ADVANCEMENTS IN SUSTAINABLE BINDER TECHNOLOGY FOR COMPOSITE WOOD PANEL APPLICATIONS

Transcription

1 ADVANCEMENTS IN SUSTAINABLE BINDER TECHNOLOGY FOR COMPOSITE WOOD PANEL APPLICATIONS Manos Karagiannidis, Gavin Hatherell Date: 4 th & 5 th of October 2017

2 NEWS RELEASE EPA Issues Final Rule to Protect the Public from Exposure to Formaldehyde JULY 27, 2016 WASHINGTON - The U.S. Environmental Protection Agency (EPA) today moves to reduce exposure to formaldehyde vapors from certain wood products produced domestically or imported into the United States. One year after the rule is published, composite wood products that are sold, supplied, offered for sale, manufactured, or imported in the United States will need to be labeled as TSCA Title VI compliant. These products include: hardwood plywood, medium-density fiberboard, particleboard as well as household and other finished goods containing these products. ECOSYNTHETIX INC. 2

3 EcoSynthetix/Chimar Who we are Experience Enhancing Nature s Best Viable and practical Global Reach Commercial reach 40 years of dedicated industrial scale knowledge Adding functionality - tailored to overcome the challenges of fossil fuel based materials Compatible with incumbent technologies, economically positive Manufacturing, distribution, customer support in over 20 countries Global and local experienced industry team ECOSYNTHETIX INC. 3

4 DURABIND delivering the highest level of renewable content CURRENT PRODUCT 87% NATURAL WOOD 13% PETROLEUM-BASED BINDER PRODUCTS WITH DURABIND 96% NATURAL WOOD 2% RENEWABLE BIO-POLYMER 2% PETROLEUM-BASED BINDER... And the lowest level of VOC in panel production ECOSYNTHETIX INC. 4

5 But. it still requires a compelling value proposition Engage Thought Leaders Performance Sustainability Global Delivery Economics Bio-based Solutions ECOSYNTHETIX INC. 5

6 CREATING DURABIND BIOPOLYMERS Sustainable Feedstocks + Chemicals Proprietary Continuous Manufacturing Engineered Biopolymer Engineered Solutions Patented Product Patented Formula Patented Process Patented Products Proprietary Engineering ECOSYNTHETIX INC. 6

7 CHANGE & COMPLEXITY Introducing a new technology into an established manufacturing can pose challenges Operating lines Switching across multiple SKUs Producing millions M 3 DuraBind requires minor changes in application but no changes to the press ECOSYNTHETIX INC. 7

8 VALUE DRIVERS: C-LEVEL VALUE LEGISLATIVE CHANGE Increasing regulatory bodies are focused on reduction / elimination of formaldehyde in wood composite materials Commercial organizations are moving even faster with greater pressure DuraBind >98% bio-based Beyond current regulation OPERATIONS VALUE Isocyanate systems have some technical limitations DuraBind can lower total cost of production Reduce waste Larger processing window Less reliance on oil-based materials Meaningful step to reduce Isocyanate usage Less dependence of volatile petrochemicals RESULT Improved quality, higher value boards that meet and even exceed the environmental and consumer goals DEVELOPMENT VISION PATH TO INCREASING SUSTAINABILITY Stepwise approach to eliminating formaldehyde in wood products Goal to 100% bio-based Life Cycle Improvement Leveraging partner with Green Chemistry Innovators ECOSYNTHETIX INC. 8

9 DURABIND TM BENEFITS INDUSTRIAL MDF PRODUCTION RESULTS 16 mm MDF Vertical Density Profile (VDP) data CONFIRMED RESULTS + EXCELLENT DENSITY PROFILE pmdi DB Emulsion IB Pr Fa (speed) pmdi % DuraBind % Average Density Top Max. Bottom Max. Min. Density Min/ Ave Improved IB vs pmdi Validated emulsion distribution vs pmdi ECOSYNTHETIX INC. 9

10 DURABIND TM BENEFITS THIN HDF INDUSTRIAL APPLICATION HIGHER QUALITY VS UF IB Thickness Swell Water Absorption Surface Soundness SAME QUALITY + Increasing Speed Lower pmdi Loading 3 mm HDF Control Control Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 UF % speed loading loading loading speed speed pmdi % Durabind % Total loading % wax % Press speed mm/sec Raw thickness mm Density Kg/m IB N/mm Surface Soudnnes N/mm Swelling 24 h % Absortion 24 h % Initial Trial Trial after press improvement for speed ECOSYNTHETIX INC. 10

11 DURABIND TM BENEFITS INDUSTRIAL PB TRIAL RESULTS CONTROL(UF 9%) DURABIND Emulsion (3%) I.B. (N/mm 2 ) CONFIRMED IMPROVEMENT IN WATER TOLERANCE M.O.R. (N/mm 2 ) M.O.E. (N/mm 2 ) h T.S. (%) h T.S. (%) Formaldehyde content (mg/100g) Moisture content (%) Surface soundness (pull) (N/mm 2 ) Density (kg/m 3 ) ECOSYNTHETIX INC. 11

12 DURABIND TM BENEFITS INDUSTRIAL OSB PRODUCTION RESULTS 11 MM OSB PANEL Control (2.6% pmdi) DuraBind 25 Bio-urethane Density Commercial product running for +12 months MOR (N/mm2) M.O.E. (N/mm2) h T.S. (%) I.B. (N/mm2) IB after Boiling (N/mm2) ECOSYNTHETIX INC. 12

13 DuraBind OSB Structural Application: Value in use Panel Quality pmdi can be substituted by up to 25% Panel Cost Reduce pmdi cost $$ per MSF Reduce the need for Release agent + lower cost $$ per MSF Panel Sustainability Increase Bio-content with up to 25% DuraBind Process Improvements Extends Pot Life of pmdi resinated chips Panel Full Solution Lower cost Non-added Formaldehyde (NAF) OSB solution

14 DURABIND TM BENEFITS DELIVERS CUSTOMER VALUE THROUGH EASIER MACHINING Amps Chart pmdi: high amperage required to cut DuraBind: reduced amperage required to cut COST SAVINGS: LOWER ENERGY CONSUMPTION AND PROLONGED TOOL LIFE ECOSYNTHETIX INC. 14

15 DURABIND TM BENEFITS REDUCED BOARD-TO-PRESS STICKING up to 25% reduction in release agent LOWER RELEASE AGENT COSTS ECOSYNTHETIX INC. 15

16 DURABIND TM BENEFITS WASTE REDUCTION Lab Analysis Reaction : in wood at 60 C 90% extension in usable window NCO Conversion (%) Time (min) Discarding fibre & resin Industrial Trial Results: Increased pot life up to 120 minutes pmdi Durabind + OTHER WASTE REDUCTION OPPORTUNITIES ECOSYNTHETIX INC. 16

17 DURABIND: Supply, Application and Shelf Life DuraBind is supplied as a dry powder (<10% moisture) For proving trials as 30% liquid dispersion for ease of operation Shelf life for DuraBind Dry powder is up to two years 30% dispersion up to two month at storage temperature > 18 C Can be used to emulsify pmdi and applied on strands Can be used at 30% dispersion and applied on strands separately before pmdi (most preferred way to avoid atomizer buildup) EcoSynthetix 17

18 Delivering responsible sustainable commitments Sustainable solutions drive strategic growth and are available now Differentiation creates additional value Consumer friendly ECOSYNTHETIX INC. 18

19 Question & Answer