Eco2 Powerpoint Master

VESTAMID® Terra High performance biopolyamides reinforced with High Performance Polymers high performance biofibers Growth Line – Resource Efficiency

Dr. Benjamin Brehmer, June 18th, 2013 Natural fibers can increase the mechanical performance while maintaining bio-content

Basic properties of the Vestamid Terra and comparable polyamides

Property Unit PA66 PA610 PA1010 PA1012 PA12 E-Module MPa 2500 2100 1700 1300 1400 Tensile Strength MPa 83 61 54 40 46 Water Uptake % 8.2 3.3 1.8 1.6 1.5 Melting Point °C 258 222 200 180 176

Global Warming Potential kg CO2 7.9 4.6 4.0 5.2 6.9 Biobased Content % of C 0 63 100 45 0 • Motivation of adding fiber reinforcement is to increase… …E-module and tensile strength • Motivation of adding natural fiber reinforcement is to maintain… …the high bio-based content of the compound

The addition of fiber reinforcement will change all the basic properties

Brehmer – World Congress on industrial Biotechnology page | 2 First stage is to compound the material as would be done in a normal operational procedure

Compound schematic and process conditions

Polymer Natural Fiber • Compounding temperature: 180 - 230°C • Throughput: 5 – 10kg/h • Screw configuration: SK524 • Screw rotation: 200 - 300rpm

Vacuum Degassing Atmospheric Degassing

Pelletizer Die 1 2 3 4 5 6 7 8 9 10 11 Air knife Water Bath Temp. Ramp Compounding Temperature

• Feeding of natural fibers can be problematic (uncontrolled dosing) • Used forced vertical dosing (dual screw type) • Water content of fibers can be problematic (void space, surface damages) • Used atmospheric and vacuum degassing, extra post-dyring needed • Thermal stability of certain natural fibers can be problematic (discoloring, smell) • Used the lowest temperature profile possible Brehmer – World Congress on industrial Biotechnology page | 3 The second stage is the injection molding to test the material for a diverse range of properties

Produced molded parts for testing

Tensile Bars • Mechanical testing

3-Stage Plate • Visual testing

Objectives and Forms Pellets Texture Plate • Surface and subjective testing • Flowability

Brehmer – World Congress on industrial Biotechnology page | 4 Fiberglass will be used as the basis for comparison as it is the global standard

Mineral glass fiber Nearly all injection molded polymers, when reinforced are reinforced with chopped fiberglass • It is the true standard, used for comparison Fiberglass originates from silica found in sand and it has a relatively high energy consumption Fiberglass is known for a good thermal and electrical stability Source • Thermal stability for processing well above 380°C • Sand / Silica

Price indication: Mid-range

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 15 – 20 0.5 – 0.7 73 – 75 6 - 8 0 Purchased • Chopped, clear/white Brehmer – World Congress on industrial Biotechnology page | 5 Basalt fiber is not a “wood” fiber, but does comes from natural sources and is promising

Basalt fiber Fiber reinforcements with basalt fibers are under investigation, many composite projects as alternative to carbon fiber • It will serve as the other natural fiber alterative Basalt fibers originates from frozen lava and is produced by extruding molten basalt rock; readily available Known for a high strength and very high thermal stability Source • Thermal stability for processing well above 650°C • Lava rock of basalt

Price indication: Mid-range

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 7 – 24 0.1 – 0.2 93 - 110 3 - 5 0 Purchased • Chopped, golden/shinny Brehmer – World Congress on industrial Biotechnology page | 6 Cellulose fibers are well known and purist form of natural fibers, but have limited potential

Cellulose fiber Through a joint venture (Daicel) Evonik has access to cellulose fiber derivatives • It will serve as the lowest grade filling fibers Cellulose fibers originate from the processing of cotton and is related to cellulose acetate Known for a relatively high thermal stability Source • Thermal stability for processing below above 230°C • Cotton or lumber

Price indication: Lower-range

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 10 – 15 4 – 6 5 - 10 0.2 – 0.8 100 Purchased • Loose, powdery/white Brehmer – World Congress on industrial Biotechnology page | 7 Regenerated cellulose fibers are further altered to add strength and thermal stability

