SUSTAINABILITY

ELASTOMERS FOR Top 10: SUSTAINABILITY First ever ranking of projects contributing most to raising the environmental pro le of the elastomers/rubber industry

he top entries for the inaugural staging of ERJ’s new production chain – with clear ben- Elastomers for Sustainability initiative has now been e ts also for the ethanol industry. decided by our judging panel* led by experts in the Commercialisation steps include a demo plant in The , eld of polymer science & technology. with rst commercial scale batches TE4S is an industry- rst sustainability initiative, designed to expected within three years. highlight signi cant advances for end-user sectors includ- ing tires, automotive components, construction, consumer, JUDGING REMARKS: industrial and medical. • Ethanol-to-butadiene via updated, lower-energy Lebedev process – with JUDGING REMARKS: a more ef cient catalyst than before. 1 Asahi Kasei / • Top marks for rolling-resistance • A process development based on and wear reduction through func- very good chemistry. With large- New-generation sty- tionalisation of SBR to stick to rub- scale application could be bene cial rene-butadiene rubber ber molecules. for industry. • Market-oriented development. What The company’s sixth generation is positive is the progress being Trinseo / Highly-func- functionalised SBR is said to show made in this vital area. tionalised SSBR grade 20% lower rolling resistance than previous versions and reduced wear. Functionalised SSBR with enhanced For this, Asahi developed a special ller-polymer interaction is now the functional group to enhance ll- 2 ETB / Bio-butadi- way to go for tire tread rubber. New er-polymer interaction – to improve ene for tire production grade Sprintan 918S featuring Trin- wear resistance and rolling resistance seo’s proprietary functionalisation – and a new polymerisation technol- The project targets the construction technology is at the leading-edge: ogy to optimise the polymer struc- of standalone bioethanol-to-buta- offering advanced wet-grip and ture for advanced abrasion resistance diene plants and those integrated rolling-resistance properties in while maintaining processability. The into fossil-based butadiene produc- tires, including those for electric advanced SBR is currently being test- tion sites. To deliver this, the team vehicles (EVs). With Sprintan 918S, ed by customers worldwide, with developed a new catalyst system to the optimised styrene/vinyl-group plans to commercialise some grades increase the energy-ef ciency and microstructure – in combination in 2021. Next target is to improve bio-butadiene yield of the Lebedev with functionalisation – is said to the wear resistance by a further 20% process. The result could be a signif- enhance wet braking performance and to increase the stability of the icant enhancement of sustainability at a relatively low glass transition polymer in the compound. indices across the synthetic rubber temperature. This, in turn, im-

EUROPEAN RUBBER JOURNAL • July/August 2020 SUSTAINABILITY

proves wear performance. Since its recent introduction to the market, Position COMPANY PROJECT SCORE the material is said to be generating strong interest for EVs, UUHP/UHP 1 Asahi Kasei New-generation SBR technology 528 summer, all-season and even winter tread applications. ETB Bio-butadiene from ethanol for tire production 525 2 Trinseo Highly-functionalized S-SBR grade 525

