GREEN MOBILITY CHALLENGES & OPPORTUNITIES FOR CARBON BLACK INDUSTRY

Transcription

1 Nov 07-09, 2017 Hotel Le Royal Meridien, Chennai, India. GREEN MOBILITY CHALLENGES & OPPORTUNITIES FOR CARBON BLACK INDUSTRY Dr. R Mukhopadhyay rm@jkmail.com 1

2 GREEN MOBILITY CHALLENGES AND OPPORTUNITIES FOR AUTOMOTIVE, RUBBER AND RELATED RAW MATERIAL INDUSTRY INTRODUCTION CONTENTS GREEN MOBILITY - ISSUE AND CHALLENGES THE NEED FOR GREEN MOBILITY SOLUTION FOR GREEN MOBILITY GREEN MOBILITY AUTOMOTIVE,TYRE & RUBBER INDUSTRY GREEN MOBILITY MATERIAL TRENDS GREEN MOBILITY - CHALLENGES OF CARBON BLACK DEVELOPMENT SUMMARY AND CONCLUSION 2

3 GLOBAL ISSUES & CHALLENGES Current Economic Model (Volatility, Uncertainty, Complexity, Ambiguity) Politics (Legislation & Regulation) Environment challenges Changing Consumer demand (Sustainable Life Style) Technological Literacy (Environmental Awareness) Information Explosion Growing Population & mobility Energy demand & challenges Demographic shifts (Urbanisation) Finite resources, Infinite Demands (Non Renewable sources) 3

4 GREEN MOBILITY Economic Growth Automotive, Rubber & Raw Material Industry Growth Environmental Regulation Transportation Impacts 4

5 GREEN MOBILITY ISSUE & CHALLENGES Environment Challenges Climate Protection Impact of Climate change is significant Economic Challenges Shortage of Resources Volatility in prices of fossil fuels Changing Consumer Demands Trend towards a sustainable lifestyle Societal demand for environmental stewardship Sao Paulo The car-centric transport model of the US needs to be replaced - even in theus Growing Population & Mobility Among the growing middle class in emerging economies Urbanization Almost 60% of the world's population will live in cities by 2030 Greater traffic density leads to increased noise emissions Politics More stringent legislation -to protect the environment -to reduce emissions and fossil fuel dependency Source: United Nations, Department of Economic & Social Affairs 5

6 Current Economic Model Fossil fuel Unbridled consumption Throw away product Inadequate concern for environment Volatility, Uncertainty, Complexity, Ambiguity GREEN MOBILITY - ECONOMIC CHALLENGES Worsen quality of lives Social Disparity resulted from rapid urbanisation Ecological Scarcity Resource exhaustion Climate disaster Food Crisis Future Economic Model Green Economy Innovation focusing Saving resources not labour Respond to the challenges of global warming and poverty Financial innovation circumventing regulation, taxes and accounting standards. Green Economy Improved human well-being and social equity, while significantly reducing environmental risks and ecological scarcities Making economies more sustainable requires three key policies: Valuing the environment Accounting for the environment Incentives for environmental improvement. 6

7 WHAT IS GREEN MOBILITY? Green mobility is sustainable transportation. Allows the basic access needs of individuals and societies to be met safely and in a manner consistent with human and eco system health, and with equity within and between generations. Is affordable, operates efficiently, offers choice of transport mode, and supports a vibrant economy. Limits emissions and waste within the planet s ability to absorb them, minimizes consumption of non-renewable resources, limits consumption of renewable resources to the sustainable yield level, reuses and recycles its components, and minimizes the use of land and the production of noise 7

8 GROWING POPULATION & MOBILITY More accidents, more CO2 emission, more noise pollution, more raw materials consumption, more energy consumption, more more etc. Only solution Sustainable Innovations Automotive & Tyre industry plays a significant role to achieve sustainable growth in an era of increased mobility 8

