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INEOS Styrolution Styrenics Innovations in Multi-Layer Styrenic Structures

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INEOS Styrolution Styrenics Innovations in Multi-Layer Styrenic Structures Cliff Pettey Market Development ABS Standard Products Presentation Overview Introduction to INEOS Styrolution • Company Portrait • Product & Process Overview • Manufacturing – Americas Region Multi-Layer Extruded Sheet • Overview – Engineered Structures • Physical Property Characteristics • Summary Introduction to INEOS Styrolution Company Portrait Global Chemical Companies DowDuPont 79.5 BASF 77.4 Sinopec 67.3 INEOS 60.0 SABIC 39.9 Mitsubishi 35.0 LBI 34.5 Exxon Chem. 28.6 Air Liquide 24.5 LG Chem 24.0 Toray 20.7 Sumitomo 20.6 Linde 20.5 Johnson… 19.8 Sales in 2017 (US$ bn) Reliance 19.2 Source: ICIS and INEOS Sept 2018 Merck KgaA 18.4 Evonik 17.3 Covestro 16.9 PPG 14.7 Ecolab 13.8 INEOS Styrolution at a glance Introduction to INEOS Styrolution Product and Process Overview ABS Feedstock Chain 60% Benzene Ethyl Styrene Benzene Ethylene 20% Crude C4 Butadiene Propylene 20% ® Acrylonitrile Lustran ABS Terluran® ABS Ammonia Structure - Property Relationships ABS As ________ increases then, SAN phase • Polybutadiene content SAN graft shell ↑ Impact/toughness ↓ Modulus/stiffness ↑ Melt viscosity ↓ Specular gloss • Molecular weight of matrix ↑ Impact/toughness ↑ Modulus/stiffness ↑ Melt viscosity Polybutadiene rubber core • Acrylonitrile content ↑ Modulus/stiffness ↑ Chemical & heat resistance Rubber Morphology – Emulsion ABS Before Agglomeration Emulsion Polymerization acrylonitrile, styrene, butadiene polymerization aids precipitation rubber powder Process Detail - Emulsion ABS Grafted Rubber Water Salt (+ Acid) Butadiene Emulsifier Grafting Water Polybutadiene (Rubber) Rubber Rubber Base Precipitated Rubber SAN Lustran® ABS Terluran® ABS Process Detail - Mass ABS Additives: Mineral oil Anti-oxidants Grafted & occluded Initiators rubber particles in polymer matrix Styrene Acrylonitrile Polybutadiene rubber grafting Devolatilization with styrene/ acrylonitrile Polybutadiene (Rubber Syrup) Pelleter Pre/Stage 1 Stage 2 Polymerization Polymerization Lustran® ABS Summary of Attributes Mass vs. Emulsion ABS Mass (mABS) Rubber Particles (mABS) • Advantages – Lower residual VOC(s) – Consistent color – Fewer gels and acrylonitrile hard spots – Consistent extrusion processing – Deep draw capabilities – Large rubber particles – Very low gloss capabilities – Competitive cost structure • Disadvantages – High gloss is low compared to emulsion – Less recipe flexibility – Generally, low/medium impact Summary of Attributes Mass vs. Emulsion ABS Rubber Particles (eABS) Emulsion (eABS) • Advantages – High gloss possible – Smooth appearance – Can be very high impact – Can have better chemical resistance – Can combine low viscosity and high impact resistance – Pre-colored and plating grades • Disadvantages – Higher residual VOCs – Increased yellow color – Higher color shift when exposed to UV – High capital costs Introduction to INEOS Styrolution Manufacturing – Americas Region Styrenic Copolymers - Americas ALTAMIRA • 2000: Copolymers Start-up • 2014: AMSAN process start up • 2017: Expansion of ABS – ~ 18,000 MT/yr • 2020: ASA expansion, Bayport, TX – 100,000 MT/yr – ~ 70,000 MT of additional ABS (Altamira) • Capacity: 185 kt. (408 MM lbs.) • Products: – Styrene Acrylonitrile (SAN) – Acrylonitrile/Butadiene/Styrene (ABS) – High Heat ABS (AMS-ABS) – Acrylonitrile Styrene Acrylate (ASA) Styrenic Polymers - Americas ADDYSTON1 • Location: Cincinnati, Ohio • Capacity: 180 kt. (397 MM lbs.) • Products: – Styrene Acrylonitrile (SAN) – Acrylonitrile/Butadiene/Styrene (ABS) – High Heat ABS (AMS-ABS) – Styrenic Specialties 1INEOS Styrolution acts as exclusive distributor for the INEOS ABS plant in Addyston, Ohio. Multi-Layer Extruded Sheet Overview - Engineered Structures Trial Overview (Materials and Set-up) Skin Layer (s) – A & C Core Layer - B • NAS® SMMA • Lustran® mABS – Material: Styrene acrylic copolymer – Material: Acrylonitrile styrene butadiene – Grade: XC – UV – Grade: 552 – Color: Clear – Color: Natural • Luran® S ASA Extruder & Sheet Overview – Material: Acrylonitrile styrene acrylate – Grade: 797SE • Three-Layer: A / B / (CD) – Color: Natural – Ext A: 10% of total