ERJ Rubber Industry Players of the Week

This week we give this section over to the current Top 10 companies in our Elastomers for Sustainability (E4S) programme.

The ranking is set to change with new entries challenging strongly for positions as projects offering the most potential to improve the environmental profile of the global elastomers/rubber industry.

A top 20 list of contenders will be announced shortly in the ERJ Daily Newsletter - ahead of the revised Top 10 being revealed in the Nov/Dec issue of European Rubber Journal magazine:

 

The top entries for the inaugural staging of ERJ’s new Elastomers for Sustainability initiative has now been decided by our judging panel led by leading experts in the field of polymer science & technology.

E4S is an industry-first sustainability initiative, designed to highlight significant advances for end-user sectors including automotive, tires, automotive components, construction, consumer, industrial and medical.   

The judging process has culminated in the following Top 10 of materials-science-based developments, based on their potential to enhance the environmental profile of the elastomer/rubber industry.   

Position	Company	Project	Score
1	Asahi Kasei	New-generation SBR technology	528
2 (joint 2nd)	ETB	Bio-butadiene from ethanol for tire production	525
2 (joint 2nd)	Trinseo Europe	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 natural rubber filler technology	459
7	Cabot Corp.	Engineered elastomer composites	447
8	Flinders University	Self-repairing rubber	440
9	Mitsubishi Chemical – MCPP	Incorporating renewable carbon in TPEs	430
10	Kraton Corp.	IMSS technology	424

Details of all projects published in the July/Aug issue of ERJ magazine. The table will be revised and updated with new projects that score higher than any of the entries. Click the E4S Programme link to enter a project for the next Top 10, which will be published in ERJ Nov/Dec issue. 

About the Top 10 table

Since early 2020, companies and individuals have been invited to supply ERS entries via an online link on the ERJ website. From the strongest 20 contenders, the expert judging panel assessed each project on the basis of: Quality of the presentation; level of innovation; USP; Commercial potential; and Contribution to sustainability. Along with ratings for overall strength and weakness, the system allowed for a maximum score of 700 points.

The expert panel comprised: 

Prof James Busfield, professor of materials & national teaching fellow director of industrial engagement & head of the soft matter group, Queen Mary University of London.

Dr. Christoph Sokolowski, lead on ‘sustainability’ issues within the German rubber industry association the WDK (Wirtschaftsverband  der deutschen Kautschukindustrie), based in Frankfurt am Main, Germany.

Martyn Bennett, who has recently founded UK-based consultancy Midsomer Science, after a career spanning over 30 years at Avon Rubber plc, most recently as chief scientist and head of its ARTIS consultancy service. 

Ji?í Brejcha, head of Brejcha Rubber Consulting, and former materials development specialist at Trelleborg Wheel Systems, and before that Mitas, Prague, Czech Republic.

       

THE TOP 10 PROJECTS

         ASAHI KASEI

Title of product or project: Asahi Kasei's 6th generation styrene-butadiene rubber (SBR)

Main materials technologies involved
Original functional group and high molecular weight technology
Main goal or objective of the development project
The goal of this project is to achieve a 20%-improvement (reduction) of rolling resistance compared to the previous grade and an advanced wear resistance while maintaining processability

Technical challenges addressed by the project team
With the increasing demand towards  fuel efficiency and to overcome the microplastic issue, the requirements of rolling resistance and wear resistance are becoming increasingly important in recent years. 
One of the solutions to improve fuel efficiency of the compound is to introduce the functional group, which can interact or react to the surface of the filler to increase filler-polymer interaction, to the polymer used for the tire tread like SBR (styrene-butadiene-rubber). 
In addition, this higher filler-polymer interaction enhances the reinforcing effect of the compound and improves to the wear resistance. Wear resistance can be also improved by increasing the molecular weight of the polymer. 
However, both the functional group in the polymer, and high molecular weight of polymer cause processability issues. To overcome this problem, Asahi Kasei developed two special technologies; first, a special functional group which achieves a strong filler-polymer interaction to improve wear resistance and rolling resistance. 
In addition, we developed a new polymerization technology to optimize the structure of the polymer which gives advanced wear resistance while maintaining processability. By the combination of these technology, Asahi Kasei’s 6th generation SBR shows excellent rolling resistance, good processability, and better wear resistance.