9 GREEN MOBILITY WHY? CLIMATE CHANGE - CO 2 CONCENTRATION & ENVIRONMENTAL IMPACT 9

10 GREEN MOBILITY WHY? GLOBAL ENVIRONMENT AUTOMOTIVE INDUSTRY Tyre Life Cycle Assessment for CO2 Emission - 185/70R14 CO2: 296.4kg-CO2/tire (ref.: Japan Rubber Manufactures Association) 4.1% 1.5% 0.2% 87.0% 7.2% (12.2kg-CO2) (4.4kg-CO2) (0.5kg-CO2) (258.0kg-CO2) (21.3kg-CO2) Materials Production (manufacturing, testing) Logistics Products use End of Life 10

11 GREEN MOBILITY - OEM AND CUSTOMER NEEDS & EXPECTATIONS Items Impacting Environment Fuel Consumption Input cost Energy Mini-mize Simultaneous Achievement Maxi-mize Safety Reliability Durability Handling Comfort Operation Eff. Performance Expectations 11

12 GREEN MOBILITY HOW? WORKING TOWARDS A SUSTAINABLE SOCIETY 12

13 CHALLENGES ENCOUNTERED AUTOMOTIVE, TYRE AND RAW MATERIAL INDUSTRY Green Mobility Demand of Fuel Efficient Vehicles Increasing Passenger Safety Regulations Technology Innovation challenge Material & Product Complexity Challenge Demand of Cars with Better Aesthetic Property Supply Chain Management Manufacturing Implementation Challenge Smart Manufacturing - Fourth industrial revolution (INDUSTRY 4.0) 13

14 SOLUTIONS FOR THE MOBILITY REVOLUTION REQUIRE A NEW ECOSYSTEM OF COLLABORATIVE PARTNERSHIPS 14

15 LEGISLATIONS & REGULATIONS Growth of tyre related legislations around the world TREAD Act : Transportation, Recall Enhancement, Accountability and Documentation Act REACH: Registration, Evaluation, Authorization and restriction of Chemical End of Life Vehicles EU legislation Labeling of Tyres EU legislation Uniform Tire Quality Grade (UTQG) Standards Global Technical Regulation on Tyres under consideration These stringent global regulations throw up challenges of adherence and optimizing various product performance goal conflicts 15

16 Efficiency enhancement of conventional powertrains TECHNOLOGY TRENDS FOR EMISSIONS REDUCTION Driveline / engine friction reduction Start-stop Advanced injection technologies Downsizing with turbo charging Transmission optimization Selective Catalyst Reduction (SCR) Exhaust Gas Recirculation (ECR) Particulate filters Non-powertrain enhancements Aerodynamics optimization Braking system optimization Accessories and loads optimization Weight reduction Tire Labeling Criteria (RR, Dry & Wet Traction & Noise) Active & Passive Safety System Reduce Emissions through Technology Use of greener powertrain technologies Hybrid electric vehicles Electric vehicles Fuel cell Use of alternate fuels Mild hybrids Strong hybrids Plug-in hybrids Range extender Electric vehicle Fuel cell vehicle Low sulphur gasoline/diesel Biofuels (ethanol/biodiesel) CNG LPG Hydrogen Fuel Cell 16

17 TECHNOLOGY TRENDS IN PASSENGER CAR 17

18 TOTAL ENERGY LOSS IN A VEHICLE ROLE OF TYRE Component IC Engine (Petrol/Diesel Operated) % Loss BEV (Battery driven Electric Vehicle) Engine Losses Accessories 2 1 Stand by 17 0 Drive line 6 28 Aero dynamic 3 14 Tyre (Rolling loss) 4 19 Brakes 6 28 Tyres play a small but significant percentages of total energy loss in the vehicle. Changing to an electric motor in place of IC Engine is shown to promote the tyre in the priority list for improvement in Rolling Resistance. 18

19 GREEN TYRE MARKET TRENDS - MATERIAL & TECHNOLOGY Value share of green tyre market by material and technology, 2012 and 2017 (%) Low rolling resistance through use of filler 2 technology 5 Low rolling resistance through use of improved synthetic elastomers Increased use of natural rubber 99 Source: Smithers Rapra 92 Improved inner liner materials With the increase in green tyre market, there will be increase in demand of NR, functionalized Solution SBR, Nd-BR, Halobutyl Rubber, Highly Dispersible Silica, Silane Coupling Agent, New Generation Carbon Black, Environmentally friendly Chemicals & Processing Aids, Ultra High Tensile Steel Tyre Cord etc. 19