thickness (4 mils) • Screw - 2.5” dia., L/D – 34:1 • Terluran ® ABS – Ext B: 80% of total thickness (32 mils) – Material: Acrylonitrile styrene butadiene • 3.5” 3.5” dia., L/D – 34:1 – Grade: EHI-7 – Ext C/D: 10% of total thickness (4 mils) – Color: Natural • Screw - 1.5” dia. ea, L/D – 24:1 Datasheet Physical Properties (Injection Molded) NAS XC-UV Lustran® 552 Luran® S 797SE Terluran® EHI-7 Units (SMMA) (mABS) (ASA) (eABS) Melt Flow Rate g/10 min 28.9 6 5 7 (220°C/10 kg) Notched Izod Impact ft-lb /in ---- 4.9 1.1 7.1 (23°C) f Tensile Modulus psi 508,000 290,000 265,000 315,000 (23°C) Tensile Yield psi 9,100 5,200 5,800 6,300 (23°C) Tensile Elongation % 4 28 2.9 9.2 (23°C) Vicat Softening Temp °C 104 95 90 100 (VST/A/50) Extruded Gloss – No Polish 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 797SE blk (ASA) EHI-7 wht (eABS) 552 nat (mABS) NAS XC-UV clear (SMMA) 60° 20° Extruded Gloss – High Polish 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 797SE blk (ASA) EHI-7 wht (eABS) 552 nat (mABS) 552 wht (mABS) 60° 20° Co-Extrusion: Lustran® mass ABS • SMMA – PMMA Acrylic – Increased modulus/stiffness – High gloss Enhanced – Water clarity (wet finish appearance) Optics • Acrylonitrile Styrene Acrylate (ASA) – Chemical resistance Increased Ultraviolet Chemical Resistance – Color fastness Resistance – Weather resistance • Emulsion ABS – High gloss Increased – Brilliant colors Stiffness – High impact resistance Multi-Layer Extruded Sheet Physical Property Characteristics Performance Target: High Gloss – Clear UV • ASA Layer – 2 mils C/D: 2 mils – Chemical resistance 98% ASA: 797SE NR 2% Black – UV resistance – Inside layer, high gloss • mABS Core Layer – 36 mils Extruder B: 36 mils – Cost performance 98% ABS: 552 2% White – Large rubber particles = great thermoforming draw characteristics – Easy color – Low gel content, minimal/no AN hard A: 2 mils spots or crosslinked rubber gels 100% NAS XC UV • NAS XC-UV Cap Layer – 2 mils – Exceptional gloss, regardless of process – “Wet” surface appearance Performance Target: UV/Chemical Resistance • Outdoor Applications C/D: 2 mils 98% ASA: 797SE NR – Materials 2% Black • Luran S® ASA 797SE • Lustran® mABS 552 • Terluran ® eABS EHI-7 Extruder B: 34 mils – How Does it work? 98% ABS: 552 2% White • ASA: Chemical/UV resistance • ABS 552: Large particles for broad thermoforming process window and economics A: 4 mils 98% ABS: EHI-7 2% White • ABS EHI-7: Smooth, super high gloss surface. Easy to color Performance Target: UV/Chemical Resistance • Outdoor Applications – 2 Layer C/D: 5 mils 98% ASA: 797SE NR – Materials 2% Black • Luran S® ASA 797SE • Lustran® mABS 552 – How Does it work? Extruder B: 35 mils • ASA: Chemical/UV resistance 98% ABS: 552 2% White • ABS 552: Large particles for broad thermoforming process window and economics – Target Properties: Low Gloss applications requiring a barrier to UV protection and chemical resistance Tensile Modulus (Extruded Sheet – 40 mil) 2,200 2,100 2,000 1,900 1,800 Modulus (MPa) 1,700 1,600 1,500 552 (nat) ASA-mABS-SMMA ASA-mABS-eABS ASA-mABS-eABS (r) mABS-ASA Machine direction Transverse direction Tensile Yield (Extruded Sheet – 40 mil) 41 39 37 35 33 31 Yield Strength (MPa) 29 27 25 552 (nat) ASA-mABS-SMMA ASA-mABS-eABS ASA-mABS-eABS (r) mABS-ASA Machine direction Transverse direction Tensile Elongation (Extruded Sheet – 40 mil) 140% 120% 100% 80% 60% Elongation (%) Elongation 40% 20% 0% 552 (nat) ASA-mABS-SMMA ASA-mABS-eABS ASA-mABS-eABS (r) mABS-ASA Machine direction Transverse direction Multi-Layer Extruded Sheet Summary Summary • Lustran® & Terluran® ABS can be used in conjunction with specialty styrenic products to build multi-layer structures with engineering polymer performance and value differentiation. • INEOS Styrolution has the broadest portfolio of ABS and specialty styrenic products to take on the challenge of meeting the needs of the most difficult applications. Contact Information • Lustran® and Terluran® ABS • Mr. Cliff Pettey – Market Development • E: [email protected] • Luran® S ASA • Mr. Milton Thomas – Technical Marketing Mgr. • E: [email protected] • NAS® styrene acrylic copolymer • Ms. Yaaxnic Magana – Market Development • E: [email protected] For more information visit www.ineos-styrolution.com Does Anyone Know What Happened Here?.
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