High Performance Polymers

Growth Line – Resource Efficiency

Dr. Benjamin Brehmer, June 18th, 2013

VESTAMID® Terra

High performance

biopolyamides reinforced with

high performance biofibers

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Natural fibers can increase the mechanical

performance while maintaining bio-content

Property Unit PA66 PA610 PA1010 PA1012 PA12

E-Module MPa 2500 2100 1700 1300 1400

Tensile Strength MPa 83 61 54 40 46

Water Uptake % 8.2 3.3 1.8 1.6 1.5

Melting Point °C 258 222 200 180 176

Global Warming Potential kg CO2 7.9 4.6 4.0 5.2 6.9

Biobased Content % of C 0 63 100 45 0

The addition of fiber reinforcement will change all the basic properties

• Motivation of adding fiber reinforcement is to increase…

…E-module and tensile strength

• Motivation of adding natural fiber reinforcement is to maintain…

…the high bio-based content of the compound

Basic properties of the Vestamid Terra and comparable polyamides

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First stage is to compound the material as would

be done in a normal operational procedure

1 2 3 4 5 6 7 8 9 10

Vacuum Degassing

Water B

ath

Die

Atmospheric

Degassing

Temp.

Ramp Compounding Temperature

11

Polymer Natural Fiber

Air knife

Pelletiz

er

1 2 3 4 5 6 7 8 9 10

Vacuum Degassing

Water B

ath

Die

Atmospheric

Degassing

Temp.

Ramp Compounding Temperature

11

Polymer Natural Fiber

Air knife

Pelletiz

er

Compound schematic and process conditions

• Compounding temperature: 180 - 230°C

• Throughput: 5 – 10kg/h

• Screw configuration: SK524

• Screw rotation: 200 - 300rpm

• Feeding of natural fibers can be problematic (uncontrolled dosing)

• Used forced vertical dosing (dual screw type)

• Water content of fibers can be problematic (void space, surface damages)

• Used atmospheric and vacuum degassing, extra post-dyring needed

• Thermal stability of certain natural fibers can be problematic (discoloring, smell)

• Used the lowest temperature profile possible

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The second stage is the injection molding to test

the material for a diverse range of properties

Produced molded parts for testing

Pellets

Tensile Bars

• Mechanical testing

3-Stage Plate

• Visual testing

Texture Plate

• Surface and subjective testing

Objectives and Forms

• Flowability

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Fiberglass will be used as the basis for

comparison as it is the global standard

Nearly all injection molded polymers, when reinforced are

reinforced with chopped fiberglass

• It is the true standard, used for comparison

Fiberglass originates from silica found in sand and it has a

relatively high energy consumption

Fiberglass is known for a good thermal and electrical stability

• Thermal stability for processing well above 380°C

Price indication: Mid-range

Source

• Sand / Silica

Purchased

• Chopped, clear/white

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

15 – 20 0.5 – 0.7 73 – 75 6 - 8 0

Mineral glass fiber

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Basalt fiber is not a “wood” fiber, but does

comes from natural sources and is promising

Fiber reinforcements with basalt fibers are under investigation,

many composite projects as alternative to carbon fiber

• It will serve as the other natural fiber alterative

Basalt fibers originates from frozen lava and is produced by

extruding molten basalt rock; readily available

Known for a high strength and very high thermal stability

• Thermal stability for processing well above 650°C

Price indication: Mid-range

Source

• Lava rock of basalt

Purchased

• Chopped, golden/shinny

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

7 – 24 0.1 – 0.2 93 - 110 3 - 5 0

Basalt fiber

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Cellulose fibers are well known and purist form

of natural fibers, but have limited potential

Through a joint venture (Daicel) Evonik has access to

cellulose fiber derivatives

• It will serve as the lowest grade filling fibers

Cellulose fibers originate from the processing of cotton and is

related to cellulose acetate

Known for a relatively high thermal stability

• Thermal stability for processing below above 230°C

Price indication: Lower-range

Source

• Cotton or lumber

Purchased

• Loose, powdery/white

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

10 – 15 4 – 6 5 - 10 0.2 – 0.8 100

Cellulose fiber

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Regenerated cellulose fibers are further altered

to add strength and thermal stability

Many names such as rayon, viscose, regenerated cellulose

and mainly used in tire cord, now studies in composites

• It will serve as the finest grade filling fibers

Rayon fibers originate from the processing of lumber/wood

Known for a high thermal stability and adhesion to plastics

and is less abrasive than fiber glass (injection molding)