20 GREEN MOBILITY SOLUTIONS - TYRES Safe & Durable Bearable Equitable Viable 20

21 TYRE PROPERTIES AND RELATED PERFORMANCE IMPROVEMENTS 21

22 % Weight Proportion PROPORTION OF MATERIALS IN TYRES Truck Bias Truck Radial Pass Radial NR SR Carbon Black Oil/Rubber Chemicals Nylon Steel Cord Beadwire Petro based materials : Truck Bias 50% Truck Radial 45% Pass Radial 71% 22

23 ENERGY AND GREENHOUSE EMISSIONS ASSOCIATED WITH THE RAW MATERIALS USED IN RUBBER INDUSTRY Material Energy (MJ/kg) Greenhouse (kgco 2 /kg) Natural Rubber Synthetic rubber Carbon black All other additives Fabric Steel tyre cord Manufacture (per kg tyre) Reclaim

24 VALUE CHAIN IN CARBON BLACK INDUSTRY Tyre/ IRP & Non-Rubber applications 24

25 GREEN MOBILITY RAW MATERIAL CHALLENGES Crude Oil based Materials Renewable Mineral Based Recycled It is possible to produce a tire with > 95 % non-crude oil base However, the application range today is still limited 25

26 CARBON BLACK DEVELOPMENT TREND - ISSUES Development is driven by market needs Current issues are : Low rolling Resistance Low heat build-up Superior Durability Superior wet & dry traction Superior handling Cost equal performance 26

27 TYRE DESIGN TRADE-OFFS 27

28 TREAD SEPARATION : CAUSE AND EFFECT CYCLE Over Loading Under Inflation Tyre Performance Cycle : Run Away Temperature Leads to Failure Reduced Stiffness Excessive Deflection Heat Buildup Tread Separation Bond Failure Carcass Degradation Quality of Materials & Construction Under or Over Cure 28

29 BREAK THE CYCLE WITH C-BLACK COMPOUNDING Over Loading Under Inflation Higher CDBP Lower Surface Area Excessive Deflection Higher Stiffness Lower Tan Reduced Stiffness Heat Buildup Tread Separation Bond Failure Carcass Degradation Reduce Heat Build-up Quality of Materials & Construction Under or Over Cure 29

30 BREAK THE CYCLE WITH C-BLACK COMPOUNDING Over Loading Under Inflation Higher CDBP Lower Surface Area Excessive Deflection Lower Running Temperature Reduced Stiffness Heat Buildup Tread Separation Bond Failure Carcass Degradation Improve Fatigue at Temperature Quality of Materials & Construction Under or Over Cure 30

31 SUSTAINABLE TYRE FOR GREEN MOBILITY - APPROACH STRUCTURE PROPERTY RELATIONSHIPS Reduction of the Fuel Consumption of a Vehicle Decreased RR & Heat Build-Up of Tires Reduction of Hysteretic Energy Loss Improved Filler Distribution Enhanced Interaction of Polymer Chains With Silica and/or Carbon Black Filler 31

32 CARBON BLACK MANUFACTURERS DEVELOPMENTAL APPROACH TO ADDRESS FUTURE DEMAND OF TYRE MANUFACTURERS? 32

33 TEMPERATURE DEPENDENCE OF TAN DELTA AND ITS RELATIONSHIP WITH TYRE PERFORMANCE Reduced temperatures for different tyre properties at 1 Hz 3 33

34 TYRE ROLLING RESISTANCE AND CARBON BLACK Reduction of carbon black loading lowers tyre rolling resistance. At a constant black loading, a rise in oil loading will increase the rolling resistance. But improves traction. Increasing black fineness raises both rolling resistance and traction. An increase in broad aggregate size distribution decreases the tyre rolling resistance with constant surface area and structure. 34