What is the commercial status of the technology or product?
Our 6th generation SBR is currently being tested by many customers in the world and we are receiving positive feedback. We are planning to commercialize some grades in 2021.

Please describe the contribution of the technology or product to sustainability
Asahi Kasei’s 6th generation SBR can contribute to the reduction of fuel consumption. In addition, it can contribute to the reduction of microplastics generated from tires by improving wear resistance.

Scope for further enhancements to the technology or product
Our next target is to improve the wear resistance by 20% compared to the 6th generation SBR and to increase the stability of the polymer in the compound.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
The compound with this grade shows superior processability. Therefore, the mixing time or mixing stage can be reduced at the tire manufacturers, which contributes to reduction of CO2 emissions.

See also supporting information

 

ETB
 

Title of product or project: Bio-butadiene from ethanol for tire production

Main materials technologies involved
Catalytic conversion, synthesis of the catalyst, petrochemical products separation, butadiene purification

Main goal or objective of the development project
ETB technology is the way to obtain butadiene - one of raw materials for BR and SBR-rubber production, that are essential for tire manufacturing together with natural rubber. Nowadays green deal policy, circular economy and renewable polymers production trends becoming stronger and forcing manufacturers search for totally bio-based new materials or change different monomers to renewable one-by-one. 
Nowadays the market of butadiene is about 15 million tons per year and will grow up to 17.9 million by 2025. 
Our technology allows to obtain renewable end product by modification already established production chain: naphta-butadiene-polymer compound-tire, by adding Bio-Ethanol-to-Butadiene plant that can be constructed separately or implemented into fossil-based butadiene production site. This solution not only allows to obtain renewable source for rubber manufacturing, to add value for the customer and to raise sustainability index for all chain, but also to boost ethanol industry that suffer from strong dependence on petroleum demand.

Technical challenges addressed by the project team
Ethanol-to-butadiene process was realized in 20th century by Lebedev in USSR and by Ostromislensky in USA, but production of butadiene from naphta ousted this process from market due to low cost of the product. 
Nowadays, renewable polymer production trend is getting stronger and our team accepted the challenge to develop new catalyst using industrially produced carrier to avoid dependence on natural sources that Lebedev process had, to increase energy efficiency and yield of bio-butadiene. 
All together these properties make our technology interesting for polymer producers and allow bio-butadiene compete with fossil-based one.

What is the commercial status of the technology or product?
Up to now the technology is already developed, it has successfully passed laboratory and pilot tests and we can offer samples of crude bio-butadiene to potential customers. Our technology is getting ready for a commercialization, ETB is developing an engineering project for demonstration plant in the Netherlands and expect that first commercial scale batches will be obtained in 2-3 years.

Please describe the contribution of the technology or product to sustainability
Our technology is a way to obtain renewable bio-butadiene from ethanol for polymer production that allows to increase bio-based rubber content in tire up to 75%. 
The process requires less energy resources than Lebedev or Ostromislensky processes and reduces carbon footprint comparing with production of fossil-based butadiene.

Scope for further enhancements to the technology or product
Further enhancement of our technology can be done by developing new version of the catalyst, by purifying byproduct or recycling it back to the process, by improving a model of the reactor. All these measures can improve productiveness of the whole ETB process.
Other way of enhancement of the technology is implementing the plant to a rubber production chain and developing production from small tire producers to the biggest ones.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
Our technology allows not only to produce bio-butadiene, that is essential for polymer industries, but also to reduce carbon footprint and energy resources consumption.
In long term perspective construction of the plant and spreading of the technology will reduce fossil-based resources usage, increase positive contribution to the economy by supporting local biomass and ethanol producers and by job placement.