Regenerated cellulose fiber (Rayon) Many names such as rayon, viscose, regenerated cellulose and mainly used in tire cord, now studies in composites • It will serve as the finest grade filling fibers Rayon fibers originate from the processing of lumber/wood Known for a high thermal stability and adhesion to plastics and is less abrasive than fiber glass (injection molding) Source • TGA show first degradation at temperature above 240°C • Pulp or lumber

Price indication: High-range (without sizing agent)

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 11 – 13 10 – 13 15 - 25 0.6 – 1.3 100 Purchased • Spoils/chopped, yellowish Brehmer – World Congress on industrial Biotechnology page | 8 Bamboo fibers are abundant and faster growing, providing a good CO2 emissions reduction

Bamboo fiber Bamboo fibers are dependent on the plant grades and harvesting season, can also come as “white” Bamboo fiber is widely available by direct plant mulching • It will serve as the cheapest grade filling fibers Known for a relatively low thermal stability, yet has been tested with other polymers (e.g. PP) to make WPC Source • Degradation begins between 210 to 240°C • Bamboo (Asia)

Price indication: Very low-range

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 10 – 40 6 – 10 10 - 20 0 – -3.5 100 Purchased • Loose fibers, light brown Brehmer – World Congress on industrial Biotechnology page | 9 Aspen wood fibers are also abundant while providing a good CO2 emissions reduction

Aspen wood fiber Aspen fibers are dependent on the tree grades and harvesting season, can also be bleached “white” Aspen fiber is widely available by direct plant mulching • It will serve as the temperate grade filling fibers Typically used in the pulp and paper industry, yet has been tested with other polymers (e.g. PP) to make WPC Source • Degradation begins between 210 to 240°C • Aspen tree (America/EUR)

Price indication: Very low-range

Average Water E-module Global Warming Bio-content Diameter Content Potential µm % GPa kgCO2/kg % of C 40 - 100 10 – 15 10 - 15 0 – -3.5 100 Purchased • Loose fibers, off-white Brehmer – World Congress on industrial Biotechnology page | 10 The mineral fibers are clearly the strongest followed by viscose/rayon and lastly natural

Resulting tensile modulus of selected/tested fibers with Terra DS

12000 Glass Basalt Cellulose 10000 Viscose Bamboo Aspen Linear (Glass) Linear (Basalt) 8000 Rayon/Viscose Linear (Cellulose) • Ideal reinforcement curve Linear (Viscose) Linear (Bamboo) Linear (Aspen) Density… 6000 • The density of natural fibers is lower then

mineral E-Module (MPa) E-Module 4000 • compensate lower weight •Natural fibers have difficulties above 50% • Cellulose, Aspen, Bamboo 2000

0 0 5 10 15 20 25 30 35 40 45 50 55 Fiber Content (%)

Brehmer – World Congress on industrial Biotechnology page | 11 The natural fibers encounter a wide range of processing issues in addition to lower strength

Resulting overview of some of the problematic issues Fiber Type Dosing Water content Color Smell

Glass NP No issue None None Basalt NP No issue Light brown None Cellulose Hard above 15% Needs drying Light brown Minor above 15% Viscose Hard Needs drying Brown above 15% Minor above 30% Bamboo Uneven Major issue Black above 30% Burnt smell Aspen Uneven Major issue Dark brown above 30% Burnt smell

• Of the natural (bio-based) fibers tested, viscose is the most promising • Difficulties arise when processing approaching 50% (not linear E-Module improvement) • Shearing forces and residence time likely bring above 240°C • Only has a minor smell at high fiber contents • The direct natural wood fibers are wet and degrade quickly • Could nonetheless be interesting for some applications • Smell tends to decrease after storage

Brehmer – World Congress on industrial Biotechnology page | 12 The results were brought to a technical flyer and launched as a new product offering

Dissemination of VESTAMID® Terra “VF” grade results

Basic technical information • Terra HS16 VF10  VF50 • Terra DS16 VF10  VF50

A press release was also prepared to inform as a part of the marketing stratgy

Brehmer – World Congress on industrial Biotechnology page | 13 Thank you for you attention!

VESTAMID® Terra is • Made from plant (bio-sourced) • Environmental friendly • Reduces global warming potential • High performing ® • Competitive against existing polyamides VESTAMID Terra • Can be reinforced with natural and mineral fibers because we care…

Brehmer – World Congress on industrial Biotechnology page | 14