Bio Tyre Project. Layman s Report

Transcription

1 Bio Tyre Project The project was supported by the European Union within the bounds of the LIFE Programme Further information: GOODYEAR S.A., Avenue Gordon Smith, L-7750, Colmar-Berg, Luxembourg Tel: (+352) , Fax: (+352) , Contact person: Mr Georges THIELEN

2 Summary The BioTyre project () has been successfully implemented by Goodyear Luxembourg S.A. during its 42 months period (December 2005 May 2009). This was enabled also by the fruitful collaboration with the partners Novamont (Italy) and BMW (Germany). The objective of the LIFE project was to demonstrate that the combination of new advanced materials developed (BioTread) and the optimisation of the tyre structure may lead to a substantial reduction (up to 30 %) of the tyre s rolling resistance. During the project development, two main objectives have been followed: the development of an alternative, to traditional non renewable fillers used in tyres (Biofiller) and, the in-depth analysis and modification of the tyre structure, aiming at minimizing the energy loss (Rolling Resistance) when the vehicle is in motion. The expected outcome was the validation of the BioTyre, developed by Goodyear, through the maximisation of the renewable raw materials content of the filler and the development of a new tyre design. The combination of both aspects was expected to allow reaching the 30 % rolling reduction target. Therefore, this leads to approximately 5% reduction of fuel consumption of the car. This is a good premise for the reduction of the CO 2 emissions from the cars. The use of biofiller also permits to lower the weight of the tyre, leading to a decrease in the inertia forces which had a direct effect on the fuel consumption. The major environmental benefit of the BioTyre represents the reduction of the CO 2 emissions from the cars during its life time. Additionally, it should be mentioned the CO 2 gain during the production process of the Biofiller becomes more important if compared with the manufacturing of silica and carbon black, a production technology that is a significant source of greenhouse gas emissions. The budget of the BioTyre project amounted to 9,423,439 EUR with maximum LIFE contribution of 2,372,821 EUR (25.18 % of total costs). Project background Goodyear is the only market player investigating run on flat tyres integrating bio-polymeric fillers. In view of validating the new tyre formulation and design, prototypes have been developed and extensively tested. Beyond demonstrating the technical feasibility, the project aimed at assessing the environmental impact and economic viability of this environmentally-friendly tyre design. In collaboration with Goodyear for the BioTyre project, partners are Novamont (Italy) and BMW (Germany), a global player in the automobiles and motorcycles manufacturing industry. Novamont S.p.A. is an independent company active in the field of biodegradable thermoplastic materials development which follows two primary research objectives: designing of new products and applications based on renewable raw materials of agricultural origin, and analysing their environmental performance according to the most innovative international criteria and standards. Goodyear has proceeded in collaboration with BMW with the extensive testing of the prototypes (laboratory and vehicle tests). After the achieving of all the technical specifications and safety requirements, Goodyear and its partners have carried out a life 2 / 8 30/05/2009

3 cycle analysis of the new product as well as the monitoring of the industrial emissions of cars equipped with the new tyres. The researchers team have investigating the potential of biofillers that can be introduced in tyres, as well as internal (e.g. tread, breaker coat, base, ply coat) and external (e.g. load, inflation, speed, temperature etc.) factors that influence the tyre s rolling resistance. The goal was to incorporate in tyres advanced biofillers, maintaining at the same time good tyre performances (e.g. braking distance, durability etc). During the research activities, Goodyear has approached the implementation of the second generation of biofillers developed. This generation of BioTRED fillers takes advantage of an innovative nano-layer technology. The innovation consists in the complexing part of the amylose molecule that is present on the starch surface. The nano-layer created can be adjusted in terms of stiffness and free volume which allows Goodyear to better control the loss properties characteristics versus frequency. When the vehicle rolls down the road, it creates a drag force which is called rolling resistance. It represents the energy loss created by the deflection of the tyre sidewall and by the compression and deformation of the tyre tread in the footprint at the road surface. Significant efforts have been made by Goodyear and its Italian partner Novamont for the development of the new biofiller (formulation volume based having a biofiller content of between 4% and 5%) made from nano-particles of corn starch that is partially replacing the carbon black and silica. The use of biofillers would contribute to improve the tyre s environmental profile particularly through the maximisation of the renewable materials content as well as the induced weight reduction. In addition to material development, Goodyear has investigating the interaction structure-material and has optimising the design and geometry of the tread pattern and tyre anchoring. The combination of material and structure research represents the optimum approach for the development of an innovative tyre design, suitable for achieving a reduction of 30% or more of the rolling resistance. The project has been also focused on the in-depth analysis of the factors that influence the rolling resistance. Numerical simulations have been performed in order to predict the tyre structure characteristics and the interaction between the material and the tyre s structure. Specific attention has been granted to maintaining a high level of performances (e.g. durability, handling, braking distance) since there was a well known antagonism between the rolling resistance characteristic and other safety aspects. The expected outcome consists of an optimised tyre design. The achievements of the BioTyre project represent a breakthrough in the tyre industry and are paving the way for the replacement of non renewable resources by renewable materials with significant environmental impact both during the production and using phase of the product. 3 / 8 30/05/2009