 

TRINSEO EUROPE GMBH  
 

Title of product or project
Highly-functionalized Sprintan 918S S-SBR: combining outstanding wet grip performance with very low rolling resistance in passenger car tread, enabling efficient EV mobility and increased fuel efficiency. 

Main materials technologies involved

Unique, proprietary, functionalization technology specifically developed for high-molecular weight oil-extended S-SBR, combining outstanding elasticity at low frequency (correlated to rolling resistance) with exceptional wet grip performance and wear resistance, while providing processing characteristics comparable to a non-functionalized S-SBR.
-    The unique microstructure (level of styrene and vinyl groups) has been optimized with the aim of achieving excellent wet braking performance at a comparatively low glass transition temperature, which in turn optimizes wear performance. 
-    In comparison to typical non-fx high grip SSBR (in passenger car summer tread), Sprintan™ 918S enables 15% improvement in rolling resistance lab indicator, as well as 8% better wet grip. Lab wear indicator shows a 20% improvement.

Main goal or objective of the development projectt

Eectric vehicles, with their high curb weight and ample torque are putting tires under severe levels of stress and strain. At the same time, to extend the battery range as much as possible, the lowest possible rolling resistance in the tires is a must. And for this combination of seemingly conflicting properties, Sprintan 918S ticks all the boxes, making it the ideal choice but not limited to electric vehicle tire tread. Of course, summer, all season, and even winter tires for other types of passenger cars can benefit greatly from the unique performance balance of Sprintan918S.

Trinseo has a strong track record of developing functionalized S-SBR for improved rolling resistance in tire applications, and Sprintan 918S is another example.

Before this grade was developed, high-grip S-SBR usually had high glass transition temperatures and its use was limited to UHP or UUHP summer tread applications. Traditionally optimized for wet grip, these polymers did not principally contribute towards improving rolling resistance in tire tread. Today’s requirements, however, are increasingly stringent towards CO2 emission reduction and require products that enable more efficient e-mobility. 

The new grade was developed exactly with such requirements in mind while still promising outstanding grip performance and improved wear resistance.

Technical challenges addressed by the project team

The main challenges in the development of medium-Tg functionalized S-SBR Sprintan 918S lay in achieving the required high wet grip performance at a comparatively low polymer glass transition temperature. Careful fine-tuning of the micro- and macrostructure, in combination with the functionalization technology was carried out to ensure that low-temperature performance as well as wear resistance could still benefit from high main chain flexibility. In order to maximize the fuel efficiency potential, strong polymer-filler interaction through reactive functional elements was designed into the grade, while still maintaining adequate processing of the compounds during mixing and extrusion in tire production. 

What is the commercial status of the technology or product?

Sprintan 918S has recently been introduced to the market and is enjoying a strong interest from customers who recognize the value of its outstanding performance balance in tires for EVs, UUHP/UHP Summer-, All-season- and even Winter tread applications.

Please describe the contribution of the technology or product to sustainability

The use of SPRINTAN™ 918S in tire tread allows a reduction of the tire rolling resistance, which reduces the amount of energy required to travel a given distance. This consequently reduces fuel consumption or extends the range of electrical vehicles.

90% of energy consumption over the life cycle of a tire is attributed to the tire use-phase, in the form of the fuel consumption of the vehicle. Therefore, developing new polymers and compounding concepts to improve rolling resistance of the tire and therewith fuel efficiency of the car, addresses the core element how the environmental impact of tires can be reduced. 

