % 440 501 Aged Tensile (100 C, 168 Hrs) MPa 11 11 Aged Modulus 100% MPa 6.8 5.4 Aged Modulus 300% MPa 0 0 Aged Elongation at Break % 183 207 Rebound Resilience (Schob) % 35 34 CS 24 Hrs, 100 C % 63 59 BBC 500 gives comparable physical properties. Estimated CO 2 reduction per tonne of compound approx. 5 tonnes.
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, 9950 28
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