35 GREEN TYRES Low Rolling Resistance + Good Wet Traction + Good Tread wear Silica + Silane + S-SBR has disadvantages - COST! Many Treads comprise Blends of Black + Silica Many alternatives available New Carbon Black technologies being developed / to be developed 35

36 CHALLENGES CARBON BLACK DEVELOPMENT New generation carbon black to be developed for addressing magic triangle without affecting the cost 36

37 CARBON BLACK/NANO MATERIAL DEVELOPMENT TRENDS Carbon Black from Natural Gas Carbon Black from Biomass Inversion Black Nano Structure Black Latex Carbon Black Master Batch Silica Treated Carbon Black Carbon Silica Dual Phase Filler Nano Clay Multiwall/Single Wall Carbon Nano Tubes Graphene 37

38 NATURAL GAS: DRIVING TYRE & CARBON BLACK PRODUCTION Comparative Emissions Carbon Black Purity 38

39 NANO MATERIAL DEVELOPMENT TRENDS IN RUBBER INDUSTRY Technology Loading (phr) Technology readiness Application Carbon black Mature Improve mechanical properties Silica + Silane Mature Lower rolling resistance without compromising performance in wet traction, grip and tread life. Montmorillonite Clay (MMT) 1-10 Market entry/ Prototype Decrease gas permeability, Improve handling & comfort, Better thermoplastic stability & reduced decay. Reduced weight % polymer Lighter and cooler running (lowering RR). 39

40 NANO MATERIAL DEVELOPMENT TRENDS IN RUBBER INDUSTRY Technology Core/shell Polymer Nanoparticles Carbon Nanotubes (Multiwall) Loading (phr) Technology readiness Application <20 Market entry Improvement in cornering and steering response Reduced heat generation. Weight reduction since the coreshell particles are significantly less dense than carbon black or silica fillers Basic /Applied Research Reduce RR through reduced heat generation. Improve durability possibly even past the life of the car. Improved tensile, tear and hardness of the composites, by almost 600%, 250% and 70% respectively compared to pure styrene-butadiene rubber. 40

41 NANO MATERIAL DEVELOPMENT TRENDS IN RUBBER INDUSTRY Technology Loading (phr) Technology readiness Graphene Basic/Applied Research tyre applications since 2008 Application The graphene can be produced at a much lower cost than carbon nano tubes. More durable tyres due to better heat dissipation. POSS* 3.5 Increase wet traction without sacrificing rolling resistance or abrasion resistance. Rubber nanoparticles Market entry Improves dry road grip by between 10% and 15%. Significantly cuts wear Silica carbide 5-30 Improve wet grip 50% reduction in abrasion * Oligomeric Silsesquioxanes 41

42 Non-food / waste biomass Annual plants Hardwood & Softwood POTENTIAL FILLERS & CHEMICALS FROM BIOMASS PROCESS Kraft By-product Cellulose for paper Crude LIGNIN Wheat straw Soda Pulping Steam Explosion Organosolv By-product Bio-Fuel (bio-ethanol) Arundo Arundo Donax Donax Bagasse of Sugar cane µm Biomass feedstock available in huge amount ( >50Mio tons/year) Low-cost material : crude lignin <1 /kg Low density (1,5 > d (g/cm 3 ) >1,30) vs silica/cb POTENTIAL TARGETS Reinforcement with tyre weight reduction Antioxidant properties Carbon black by pirolysis? 42

43 SUMMARY & CONCLUSION As vehicles are one of the main sources of air pollution responsible for poor urban air quality, suitable measures should be taken by all concerned to build a green sustainable future. The challenge today is to sustain and further improve the air quality gains even as the city is growing and motorising rapidly. This is possible if strategic use of natural gas, electric power and renewable energy can expand alongwith aggressive clean up of all main stream fuels and technologies to cut toxic emissions (GHG) at source. Challenge to Zero-nize (environment, fuel consumption, input cost & energy) and the effort to Maxi-mize (safety, reliability, durability, handling, comfort and operational efficiency) continue. New generation Carbon Black will play vital role in tyre & rubber industry for green mobility alongwith Silica and other nano fillers. 43

44 THANK YOU FOR YOUR ATTENTION Any Questions???? 44