Based on lab indicator data confirmed by tire customers, grade 918S (compared to non-functionalized high grip SSBR) improves fuel efficiency of the whole car by approx. 1.5%. Considering in Europe alone, 18 million vehicles are sold, the benefit of this increased fuel efficiency would translate in approx. 540.000 tons less fuel consumed or a reduction of CO2 emissions by 1.3 million tons.*¹ 

When it comes to electric mobility, SPRINTAN™ 918S, as a grip component in the tire tread, is an important step towards extended range in high-torque electric vehicles. To further support the move from internal combustion engines towards more sustainable forms of propulsion, Trinseo is actively collaborating with key customers to continuously improve tire performance for this growing segment. 

Scope for further enhancements to the technology or product

Trinseo is already actively developing the next generation of functionalized S-SBR with further enhanced interaction between the polymer backbone and surrounding filler particles. The next generation S-SBR will enable continuous improvements in rolling resistance and greater wear performance, and therefore will positively impact environmental footprint. 

Any further comments to further highlight the contribution of this development project to environmental sustainability?

Looking at the contribution tires can bring to sustainable, individual mobility, it is not enough to focus only on rolling resistance and wet grip potential but also on tire wear. Indeed, tire weight can be lowered further, reducing rolling resistance and in turn reducing particulate emissions during the tire use phase. 

Sprintan 918S, with its unique composition and proprietary, effective functionalization technology addresses all these key requirements, and is thus supporting the global decarbonization initiatives of the transportation sector, so vital in the fight against accelerating global warming and for the preservation of primary raw materials.

TYROMER INC.

Title of product or project: Tire-to-Tire recycling: A chemical-free technology for continuous devulcanization of ELT rubber crumb into a Tire-Derived Polymer (TDP) for use in the manufacture of new/retreaded tires.

Main materials technologies

Twin-screw extrusion of ELT (End-of-Life Tire) rubber crumb (and other waste rubber such as tire production rubber waste, retread buffing waste, EPDM production waste) to produce devulcanized rubber without the use of chemical solvents or devulcanization chemicals. This technology is environmentally sustainable because no chemicals are used.

Main goal or objective of the development project
Tire-to-Tire recycling solution is required to prepare the tire industry to meet the challenges of the circular economy. 
For proper recycling of ELT rubber, the Holy Grail of the industry is devulcanization so ELT rubber can be reused directly in the production of new tires. 
Devulcanization can divert ELT from landfill, TDF (Tire-Derived Fuel) or other low-value uses by producing a recycled rubber compound that can be used directly in tire production in meaningful amounts. ELT rubber reuse at the 5% level does not contribute materially to the circular economy. The goal of the project is to develop a recycled ELT rubber compound that can be used in the 20-30% range in the production of new tires.

Technical challenges addressed by the project team
- To adapt an industrially reliable plastic extrusion technology for reliable and continuous devulcanization of ELT rubber to produce TDP.
- To scale up the rubber devulcanization process to more than 1 ton per hour to meet the scale of the tire industry.
- To optimize the devulcanization process to produce TDP consistently and reliably to meet the quality standard of the tire industry.
- To optimize TDP properties to enable its use as a functional tire compound in the 20% - 30% range, across a wide range of tires.
- To optimize the TDP production process to ensure TDP provides tangible cost savings to the tire industry.

What is the commercial status of the technology or product?
Since 2016, Tyromer has been operating its first TDP production facility within the AirBoss Rubber Solutions
(https://airbossofamerica.com/rubber-solutions/home.php) plant as an in-house supplier to AirBoss. 
KAL Tire has used an OTR retread compound with 20% TDP produced by AirBoss since 2016 (https://www.kaltire.com/en/responsibility-retreading/). With positive feedback form its customers, KAL is now increasing TDP content to 25% and expanding the use of this compound to its international operations. 
A similar compound, in excess of 20% TDP, has been developed for the manufacture of new OTR tires. OTR, truck and passenger tires with 15%-20% TDP are currently on road trials in North America and Europe. 
A passenger tire manufacturer is optimizing a tire compound with 30% TDP.
A second TDP production facility is nearing completion in Windsor, Ontario, Canada to supply a top brand in North America.
With financial support from the government of the Netherlands, a third TDP production facility is being built in the Netherlands to supply a top brand customer in the EU.
Currently, a number of TDP production facilities are in planning for the US, EU, Australia and China.