3 Tyromer Tire-to-tire recycling 521

4 Continental Eco-rubber hose 510

5 Covestro Sports flooring based on CO2 494

6 Behn Meyer Europe Epoxidised filler technology 459

7 Cabot Corp. Engineered elastomer composites 447

8 Flinders University Self-repairing rubber 440 JUDGING REMARKS: • With a view to electric mobility, this 9 Mitsubishi Chemical – MCPP Incorporating renewable carbon in TPEs 430 product de nitely has signi cant market potential. 10 Kraton Corp. IMSS technology 424 • Innovative product that could have a signi cant effect on fuel reduction, which is important. questions in the applications area and • Similar to Asahi entry, but the mech- about the next development steps anism of better ller-dispersion and polymer- ller interaction is less First ever ranking of projects contributing most to raising clearly detailed. 4 the environmental pro le of the elastomers/rubber industry Continental / Eco-rubber garden hose 3 Tyromer / Tire- The strength of this project-entry is that it has delivered a pipeline taking to-tire recycling a bio-ethylene monomer from sugar PR: While devulcanisation has long cane to a fully commercial product. been the ‘holy grail’ for rubber re- The R&D work involved led to Arlanx- cycling, it remains a challenge to eo’s development of an optimised achieve properties anywhere close bio-EPDM compounds able to match to those of virgin polymer. This pro- the performance of conventional pe- ject uses twin-screw extrusion to troleum-derived polymer. The gar- Here, a CO2-based polyol enabled carefully process ELT rubber crumb den-hose project is linked a broader sport surfacing maker Polytan to create ABOUT THE and other waste rubber – with en- programme at Continental; targeting a sustainable binder for hockey pitch- TOP 10 TABLE couraging results. Since 2016, a similar products containing up to es. This replaced an oil-based binder Since early 2020, com- facility within AirBoss Rubber Solu- 95% of renewable and reclaimed/ for the arti cial turf, which typically panies and individuals tions has supplied ‘tire-derived pol- recycled feedstock and materials – in- contains an elastic underoor compris- have been invited to ymer’ (TDP) to KAL Tire. The client cluding that from end-of-life tires and ing recycled styrene-butadiene rubber supply E4S entries via has used it in an OTR retread com- other rubber products. granules. The rst successful installa- an online link on the pound with 20% content, as well tion was at the CHTC hockey club in ERJ website. From the as OTR, truck and passenger tires JUDGING REMARKS: Krefeld, , a venue for interna- strongest 20 contenders, with 15-20% TDP. Products are cur- • Commercialisation is key to achieve- tional matches. Polytan’s sports oor- the expert judging panel rently on road trials in N. America ments in sustainability. This project ing employing the CO2-based binder assessed each project and Europe while a car tire maker seems to succeed in this point is now sold and installed globally. The on the basis of: Quality is optimising compound with 30% • Sugar cane to EPDM rubber is real- next goal is to apply the CO2 technol- of the presentation; level TDP. A second TDP facility is nearing ly an Arlanxeo innovation. I like the ogy to the arti cial turf backing, there- of innovation; USP; Com- completion in Windsor, Ontario to potential in many other applications. by making the entire ooring system mercial potential; and supply a top American brand. With even more sustainable. Contribution to sustaina- nancial support from the Dutch bility. Along with ratings government, a third TDP plant is JUDGING REMARKS: for overall strength and being built in The Netherlands to 5 Covestro / Sports • A smart project, about using less weakness, the system supply a top brand in the EU. Fur- flooring based on CO2 crude oil and integrates CO2 into the allowed for a maximum ther plants are planned worldwide. production process. Extension beyond score of 700 points. This project stems from Covestro’s binders would be a good achievement JUDGING REMARKS: development – with partner RWTH • Covers a complete value chain, plus • If it really works the way it is present- Aachen – of a process for CO2 utilisa- the innovative use of CO2 as a pol- ed, the innovative power is very high. tion in polymers, which is said to save ymer feedstock. • Project using simple process. Some up to 20% of crude oil in production. CONTINUED ON PAGE 40

