VESTAMID Terra. High performance biopolyamides reinforced with high performance biofibers. High Performance Polymers Growth Line Resource Efficiency

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1 VESTAMID Terra High performance biopolyamides reinforced with high performance biofibers High Performance Polymers Growth Line Resource Efficiency Dr. Benjamin Brehmer, June 18 th, 2013

2 Natural fibers can increase the mechanical performance while maintaining bio-content Basic properties of the Vestamid Terra and comparable polyamides Property Unit PA66 PA610 PA1010 PA1012 PA12 E-Module MPa Tensile Strength MPa Water Uptake % Melting Point C Global Warming Potential kg CO Biobased Content % of C 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 The addition of fiber reinforcement will change all the basic properties Brehmer World Congress on industrial Biotechnology page 2

3 First stage is to compound the material as would be done in a normal operational procedure Compound schematic and process conditions Polymer Natural Fiber Atmospheric Degassing Vacuum Degassing Temp. Ramp Compounding Temperature Die Compounding temperature: C Throughput: 5 10kg/h Screw configuration: SK524 Screw rotation: rpm Water Bath Air knife Pelletizer 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 Brehmer World Congress on industrial Biotechnology page 3

4 The second stage is the injection molding to test the material for a diverse range of properties Produced molded parts for testing Tensile Bars Mechanical testing 3-Stage Plate Visual testing Pellets Texture Plate Surface and subjective testing Objectives and Forms Flowability Brehmer World Congress on industrial Biotechnology page 4

5 Fiberglass will be used as the basis for comparison as it is the global standard Mineral glass fiber 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 Source Sand / Silica Price indication: Mid-range Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Chopped, clear/white Brehmer World Congress on industrial Biotechnology page 5

6 Basalt fiber is not a wood fiber, but does comes from natural sources and is promising Basalt fiber 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 Source Lava rock of basalt Price indication: Mid-range Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Chopped, golden/shinny Brehmer World Congress on industrial Biotechnology page 6

7 Cellulose fibers are well known and purist form of natural fibers, but have limited potential Cellulose fiber 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 Source Cotton or lumber Price indication: Lower-range Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Loose, powdery/white Brehmer World Congress on industrial Biotechnology page 7

8 Regenerated cellulose fibers are further altered to add strength and thermal stability Regenerated cellulose fiber (Rayon) 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 Source Pulp or lumber Price indication: High-range (without sizing agent) Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Spoils/chopped, yellowish Brehmer World Congress on industrial Biotechnology page 8

9 Bamboo fibers are abundant and faster growing, providing a good CO 2 emissions reduction Bamboo fiber 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 Source Bamboo (Asia) Price indication: Very low-range Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Loose fibers, light brown Brehmer World Congress on industrial Biotechnology page 9

10 Aspen wood fibers are also abundant while providing a good CO 2 emissions reduction Aspen wood fiber 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 Source Aspen tree (America/EUR) Price indication: Very low-range Average Diameter Water Content E-module Global Warming Potential Bio-content µm % GPa kgco2/kg % of C Purchased Loose fibers, off-white Brehmer World Congress on industrial Biotechnology page 10

11 E-Module (MPa) The mineral fibers are clearly the strongest followed by viscose/rayon and lastly natural Resulting tensile modulus of selected/tested fibers with Terra DS Glass Basalt Cellulose Viscose Bamboo Aspen Linear (Glass) Linear (Basalt) Linear (Cellulose) Linear (Viscose) Linear (Bamboo) Linear (Aspen) Rayon/Viscose Ideal reinforcement curve Density The density of natural fibers is lower then mineral compensate lower weight Natural fibers have difficulties above 50% Cellulose, Aspen, Bamboo Fiber Content (%) Brehmer World Congress on industrial Biotechnology page 11

12 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 Brehmer World Congress on industrial Biotechnology page 12

13 The results were brought to a technical flyer and launched as a new product offering Dissemination of VESTAMID Terra VF grade results 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 Brehmer World Congress on industrial Biotechnology page 13

14 Thank you for you attention! 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 Brehmer World Congress on industrial Biotechnology page 14

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