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FABRICATION OF STRUCTURAL PET FOAM CORE BOARDS FROM MIXED SOURCES OF RPET AND THEIR POTENTIAL APPLICATIONS
Lisa Scholle
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
Tuesday 13 April 2021
Name
SUMMARY
• About Armacell• Armacell in PlastiCircle• Applications of ArmaPET foam boards
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
4
ARMACELL AT A GLANCE
A global leader and the inventor of flexible elastomeric foams for equipment insulation
HQ in Luxembourg with regional head offices around the globe
3,135 employees worldwide
24 production facilities in 6 countries on 4 continents
€ 644,4 m total net sales in 2019
A multi-material andmulti-product company
2 main businesses: Advanced Insulation and Engineered Foams
6 destination markets: Commercial Equipment / Residential Equipment / Energy / Industrial / Transport / Sports & Leisure
5
ENGINEERED PET FOAMSPUTTING PLASTIC WASTE TO GOOD USE
• PET Foams is a business division of Armacell and is fully dedicated to PET foam technology.
• Our diverse product portfolio of innovative, eco-friendly PET foam solutions is produced in:» Thimister-Clermont, Belgium (PET Foams headquarters)» Brampton, Canada» Suzhou, China
• Since 2010, Armacell’s rPET facilities have reused over 1,500,000,000 PET bottles and saved more than 67,000 metric tonnes of CO2 emissions in the process.
• That is equivalent to the emissions of ...
6
FROM BOTTLE TO FOAMPUTTING PLASTIC WASTE TO GOOD USE
• Sustainable product solutions based on 100% post-consumer PET
1. PET bottles
2. RPET flakes
3. In-house granulation
4. Extrusion foaming
5. Use-phase
6. Recyclable PET foams
ArmaPET Struct ArmaPET Eco
ArmaPET Shape ArmaPET Curve
2. ARMACELL IN PLASTICIRCLE
7This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
• Technical requirements of recycled polymers for the new products• Development of recycled products in lab scale
– Raw material screening & properties comparison– Recipe development
• Development of recycled products in pilot scale in the industries– Assessment of processability of RPET from tray– Analysis of cell structure & mechanical properties of the demonstrator foam board
• Technical and economic validation
Target: Production of PET foam boards using RPET from mixed sources including trays
8
WP5 – RECOVERY AND RECYCLING
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
• Different sources of RPET were assessed on lab scale
RAW MATERIAL SCREENING
9This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
IV: Intrinsiv viscosity | CEG: Carboxyl end groups
00,10,20,30,40,50,60,70,80,9
vPET rPET goodbottle grade
rPET mixedbottle grade
Tray-richmaterial
Tray
IV
0
5
10
15
20
25
30
35
40
vPET rPET goodbottle grade
rPET mixedbottle grade
Tray-richmaterial
Tray
CEG
• Different sources of RPET were assessed on lab scale
– Left: Reactivity of different sources of post-consumer RPET
– Right: Reactivity of different mix of RPET from bottles and RPET from trays
RAW MATERIAL SCREENING
10This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
*Armacell Method
00,20,40,60,8
11,21,41,61,8
2
vPET rPET goodbottle grade
rPET mixedbottle grade
Tray-richmaterial
Tray
Reactivity*
0,00
0,20
0,40
0,60
0,80
1,00
1,20
0,00 10,00 20,00 30,00 40,00 50,00 60,00
Tray [%]
Reactivity*
• Challenges when using RPET from tray material
– Potentially more contaminations with other materials– Lower IV– Higher CEG– Lower reactivity
Adjustments to the recipe are needed to make RPET from tray suitable for the foam extrusion process.
RAW MATERIAL SCREENING
11This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
*Armacell Method
0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 0,2 0,4 0,6 0,8 1 1,2
Reac
tivity
Total reactive additives [wt.-%]
• Different optimization routes and reactive additives were assessed in lab scale
– Increase load of MM (MM1)• MM1 can be increased but will lead to degradation and
reduced shear properties at elevated levels
– Alternative MM (MM2)• MM2 alone does not show the required IV increase at low levels• Higher levels of MM2 lead to crosslinking rather than chain
extension.
