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Lehigh Technologies CONFIDENTIAL “Technology and Innovation in the use of Micronized Rubber Powder in today’s Green World” 11 April, 2013 CONFIDENTIAL • Setting the Stage and What we are Learning • Who is Lehigh Technologies • Technical Presentation • What Does it All Mean in Terms of Green? 1 | Lehigh Technologies Inc. Millions of End-of-Life Tires Generated Each Year Energy Recovery Civil Engineering Landfill Stockpiled Data Not Available 292 250 112 80 30 2 | Lehigh Technologies Inc. 2 CONFIDENTIAL The First Chemical Revolution 1800s 1850-1900 1900-1930 dyes/pigments oil and gas cracking/refining discoveries metals synthetic chemistry carbohydrates soaps atomic theory and the chemical bond 3 | Lehigh Technologies Inc. 3 The World Today – 3 Challenges 4lbs /person/day oil prices over $80 world population and spiking to 7B people >$100/bbl over 200 million tons per year 1 billion in the borrow-buy-burn developed world is US energy consume as much strategy energy as the other 6B. 4 | Lehigh Technologies Inc. 4 The Second Chemical Revolution Bury or burn is not a solution infinite cycles of Vast resource pools available use • Huge technology challenge • • sustainable Must be waste based. production of Amyris, Kior, Renmatix, Genomatica building blocks • Small companies leading • • efficient use of Principles of Green Chemistry existing carbon Chemical companies leading sources • • 5 | Lehigh Technologies Inc. 5 Micronized Rubber Powder Industry – Lehigh Experience Image of industry: Reliability of supply-process safety; quality Scale-not capable of supporting global applications Capitalization “Tried it 15 years ago – didn’t work” Absence of technical knowledge: No shortage of conjecture Very little data-insufficient experimental rigor Potential customers “ on their own” No technical knowledge = no adoption Long sales cycles: All performance markets have long development cycles-testing, optimization, re- testing, production trials, optimization-launch-that’s why stuff works! All markets need foundational knowledge and technical support-customers rarely have sufficient resources to do this-mindset matters. 6 | Lehigh Technologies Inc. 6 Infinite Uses – The Next Steps Change in mindset: Move from “getting rid of waste material” to “supplier of specialty materials”. Good science and technical support drive adoption. This changes the way everything is done. Raw material type and structure: Different rubber compositions and tire components behave differently in complex formulations-tire compounds, asphalt systems, plastics etc. Only limited ability to provide discrete raw materials for specific uses. This requires “demand” and “capability”. History suggests that the value proposition enables adoption not subsidies: Chemical building blocks have always delivered performance at economic cost No customer pays more unless the material delivers more Bio-based feedstocks, solar cells etc are burdened with this issue We must drive to provide value and performance- 7 | Lehigh Technologies Inc. 7 Lehigh Technologies: Overview Key Facts Headquartered in Tucker, GA Founded in 2003 75 employees Blue Chip Investors: Third Party Tire Recycler Tires Asphalt Proven Technology Plastics +140 million tires manufactured utilizing Lehigh’s PolyDyne™ Coatings 45,000MT of annual manufacturing Sealers capacity Others 5 out of top 10 tire manufacturers companies are Lehigh customers Lehigh Technologies is a technology driven green materials Up-cycle post-consumer scrap manufacturer that turns end-of-life tires and other post-industrial rubber into sustainable powders that are used in a wide range of ISO 14001 / 9001 Certified high-value industrial and consumer applications. PolyDyne / MicroDyne Lehigh Technologies Particle Sizes Range from 40 to 300 Mesh – Clean: Metal & Fiber Free 40 Mesh / 400 µ 80 Mesh / 180 µ 140 Mesh / 105 µ PolyDyne 40 PolyDyne 80 PolyDyne 140 200 Mesh / 75 µ 300 Mesh / 50 µ PolyDyne 200 PolyDyne 300 Expanded Product-Line to Include EPDM, Nitrile, Butyl & Natural Rubber Powders in Certain Sizes 9 | Lehigh Technologies Inc. 9 CONFIDENTIAL CONFIDENTIAL Optimization of Rubber Compounds: Incorporating Sustainable, Micronized Rubber Powders Agenda Introduction Experimental Results and Discussion . Addition Point of Micronized Rubber Powder (MRP) . Sulfur-Accelerator Optimization . Particle Sizes Summary of Findings and Recommendations 11 Introduction The status of End-of-Life Tires1 The need for the work . On a global basis each year, one . The rubber rheological and billion tires become unusable physical properties are adversely and are classified as end-of-life. affected when MRP is added to In the European Union, the the mix practice of land filling tires was banned in 2006. Cure rate and viscosity