• TGA show first degradation at temperature above 240°C

Price indication: High-range (without sizing agent)

Source

• Pulp or lumber

Purchased

• Spoils/chopped, yellowish

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

11 – 13 10 – 13 15 - 25 0.6 – 1.3 100

Regenerated cellulose fiber (Rayon)

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Bamboo fibers are abundant and faster growing,

providing a good CO2 emissions reduction

Bamboo fibers are dependent on the plant grades and

harvesting season, can also come as “white”

Bamboo fiber is widely available by direct plant mulching

• It will serve as the cheapest grade filling fibers

Known for a relatively low thermal stability, yet has been

tested with other polymers (e.g. PP) to make WPC

• Degradation begins between 210 to 240°C

Price indication: Very low-range

Source

• Bamboo (Asia)

Purchased

• Loose fibers, light brown

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

10 – 40 6 – 10 10 - 20 0 – -3.5 100

Bamboo fiber

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Aspen wood fibers are also abundant while

providing a good CO2 emissions reduction

Aspen fibers are dependent on the tree grades and harvesting

season, can also be bleached “white”

Aspen fiber is widely available by direct plant mulching

• It will serve as the temperate grade filling fibers

Typically used in the pulp and paper industry, yet has been

tested with other polymers (e.g. PP) to make WPC

• Degradation begins between 210 to 240°C

Price indication: Very low-range

Source

• Aspen tree (America/EUR)

Purchased

• Loose fibers, off-white

Average

Diameter

Water

Content

E-module Global Warming

Potential

Bio-content

µm % GPa kgCO2/kg % of C

40 - 100 10 – 15 10 - 15 0 – -3.5 100

Aspen wood fiber

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The mineral fibers are clearly the strongest

followed by viscose/rayon and lastly natural

Density… • The density of natural

fibers is lower then

mineral • compensate lower weight

•Natural fibers have

difficulties above 50% • Cellulose, Aspen, Bamboo

Resulting tensile modulus of selected/tested fibers with Terra DS

0

2000

4000

6000

8000

10000

12000

0 5 10 15 20 25 30 35 40 45 50 55

Fiber Content (%)

E-M

od

ule

(M

Pa)

Glass

Basalt

Cellulose

Viscose

Bamboo

Aspen

Linear (Glass)

Linear (Basalt)

Linear (Cellulose)

Linear (Viscose)

Linear (Bamboo)

Linear (Aspen)

Rayon/Viscose • Ideal reinforcement curve

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The natural fibers encounter a wide range of

processing issues in addition to lower strength

Resulting overview of some of the problematic issues

Fiber Type Dosing Water content Color Smell

Glass NP No issue None None

Basalt NP No issue Light brown None

Cellulose Hard above 15% Needs drying Light brown Minor above 15%

Viscose Hard Needs drying Brown above 15% Minor above 30%

Bamboo Uneven Major issue Black above 30% Burnt smell

Aspen Uneven Major issue Dark brown above 30% Burnt smell

• Of the natural (bio-based) fibers tested, viscose is the most promising

• Difficulties arise when processing approaching 50% (not linear E-Module improvement)

• Shearing forces and residence time likely bring above 240°C

• Only has a minor smell at high fiber contents

• The direct natural wood fibers are wet and degrade quickly

• Could nonetheless be interesting for some applications

• Smell tends to decrease after storage

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The results were brought to a technical flyer and

launched as a new product offering

Basic technical information

• Terra HS16 VF10 VF50

• Terra DS16 VF10 VF50

A press release was also prepared to inform as a part of the marketing stratgy

Dissemination of VESTAMID® Terra “VF” grade results

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VESTAMID® Terra is

• Made from plant (bio-sourced)

• Environmental friendly

• Reduces global warming potential

• High performing

• Competitive against existing polyamides

• Can be reinforced with natural and mineral fibers

VESTAMID® Terra

because we care…

Thank you for you attention!