4 Description of the technique/methodology implemented and the results achieved The objective of the BioTyre project was the development, assessment and manufacturing of new materials that are suitable for being incorporated in tyres and that would allow a significant reduction of the rolling resistance by 30% (in combination with the tyre structure optimisation). The materials have been used as fillers for reinforcing the tyres and improving their characteristics, like higher tear resistance and strength. Fillers are typically made of either Carbon Black or Silica. The aim of Goodyear was to develop an innovative rubber formula which includes biopolymers as fillers, and could offer the solution for partly replacement of Carbon Black and Silica. The improvements of the biofillers technology have been successfully adapted to run on flat tyres, which will represent the majority of tyres in the near future, taking into account the improved car safety as well as their environmentally friendly impact (the 5 th tyre of each car, the reserve one, becomes unnecessary). Novamont was able to supply Goodyear with a new industrial biofiller formulation (2 nd generation of biofiller). Part of the activity was focused on the industrial validation of such 2 nd generation of biofiller, in order to provide Goodyear with sufficient material to set up the first production of tyres to be tested by BMW. Another part of the activity was focused on the conception of new biofiller experimental grades. More than eighty new materials were produced (quantitative representing about 4,000 kg of materials). Their dispersion ability in rubber was tested with the dispersion test established in Novamont by using two model compound formulations. Four of them, having different physical, chemical and rheological behaviour from the biofiller of 2 nd generation, passed successfully this pre-screening and were selected for further testing at Goodyear. Moreover, Novamont tested the reproducibility of the biofiller based on a low melting complexing agent both in term of production process on pilot plant and in term of dispersion capability in the Model Test Compound formulations based on Natural Rubber and Carbon Black. Such a grade confirmed to be reproducible and dispersible. The mechanical characterisations of vulcanised specimens was started in order to make a more efficient pre-screening of the new biofiller grades in terms not only of dispersion capabilities in rubber, but also in terms of physical and mechanical performance tests. The next step of the development of the BioTyre project was to modify and optimise the tyre structure by using numerical methods. Five types of activities have been foreseen at Goodyear s premises: the study of the interaction structure-material, the micro-macro approaches, the tread pattern, the ply line theory, the tyre anchoring. The numerical analyses have demonstrated that the main contributor to the overall performance of the tyre is the tread compound, representing almost 50% of the rolling resistance. The objectives were to reduce the rolling resistance through mould cavity concepts and to improve the braking performances. The tread pattern optimisation has been achieved at the beginning of For maintaining and improving 4 / 8 30/05/2009

5 the braking performances of the tyre (by having a consistent decrease of rolling resistance), Goodyear has developed an innovative concept of the extended shoulder for the BioTyre, which enables an evolutive footprint area during the braking load. The mould cavity was adapted accordingly. The main conclusion of the tests was the combination of a specific design associated with the ORBiT mould which reduces the vertical stiffness and Dynamic Loading Factors (DLF). At Goodyear and BMW premises, tests was carried out to incorporate the new advanced materials developed and the results of the optimisation of the tyre structure in order to develop physical prototypes and to test them on vehicle and in laboratory. During the tests, we have closely monitored the rolling resistance, the handling characteristics, the traction on wet/dry surfaces, the resistance to abrasion, the durability, the dimensional stability, the noise and braking performances as well as the run on flat characteristics. The objective of the performed intensive tests on prototype tyres was to control the latest technologies concerning low rolling resistance tyre components. Tests were done in the tyre testing department of BMW on test benches and on different vehicles of the BMW Group. A continuous optimisation process started in order to reach the required handling and tyre characteristics. The main emphasis of the testing was beside the rolling resistance on important test criteria like handling characteristics on dry and wet roads, comfort, aquaplaning and braking distance and traction. Braking distance (on a dry surface) is a very important safety feature, during the development process of new cars. In this context, the tyre has an important part to play in optimising braking distance. Finally, the continuous optimisation of the prototypes and the development of the transferability plan for the industrial application of the project and market introduction were performed. Concerning the transferability potential at large production s level, one critical issue represents the industrial constraints in terms of equipments (e.g. size) and costs. A preliminary LCA study on the 2 nd generation of biofiller has been prepared by our partner Novamont to meet the series ISO standards. Environmental benefits of the project Road transport generates more than 20 % of all CO 2 emissions in the European Union, with passenger cars being responsible for more than half of these emissions and represents therefore a major concern for the EU. The CO 2 emissions generated by vehicles were subject to a voluntary agreement between the car manufacturers and the European Commission. Due to the fact that this agreement is estimated to fail its targets, a new European regulation under discussion is expected to limit the CO 2 emissions for the new passenger cars to 120 (130) g/km by 2012 (from 186 g/km in 1995 and around 160 g/km in 2005). Under such circumstances, the objective of the BioTyre project of building an ultra low rolling resistance / run on flat tyre (less fuel consumption and related CO 2 emissions by improving the rolling resistance of the tyre) represents the appropriate answer for energy efficiency and environmental protection. A reduction of rolling resistance between 5% and 7% leads to 1% less fuel consumption for the cars. 5 / 8 30/05/2009

