VinylSUM: A Research Network to Improve the Sustainability of PVC. N.L. Thomas, M. Gilbert & S.G. Patrick, IPTME, Loughborough University, UK

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1 VinylSUM: A Research Network to Improve the Sustainability of PVC N.L. Thomas, M. Gilbert & S.G. Patrick, IPTME, Loughborough University, UK

2 Outline of Presentation Introduction Who we are Objectives Where we fit in Activities Meetings & Workshops Research Projects Expansion of Network Associate Membership Scheme Future Plans

3 Introduction EPSRC funded April 2004 March 2007 Organised by the Institute of Polymer Technology and Materials Engineering (IPTME), Loughborough University Dr Noreen Thomas is Principal Investigator with Professor Marianne Gilbert as coinvestigator and Mr Stuart Patrick as coordinator/administrator.

4 Industrial Partners Ineos ChlorVinyls Hydro Polymers British Plastics Federation European Council for Plasticisers and Intermediates (ECPI) European Stabiliser Producers Association (ESPA)

5 Academic Partners IPTME, Loughborough University Prof Adisa Azapagic, CEAS, Manchester University IRC, Bradford University Wolfson Centre, Brunel University Biocomposites Centre, Bangor University

6 Additional Members The Natural Step (TNS) and the PVC Stakeholder Council (chaired by Jonathon Porritt) COSTdown (Recycling) Dutch PVC Network

7 Objectives To establish a forum for an industry-wide discussion of research required to improve the sustainable use of PVC To review research to date, and identify knowledge gaps To develop an approach for a full evaluation of sustainability on a life cycle basis, and set up a modus operandi in which the whole industry works together to achieve the objectives for sustainable use which can then be applied to other polymers To become a source of impartial information to all stakeholders

8 Vinylsum.org.uk About Us Members Area Minutes of meetings, Presentations Associate Members - Summary of Results from Research Projects, Technical reports, Updated literature review Research Projects Detailed Results of current project News Events Literature Links

9 Literature Review I PVC Research General PVC references, recent reviews Additives: stabilisers, plasticisers & issues Fire retardants and smoke suppressants Nanocomposites and related topics Polymerisation Resins and compounds Processing and products Recycling and waste treatments Life cycle analysis/sustainability

10 Literature Review II - Sustainability Review of Life Cycle Assessments Available on PVC Review of Environmental Issues Associated with PVC Review of Recycling and Waste Treatment Issues and Methods

11 Improving Sustainability of PVC through Novel Materials, Processes and Life Cycle Methodologies N L Thomas, M Gilbert, B Haworth (IPTME) A Azapagic, Manchester University Supported by INEOS ChlorVinyls, Hydro Polymers, BPF and ECPI

12 Processes POLYMERISATION (WP1) + Materials = NANOCOMPOSITES (WP2) Products PVC PRODUCTS Processing Use Non-aqueous Polymerisation Incorporation of Additives during Polymerisation (WP1&WP2) Stabilization Plasticiser Migration Smoke Suppression Processing Re-use & Recycling LIFE CYCLE SUSTAINABILITY OF PVC (WP3)

13 Research Workers on the Project Polymerisation WP1 Prof Brian Brooks Emeritus professor, Chemical Engineering, Loughborough Dr Styliani Georgiadou RA (IPTME) Nanocomposites WP2 Dr David Hitt RA (IPTME) Mr Fabio Papini PhD student (IPTME) Mr Xiaoran Zheng PhD student (IPTME) Life Cycle Sustainability of PVC WP3 Dr Shahriar Amini RA University of Manchester

14 Novel Sustainable Processes for making PVC The aim of the project is to address some of the environmental and sustainability issues associated with PVC production by achieving Energy savings Reduction of emissions Elimination of water contamination during polymerisation Use of smaller quantities of sustainable additives These objectives will be achieved by the development of novel non-aqueous polymerisation processes novel PVC nano-composites with sustainable additives

15 Non-aqueous Polymerisation A polymerisation process that does not require water has substantial environmental benefits, particularly regarding energy savings.

16 Non-aqueous Polymerisation SEM pictures showing Grain Morphology and Surface Detail of PVC polymerised by the Non-aqueous Process.

17 Nanocomposite Development by In-situ Polymerisation In situ polymerisation facilitates the dispersion of the nanoparticles. Inorganic materials that will be used include ultrafine:- calcium carbonate silica Clays & other platy particles

18 Nanocomposite Development by In-situ Polymerisation Incorporation of nano-particles of CaCO 3 into PVC

19 Nanocomposite Development by Melt Compounding Addition of ultra-fine or nano-particles during dry blending followed by melt compounding on a range of processing equipment including a Haake rheometer, twin-roll mill and twin-screw extruder. Dispersion of nano-scale additives should improve thermal stability and help to reduce toxic smoke emissions on burning. Other advantages are to improve mechanical properties particularly impact strength.

20 Charpy Impact Strength of PVC Compounds with Hydrotalcite Hydrotalcite (phr) Charpy Impact Strength (kjm -2 ) ± ± ± ± 8.8

21 Hydrotalcite CO 3 2- Ions The Hydrotalcites have similar structures to the natural clay minerals e.g.. Montmorillonite, but with opposite charge. H 2 O water intercalated between the layer Al(OH) 6 - octahedron Mg(OH) 6 - octahedron

22 Basic Layer [Mg 1-x Al x (OH) 2 ] x+ Hydrotalcites as PVC Stabilisers Mg 1-x Al x (OH) 2 Mg 1-x Al x (OH) 2 H 2 O CO 3 H 2 O + 2HCl Mg 1-x Al x (OH) 2 (in PVC) H 2 O Cl H 2 O Cl + CO 2 + H 2 O Mg 1-x Al x (OH) 2 Basic Layer [Mg 1-x Al x (OH) 2 ] x+ Ion exchange reactions with HCl - Hydrotalcites can act as stabilisers and smoke suppressants for PVC

23 Reducing Plasticiser Migration Reduce migration of plasticiser in flexible PVC by dispersing small amount of platy nanofiller in PVC that increases tortuosity of diffusion path. Tactoid peeling Intercalation 20 nm

24 Life cycle sustainability of PVC Adisa Azapagic and Shahriar Amini School of Chemical Engineering and Analytical Science The University of Manchester

25 Sustainability of PVC: Project Aims Development of a life cycle methodology and decision-support tool for assessing and improving sustainability of PVC Development of databases to support assessment and decision-making Demonstration of the methodology and decisionsupport tool on a number of case studies

26 Software Overview The whole life cycle of PVC Materials and energy options Processes and technologies Products End-of-life options Capability Sustainability assessment and optimisation Selection of the best options for improved sustainability

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29 Global Warming Potential (GWP 100 years) [kg CO2-Equiv.] Scenario 1 Scenario 2

30 DTI & Industrial Funded Project - Development of Bio-based Products for Use as PVC Plasticisers started April 2006, Bangor Biocomposites Centre.

31 Associate Membership Associate membership of VinylSUM - open to all stakeholders Associate members updated by newsletter (two per year) also including an overview of results from the current sustainability improvement Work Programmes Associate members are also made aware of potential new research proposals and/or funding possibilities covering PVC sustainability improvement and given the opportunity to participate from the start. Current associates include Solvin, Braskem, ECVM, Teknor Apex and Synthomer.

32 Associate Membership & Future Plans Current plans to launch new research project on reduction of smoke and HCl emissions from burning PVC. Another area is product design to save material: use of nano-scale modifiers, PVC composites, foaming processes. Continue to work together with all stakeholders so that the whole industry works together to achieve the objectives for sustainable use of PVC