Please describe the contribution of the technology or product to sustainability
Producing new material for tire rubber compound is energy intensive. TDP production from ELT, including the energy required to downsize ELT to ELT rubber crumb, represents less than 10% of the energy required for producing new tire rubber compound.
According to the European Environment Agency (2016), electricity generation in Europe produces approximately 0.3 MT CO2/MWh.
This means that using 1 MT of TDP to replace virgin tire rubber compound can save the equivalent of 7.3 MT of CO2.
Lowering rolling resistance can reduce fuel consumption during the use phase of tires, thereby contributing to sustainability. However, meaningful reduction in rolling resistance is becoming more and more challenging. 
Furthermore, reducing fuel consumption from tires of lower rolling resistance requires consumer diligence in proper tire maintenance and government diligence in the construction of roads with surfaces that minimize tire rolling resistance.
Using TDP in tire production automatically provides the sustainability benefit, without relying on other factors.

Scope for further enhancements to the technology or product
As tire recycling transitions to a more material recovery industry, there will be ELT rubber crumb with improved properties. 
For example, sorting of truck tires from passenger tires for crumb production will produce a more reliable feedstock for TDP. As Giant Mining Tires are recycled, crumb rubber of much higher material properties will be available for TDP feedstock. As with innovation, continuous improvement will bring enhancements in product performance and production cost reduction.
Driving sustainability is not limited to the tire industry. TDP use can expand to the non-tire rubber industry which accounts for the other half of global rubber consumption. Tyromer is working with the mining industry, the automotive rubber molding industry and the infrastructure sector on the use of TDP in a wide range of applications.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
While organizations representing tire manufacturers claim success in the high percentages of recycling of ELT, the fact remains that most of the recycling is not extracting the most value out of ELT. For example, in the US, nearly 50% of ELT is used for energy recovery in the form of TDF (Tire-Derived Fuel). TDF recovers about 35% of the energy in ELT rubber while TDP recovers over 90%.
The best recycling is to use the material for its originally intended purpose. For the tire industry, the ultimate objective must be Tire-to-Tire - in meaningful amounts. TDP represents the best reuse option for ELT in the true sense of recycling. Extracting more value from waste is the intent of the Circular Economy.

 

CONTINENTAL

Title of product or project: EcoRubber Garden Hose

Main materials technologies involved
Continental has developed a garden hose that uses an Arlanxeo EPDM with ethylene derived from sugar cane, a bio-renewable resource.
Main goal or objective of the development project
Continental wants to increase the sustainability of our product lines by using raw materials from sources that have less impact on our environment. Continental wants to have a product that shows Continental cares about our global footprint and providing products that lead to a better, more green tomorrow. Continental saw a need to improve our interaction with our world.

Technical challenges addressed by the project team
There are only a few EPDM grades available with bio-renewable content. The grades of EPDM that had sustainable content were not exact replacements for the petroleum-based EPDM’s that Continental currently uses. Continental needed to use a rubber recipe that utilized a higher amount of EPDM, less fillers, in order to maintain hose performance. The advantage was it increased to overall amount of renewable material in the hose construction.

What is the commercial status of the technology or product?
This garden hose with the renewable content EPDM is being sold online through major retail home improvement stores. If it does well online, it may be brought into the physical stores for additional sales.

Please describe the contribution of the technology or product to sustainability
The garden hose utilizing EPDM with sugar cane ethylene is removing some of Continental’s dependency on petroleum-based EPDM.
Continental uses an EPDM grade with the highest amount of naturally derived ethylene from sugar cane to further maximize the renewable content in the hose while minimizing the amount of petroleum derived components in the EPDM and the resulting hose. The EPDM polymer Continental is using has 70% of its mass derived from sustainable content in the sugar cane plant.