increases . There is much work yet to be General physical property decline done worldwide to encourage Reduced performance in abrasion, higher heat build-up and and teach rubber article compression set, and increased producers ways to incorporate hysteresis more micronized rubber . powder, MRP, into new rubber Many rubber article products. manufacturers do not modify their base recipes when incorporating MRP. 1. ETRMA source document 12 Introduction Many researchers have offered explanations for the reported losses in rheological and physical properties when incorporating MRP into new rubber 1-9 . MRP particles in new cured rubber are discontinuities and act like stress-raising flaws.4 . Scanning electron microscope (SEM) photographs showing improper bonding of MRP to the new rubber matrix.6 . The decreased modulus is caused by sulfur in the new rubber matrix migrating into the MRP causing a lower cross-link density in the final product.2,3,9 . The shorter scorch times and faster cure rates which are explained by the migration of accelerator fragments from the MRP into the new rubber matrix.3 . Trouser tear resistance actually improves slightly and this effect was explained by the theory of crack tip blunting.4 . Reviews and summaries were presented previously by this author elsewhere.7,8 1. D. Gibala, K. Laohapisitpanich, D. Thomas, G. R. Hamed, Rubber Chem. Technol. 69, 115(1996) 2. R. A. Swor, L. W. Jensen, M. Budzol, Rubber Chem. Technol. 53, 1215(1980) 3. D. Gibala, G. R. Hamed, Rubber Chem. Technol. 67, 636(1994) 4. D. Gibala, D. Thomas, G. R. Hamed, Rubber Chem. Technol. 72, 357(1999) 5. M. D. Burgoyne, G. R. Leaker, Z. Krekic, Rubber Chem. Technol. 49, 375(1976) 6. A. A. Phadke, S. K. Chakraborty, S. K. De, Rubber Chem. Technol. 57, 19(1984) 7. F. Papp, Technical Challenges for the Recycled Rubber Industry. Presented at the ITEC2010, Cleveland, Ohio, September 21-23, 2010 8. F. Papp, Optimization the Use of Micronized Rubber Powder, presented at a meeting of the Rubber Division, American Chemical Society, Cleveland, Ohio, October 11-13, 2011 9. Z. I. Grebenkina, N. D. Zakharov, and E. G. Volkova, International Polymer Science and Technology 5, No. 11, 2 (1978) 13 Experimental – Base Compound Addition Base Compound Ingredients Sequence PHR First Pass ESBR1500 (Non-oil extended) 70.00 First Pass High Cis Polybutadiene Rubber 30.00 First Pass Micronized Rubber Powder (MRP) From Whole Tire As Per Studies First Pass N339 Carbon Black 65.00 First Pass Heavy Naphthenic Process Oil 25.00 First Pass Homogenizing Agent 1.00 First Pass Alkyl Phenol Formaldehyde Novolak Tack Resin 3.00 First Pass 6PPD Antidegradant 2.50 First Pass TMQ Antidegradant 1.50 First Pass Microcrystalline and Paraffin Wax Blend 2.50 First Pass Zinc Oxide Dispersion (85% ZnO) 3.53 First Pass Stearic Acid 2.00 Finish Pass TBBS Accelerator 1.00 Finish Pass Sulfur Dispersion (80% Sulfur) 2.50 Finish Pass Retarder N-(cyclohexylthio) phthalimide 0.10 Total PHR Finish Batch 209.63 Density kg/l 1.126 14 Experimental Procedure All mixes were performed in a 1.6L MDR2000 Rheometer ASTM D 5289 Farrel Banbury internal mixer. @ 160°C . Mixing was conducted either as a two Tensile, Elongation, Modulus ASTM D or three pass mix 412, unaged & oven aged Milling was performed on a KSB 2- Trouser tear resistance, ASTM D 624 roll mill 33 cm x 15 cm. T, unaged & oven aged In all studies for each operation, Hardness tested with Rex Digital weighing, mixing, curing, and Durometer, ASTM D 2240 Type A on testing, a unique randomized rebound specimens sequence was employed to reduce BF Goodrich Flexometer ASTM D 623, or eliminate bias scatter of the data. Method A Some of the experimental designs Zwick Rebound ASTM D 7121 used replication of batches, and Zwick Rotary Drum Abrader ASTM D some of the designs with replicated 5963, Method A batches used a procedure of blending the master batches for Static Outdoor Exposure (20% Strain) reducing variation. ASTM D 518, Method A 15 Introduction MDR Rheometer 160°C Tread with 177 Micron RRP Normalized Physical Properties of Tread Normalized Time to Stated Property with 177 Micron MRP 120 120 100 100 80 80 60 60 Percent Percent 40 40 20 20 0 0 Control 3% 6% 9% 12% Control 3% 6% 9% 12% Control Scorch Ts1 T10 T90 Control Tensile Strength 300% Modulus Elongation @ Break Flexometer Heat Build-Up and Compression Set Normalized Abrasion Resistance Index and Rebound Tread with 177 Micron MRP @ 60°C Tread with 177 Micron MRP 200 180 120 160 100 140 120 80 100 60 Percent 80 Percent 60 40 40 20 20 0 0 Control 3% 6% 9% 12% Control 3% 6% 9% 12% 16 Control HBU Comp Set Control AR Index Rebound 60°C Addition Point of MRP Which addition point in the mix for the MRP gives better physical properties? . In the first master pass
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