6 The partial replacement of silica and carbon black by the BioTRED filler of 2 nd generation are interesting approaches for the reduction of tyre s CO 2 impact. The production process of the 2 nd generation of biofiller has a positive CO 2 balance. For each kg of biofiller manufactured, 0.62 kg of CO 2 are saved (See picture below). The total gain for 20% weight silica replacement brings a CO 2 reduction of up to 8.2 g/km. Extrapolated to the production of 1,000,000 of BioTyres, it will result a total CO 2 reduction of 117 tons. The main CO 2 gain is given during the using phase of such tyres. Considering 20,000 km run by 1,000,000 BioTyres and 30% reduction in rolling resistance, the CO 2 cuts will amount to 41,000 tons. Nevertheless, due to the improved fuel consumption, the broad and quick implementation of the BioTyre technology could help Europeans to better comply with other legal requirements such as concerning the PM emissions. Being a run on flat tyre development, the BioTyre is reducing the resources needed for equipping the vehicles (only 4 tyres needed instead of 5). The use of non renewable resources like carbon black can also be decreased. Moreover, it offers a significant increase in road security, by maintaining the car control after sudden air loss. production process kg CO 2 /kg starch BioTyre concept IMPACT ON CO 2 EMISSIONS kg CO 2 / kg -30% rolling resistance in optimised tire Clean structure BioTRED filler for Partial replacement of silica or carbon black CO 2 emission reduction 8 g/km > 0.12 g/km 0.62 CO 2 elimination/kg BIOTRED filler second generation Total gain for 20% weight silica replacement, up to 8.1 g/km (CO 2 reduction) =17 % contribution car manufacturer objective (46 g reduction for 2008) BioTyre concept 6 / 8 30/05/2009

7 Visibility of the project The visibility of the project was assured by the participation to different specialised fairs and exhibitions, by publication of articles, by participation of meetings and elaboration of the related website ( as well as by printing and distribution of information material (brochures, presentations). The following exhibitions have been attended by Goodyear during the life time of the BioTyre project: Green Week EXPO 2007, which was organised by the European Commission in Brussels (Belgium). A TV reportage called Curbing CO 2 emissions from road transport prepared by Mostra communications in June 2007 has been broadcasted by several televisions (e.g. Arte, Euronews); Intelligent Tire Technology conference that has been organised in September 2007 in Frankfurt (Germany); International plastics and rubber trade fair, K2007 took place in Düsseldorf (Germany) in October 2007; International Geneva Motor Show 2008 took place in Geneva (Switzerland) in March During the exhibition, Goodyear was the official partner of the press center. Moreover, internal as well as external press releases and articles have been published in relation to the participation of Goodyear at Geneva Motor Show 2008; European Research & Innovation Exhibition 2008 has been organised in Paris (France) in June 2008; International Geneva Motor Show 2009 took place in Geneva (Switzerland) in March 2009; Symposium Facing the Challenge of Future CO 2 Targets: Impact on European Passenger Car Technologies on June, 19 th 2009 in Turin. In order to take into consideration the necessary activities for granting the BioTyre project of a good visibility, a dissemination plan has been elaborated for clients, industry stakeholders, car manufacturers or general public. The communication activities of the BioTyre project have been focused on the significant environmental benefits of the new developed tyre concept Another important dissemination channel is represented by the regular meetings of Goodyear with different car producers (e.g. Peugeot, Fiat, Mercedes, and Volvo) in order to present the technical and environmental advantages of the new tyre concept. An important step towards the dissemination and the transferability potential of the BioTyre technology was the meeting organised with Green Propulsion in March The discussions have shown a real interest from the Green Propulsion s side related to the new technology developed. It is of high importance to combine new technology concepts such as hybrid cars with run on flat BioTyre. This combination offers new opportunities for the future deployment of the ultra low rolling resistance tyres. 7 / 8 30/05/2009

8 Transferability The intention of Goodyear is to implement the project at the industrial scale and to proceed to the manufacturing of tyres with biopolymeric fillers after the termination of the pilot project. If the upscale of the BioTyre technology is successfully implemented on the larger scale, the production could be adapted to other tyre sizes. This technology has good opportunity to be well spread on the market and not remain at a nice level. In addition, it could also be possible to extend the use of the bio fillers to other components of the tyre s structure, such as the sidewall. Goodyear is also analysing the possibility of implementing the know-how also for other tyre sizes. A final objective would be the complete replacement of the conventional Carbon Black or Silica fillers by environmentally-friendly ones, while maintaining high tyre performances in terms of braking distance, handling or durability. 8 / 8 30/05/2009