Scope for further enhancements to the technology or product
Continental is currently evaluating renewable oils and reclaimed/recycled materials which could both reduce the amount of new petroleum-based products needed to create rubber hoses but to also reduce the impact on landfills of end of life tires and other rubber products. Continental’s goal is to incorporate a broad spectrum of sustainable and recycled materials in order to create industrial hoses with as much as 95% of the content to be from green or non-petroleum raw materials. 
Continental is striving to replace petroleum-based oils and plasticizers in our rubber formulations with bio-based, renewable materials like coconut, soybean, linseed, and olive oils.
We would also like to implement natural fiber materials like hemp in place of petroleum-based textiles like polyester, polyamide and aramid.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
There is an 85% reduction in greenhouse gas emissions by using the sugar cane polymer versus the petroleum based. The production of the ethanol from sugar cane for this EPDM is carbon negative to the amount of almost 2 tons of CO2 per ton of polymer. 
In contrast, petrochemical-based ethanol generates about 2 tons of CO2 per ton of polymer. Finally, the yield of ethanol from sugar cane used in the EPDM is twice that of corn-based ethanol.

 

COVESTRO AG

Title of product or project: Sustainable sports flooring based on CO2

Main materials technologies involved
For the first time, synthetic sports floorings can be partly produced with carbon dioxide – which means less crude oil is needed as a raw material. The CO2 is incorporated in so-called polyether polyols which are needed to produce binders used in the floorings. The particularly sustainable new material named cardyon® comes from the materials manufacturer Covestro, who has developed a groundbreaking process for CO2 utilization in polyether polyols to market maturity. This can save up to one-fifth of crude oil in production – an innovative contribution to resource protection and recycling management.

Main goal or objective of the development project
The use of CO2 as a raw material for plastics is made possible by an innovative technology that Covestro has developed together with its partner RWTH Aachen. CO2 is used as a supplier of the important element carbon – instead of petroleum-based raw materials. Up to 20 percent of traditional fossil raw materials can thus be replaced by carbon dioxide. This new CO2-based polyol enabled our partner Polytan - a member of Sport Group - to offer more sustainable products to its customers. They set themselves the task of creating a new sustainable binder based on Covestro's raw material recommendation, meeting all the requirements imposed by the International Field Hockey Federation (FIH).
The first successful installation was at the CHTC hockey club in Krefeld, Germany which serves as a venue for international matches and championships.

Technical challenges addressed by the project team
The development of the CO2-based polyol and the revolutionary process leading to it has been done by Covestro together with its partner RWTH Aachen.  It is more than a purely technical innovation in plastics and synthetics production - it conserves fossil fuels such as crude oil and reduces the amount of carbon dioxide in the air. This is a real contribution to the efficient use of resources, climate protection and recycling.
New sports fields made of artificial turf often contain an elastic underfloor consisting of recycled styrene-butadiene rubber (SBR) granules. But this layer is usually formed using an oil-based binder, a situation that our Polytan wanted to improve. Intensive exchange between Polytan and Covestro on the possible raw materials and process to create this new binder led to the development of the new product using our cardyon® based on CO2.

What is the commercial status of the technology or product?
The cardyon® product family is being continuously produced in our designated production facility in Dormagen, Germany and the products are on one hand being used internally as raw material for different value added products and on the other hand sold to a growing customer base within the region. 
The sustainable sports flooring employing the cardyon® based binder has become a standard product at our partner Polytan and is sold and installed globally, recently for hockey fields for a major sports event planned in Japan for 2020, which has now been postponed to 2021 due to the outbreak of Covid19.

Please describe the contribution of the technology or product to sustainability
Using CO2 and saving oil: The use of carbon dioxide as a new raw material is a promising approach for making production in the chemical and plastics industries more sustainable. This way, we use CO2 in a closed-loop process and save oil. CO2 is used as a supplier of the important element carbon – instead of petroleum-based raw materials. Up to 20 percent of traditional fossil raw materials can thus be replaced by carbon dioxide. On this basis, we want to offer a comprehensive product portfolio for as many areas of application as possible – in line with our vision of making the world a brighter place.