RECIPE DEVELOPMENT
12This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
MM: Melt Modifier
1:1
2:1
1:0
Data labels indicate ratio of MM1 : MM2
• Target: Stable process Optimal foaming conditions Homogeneous and fine-celled microstructure Good mechanical properties of the PET foam board
• Influencing factors:• Recipe: Addition of melt modifiers• Processing parameters, like processing temperature
Development of recycled products in pilot scale
13This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
Foaming conditions Cell structure Mechanical
properties
Recipe
Process
0
20
40
60
80
100
120
255 260 265 270 275 280 285 290
pres
sure
[bar
]l
Temperature [°C]
• The RPET was selected based on the screening and recipe development Tray-rich RPET with up to 20% tray
• To achieve optimal foaming conditions, the die pressure must be kept stable.
• Low process temperature high pressure (unstable process)
• High process temperature low pressure• Low MM Low pressure• High MM High pressure (unstable process)
ASSESSMENT OF PROCESSABILITY
14This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
0
20
40
60
80
100
0 0,1 0,2 0,3 0,4 0,5
pres
sure
[bar
]
MM2 [%]
MM1 A-Concentration MM1 B-Concentration
MM: Melt Modifier
• Cell structure analysis of PET foam board with different proportions of MM The more MM added, the higher the number of small
cells.
ANALYSIS OF CELL STRUCTURE AND MECHANICAL PROPERTIES
15This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
0
200
400
600
800
1000
1200
1400
160 226 276 319 357 391 422 451 479 505 529 553 575 597 618 638 658
num
bers
diameter (µm)
MM1 B-Concentration
0%
0.05%
0.1%
0.15%
0.2%
0
200
400
600
800
1000
1200
1400
160 226 276 319 357 391 422 451 479 505 529 553 575 597 618 638 658
num
bers
diameter (µm)
MM1 A-Concentration
0.1%
0.15%
0.2%
0.25%
0.4%
MM: Melt Modifier
To obtain optimal foaming conditions, a homogeneous and fine-celled microstructure and finally good mechanical properties, a certain level of MM1 needed + an addition of MM2.
PROPERTY RESULT UNIT
Density 96 kg/m³
Compression strength 1.3 MPa
Compression modulus 52 MPa
Shear strength 0.7 MPa
Shear modulus 15 MPa
Tensile strength 2 N/mm²
Tensile modulus 68 N/mm²
16This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
ANALYSIS OF CELL STRUCTURE AND MECHANICAL PROPERTIES
0,00
0,50
1,00
1,50
2,00
0 0,1 0,2 0,3 0,4 0,5
Com
p. S
tr.
[MPa
]
MM2 [%]
Comp. Strength
0,0000,2000,4000,6000,8001,000
0 0,1 0,2 0,3 0,4 0,5
Shea
rStr
. [M
Pa]
MM2 [%]
Shear Strength
0,000,501,001,502,002,50
0 0,1 0,2 0,3 0,4 0,5
Tens
ileSt
r. [M
Pa]
MM2 [%]
Tensile Strength
MM1 Concentration-A MM1 Concentration-B
• It is possible to produce extruded foam boards from RPET with a share of RPET from trays.
• The quality is comparable to foam boards produced from RPET from bottles.
• The mechanical properties are sufficient for a wide range of applications.
• Provided that sufficient quantity of tray material of stable quality is available in the future, it is conceivable to use tray material for Armacell’sproducts.
• Benefits:– Additional source of raw material– Enable recycling of difficult to recycle packaging
TECHNICAL AND ECONOMIC VALIDATION
17This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730292.
19
ArmaPET Destination Markets and Applications
ROTOR BLADESOver 120,000 wind turbine blades globally are cored with ArmaPET Struct.
BODY STRUCTUREPenso’s Blue Ocean Home Delivery Pods are made of ArmaPET Struct.
FLOORINGArmaPET Struct is used in the floor panels of Czech tram For City.
BRIDGINGArmaPET Struct is used for the Millennium Walkway in Derbyshire, UK.
.
Sports EquipmentArmaPET is used in racing windsurf boards, SUP blades or skis.
.
.ECO-FRIENDLY HOUSINGA 186 m² house in Nova Scotia (Canada) made entirely of 170 ArmaPET Struct cored panels.
20
ArmaPET Applications in Building and ConstructionEco-friendly housing
Formworks Modular housing Facade cladding Decorative Domes
Flooring(access floor systems)
Roof structures(in particular domes)
Interiors(partition walls, doors, worktops …)
ETICS(external thermal insulation systems)
Facade claddings(external decorative elements)
21
Armacell Benelux S.C.S. Contact
Lisa Scholle
Innovation Scientist, PET Foams
Armacell
T. +32 (0)87 450 773
M. +32 476 260 119E. [email protected]