July/August 2020 • EUROPEAN RUBBER JOURNAL SUSTAINABILITY

in rubber properties include: 20% Mitsubishi Chemical’s TPE com- E4S JUDGING lower hysteresis, 25% higher rein- pounds utilise ‘renewable’ carbon The expert panel forcement, delayed crack initiation derived from PCR/PIR streams, bi- comprised: and 70% slower crack growth. omass or carbon capture. They are Prof James Busfield, Off-road tires – already being said to overcome barriers to using professor of materials & commercially used in the mining bio-based or recyclate materials in national teaching fellow industry – are a particular focus TPEs for applications requiring high director of industrial en- with potential for fuel-efficient on- levels of technical performance, reg- gagement & head of the road tires also being explored. ulatory compliance and quality-con- soft matter group, Queen sistency. Formulations can include JUDGING REMARKS: 40% of bio-based carbon, or up to Mary University of London. • Very good process, using experience 70% of recyclate, for a wide hard- Dr. Christoph Sokolowski, CONTINUED FROM PAGE 39 of previous work and patents. Clear ness range – both options available lead on ‘sustainability’ is- strategy, clear impact. in natural colour. Early applications sues within the German rub- 6 Behn Meyer / include over-moulded grips, sanitary ber industry association the parts and industrial seals, with MCPP WDK (Wirtschaftsverband Epoxidised NR filler 8 Flinders University also expecting commercialisation in der deutschen Kautschukin- technology the , especially of dustrie), based in Frankfurt This project addresses two impor- / Self-repairing rubber bio-based solutions for interior parts. am Main, Germany. tant aspects of sustainability: the Tapping the ability of certain rub- Martyn Bennett, who replacement of fossil-based materi- ber materials to self-repair is an in- JUDGING REMARKS: has recently founded als in tires and rubber products; and triguing area of polymer research, • Interesting approach, though the UK-based consultancy reducing abrasion and, thereby, with particular implications for re- commercialisation path is unclear Midsomer Science, after the potential contribution of tires use and recycling. This Australian • Even many minor achievements a career spanning over 30 to ‘microplastics’ pollution. This is research team has focused in on a can add up to a signi cant advance years at Avon Rubber plc, achieved via a process technology specially developed polymer based in sustainability most recently as chief sci- that overcomes the challenges of on sulphur, canola oil and dicyclo- entist and head of its AR- incorporating silica-silane systems pentadiene. Their ndings show TIS consultancy service. in epoxidised natural rubber com- how polysulphide groups on the 10 Jiří Brejcha, head of pounds. While work to commercial- polymer surface react in the pres- Kraton Corp. / Brejcha Rubber Consult- ise the technology is still ongoing, ence of pyridine catalyst at room IMSS technology ing, and former materials the R&D effort and ndings to date temperature to undergo S–S me- represent a potentially signi cant tathesis that joins together polymer development specialist at step towards that important goal. pieces into a new shape. The new Trelleborg Wheel Systems, rubber could, they say, be used to and before that Mitas, JUDGING REMARKS: make products including car tires, Prague, Czech Republic. • Part of their long-term develop- which can be fully repaired and re- ment around extending the use of stored to original strength in min- sustainable materials. Background utes at room temperature. of the project is very well prepared. Good combination of materials and JUDGING REMARKS: processes. • If the project can bring its power to • ENR incorporating silica – an older tires, the contribution to sustaina- story than other submissions. bility could be high • Self-healing chemistry is still a long way from commercialisation Kraton has put in some serious 7 Cabot Corp. / work in developing a challenger to CAN YOUR PROJECT Engineered elastomer 9 slush-moulded PVC in automotive CHART HIGHER? MITSUBISHI instrument panel skin applications. composites As well as matching the ne-gauge As the E4S rankings CHEMICAL - MCPP / Cabot has applied some signifi- processability and physical properties will be updated on a reg- cantly innovative mixing technol- Incorporating renewable of the established polymer, the new ular basis, companies and ogy to provide rubber compounds carbon in a range of HSBC also offers bene ts in terms of individuals are invited to for tire and non-tire rubber ap- applications lower part weight, reprocessability, enter for review new pro- plications. The patented mixing non-fogging and lower energy-con- jects throughout the year. process results in three times less sumption during transformation. Ex- The next Top 10 is sched- undispersed carbon black in rub- citement mounts as the rst (of sev- uled to be published in the ber compounds than conventional eral) commercial car model with the Nov/Dec issue of European mixing methods. The enhanced Kraton IMSS technology is scheduled Rubber Journal magazine. levels of filler dispersion are said to to start production in Q4 2020. Please visit the ERJ web- improve the performance, safety site for details of how to and lifespan of tires, while reduc- JUDGING REMARKS: enter your company’s pro- ing the environmental impact of • The potential is indeed high if the ject for review. production. Stated improvements material can outsmart PVC

Further details of all the Top 10 projects will be published on the ERJ website.

EUROPEAN RUBBER JOURNAL • July/August 2020