Scope for further enhancements to the technology or product
Polytan has even more ideas to broaden the application base: Together with our customer we seek to integrate cardyon® into the last step of the production process, the artificial turf backing to make the whole flooring system even more sustainable.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
Meanwhile RWTH Aachen University is working on the production of synthetic fibers with carbon dioxide: Together with colleagues from the Technical University of Berlin and our experts, the researchers in Aachen have succeeded in producing high-performance fibers on a large scale and is processing them into their first garments. First fibers have been produced for demonstration purposes with the aim of making the new application solution ready for the market.

 

BEHN MEYER EUROPE GMBH
 

Title of product or project: Epoxidized Natural Rubber (ENR) filler technology

Main materials technologies involved
Epoxidized Natural Rubber (ENR), silica

Main goal or objective of the development project
Modified silica filler enabling ENR to exhibit its full potential
Technical challenges addressed by the project team
Compounding with high performance fillers like silica as well as blends with other elastomers have been difficult in the past
What is the commercial status of the technology or product?
Early results have been presented at the Tire Technology Expo

Please describe the contribution of the technology or product to sustainability
Opportunities in many applications: Tire as well as in Non-tire.

Scope for further enhancements to the technology or product
Information supplied separately

Any further comments to further highlight the contribution of this development project to environmental sustainability?
Information supplied separately

 

CABOT CORPORATION
 

Title of product or project: Cabot Engineered Elastomer Composites (E2C™)

Main materials technologies involved
E2C solutions are transformational pre-mixed composite solutions that are structurally different from compounds produced by conventional methods, offering superior levels of filler dispersion.

Main goal or objective of the development project
E2C solutions were specifically engineered to improve the performance, safety and lifespan of tires while reducing the cost and environmental impact of production.

Technical challenges addressed by the project team
E2C Solutions are produced in a proprietary and patented mixing process that results in three times less undispersed carbon black in rubber compounds than conventional mixing methods. 
When properly compounded using Cabot’s Light Touch mixing guidelines, E2C Solutions transform performance through dramatic improvements in rubber properties such as 20% lower hysteresis, 25% higher reinforcement, delayed crack initiation and 70% slower crack growth.

What is the commercial status of the technology or product?
E2C Solutions have been successfully commercialized by industry leaders in both tire and industrial rubber product applications.
Cabot’s first E2C solution, DX9730, was introduced in February 2020 and is part of a new Durability series of products designed to reduce in-field failures and maximize operational uptime for off-the-road tires.
Contribution of the technology or product to sustainability
E2C solutions have been shown to break critical trade-offs in tire design by both lowering operating temperatures and extending tire life by more than 15 percent. In an average mine using tires made with E2C™ solutions, this change can increase haulage capacity, boost output, and reduce annual downtime for tire changes leading to a potential benefit up to $150m per year.
Additionally, because tires made with E2C™ solutions last longer and are more energy efficient, raw material consumption and CO2 emissions are reduced and fewer end-of-life tires are generated – a benefit for the environment, especially given that more than 1 billion waste tires are generated each year worldwide.
In terms of tire manufacturing, E2C™ solutions require 50% less mixing time and energy than conventional products, so the energy consumed in manufacturing tires is reduced, lowering tire manufacturers' overall environmental footprint.

Scope for further enhancements to the technology or product
We will continue to launch products for mining applications such as off-the-road tires and related industrial rubber product applications.
We will also explore how E2C solutions can be used in on-road tires such as the truck/bus/radial segment to create low rolling resistance tires to drastically reduce fuel consumption and greenhouse gas emissions, while reducing the asset footprint of tire companies by enabling manufacturers to rethink their value chain and the design of their plants, and speeding up rubber product innovation and launch cycle by adopting made-for-purpose E2C solutions that are ready for commercialization – in so doing, reducing the time and investment required for product development.

 

FLINDERS UNIVERSITY
 

Title of product or project: Self-repairing rubber

Main materials technologies involved
Development of polymer based on sulphur, canola oil and dicyclopentadiene

Main goal or objective of the development project
New rubber that can be used to make flexible, repairable, sustainable objects – including car tyres

Technical challenges addressed by the project team
Ensuring polymer can be completely repaired and returned to its original strength in minutes – even at room temperature

What is the commercial status of the technology or product?
R&D stage / see supporting info

Please describe the contribution of the technology or product to sustainability
"Underlying chemistry of these materials has such wide potential in recycling, next-generation adhesives, and additive manufacturing,”
Scope for further enhancements to the technology or product
See supporting information

Any further comments to further highlight the contribution of this development project to environmental sustainability?
See supporting information

 

MCPP (MITSUBISHI CHEMICAL CORPORATION)
 

Title of product or project: Incorporating renewable carbon in a wide thermoplastic offer

Main materials technologies involved
Thermoplastic Elastomers (TPE)
Vinyl Elastomers (soft PVC)
but also Bioplastics, Oxygen barriers, 3D filaments

Main goal or objective of the development project
Mitsubishi Chemical Corporation (MCC) is engaged to realize KAITEKI: “The sustainable well-being of people, society and our planet Earth.”
KAITEKI deployment at MCPP, the performance polymer department of MCC, consists of incorporating renewable carbon in a comprehensive and consistent portfolio of technologies, products and solutions, to be addressed to all markets.
Technologies: compounds, neat polymers, modified polymers
Products:  Thermoplastic Elastomers, PVC compounds, Bioplastics, Functional polymers, Gas barriers, 3DP filaments
Markets: Automotive, Consumer, Industry, Packaging

Technical challenges addressed by the project team
Renewable Carbon is carbon circulating close to our environment that could be used as an alternative to primary fossil carbon, issued from oïl and geologic layers, and which extraction will undoubtely lead to increase CO2 content in atmosphere in the long term.
Renewable carbon can be issued from material recycling streams (PCR/PIR), biomass (bio-based plastics), or carbon capture (synthetic photosynthesis) and its preferable use for plastics will help to reduce the extraction of carbon from geosphere to atmosphere.
Thermoplastic Elastomers are compounds with limited access to ingredients for incorporation of biobased building blocks and/or technologies issued from recycling streams, because their use is generally for high-end applications where technical features, compliancy to regulations, quality consistency are primarily considered before the impact benefit on environment.
MCPP has been able to develop a full range of solutions based on renewable carbon.
Thermoplastic Elastomers can be proposed under the brand TEFABLOC with :
- either 40% of biobased carbon in the formulation (Bio-based TPE)
- or up to 70% of recycled material (majority of Post Consumer) for a wide range of hardnesses.
It is important to nice that both solutions can be proposed in natural colour (when most of PCR is black material) so easy-colouring, for injection and extrusion molding, adhesion to polyolefins, suitable contact with skin and as a drop-in solution for TPE processing
MCPP has also developed a vinylic compound that can be processed through slush-moulding for automotive dashboards and interior panels, that can incorporate up to 48% of biobased carbon, while meeting the high-end standards of automotive OEMs.

What is the commercial status of the technology or product?
TPE and PVC compounds with use of renewable carbon are ready for commercialisation and have been introduced to the market during last K show 2019.
TPE based on renewable carbon, mainly the ones based on recycled carbon, have already started to be commercialized to few applications in the industry and consumer articles, mainly for grips/overmolding (over recycled polyolefins), sanitary parts and industrial seals.
Automotive industry has already evaluated successfully biobased solutions for interior parts and MCPP remains ready for commercialisation.

Please describe the contribution of the technology or product to sustainability
Incorporating a significant amount of renewable carbon (recycled carbon or biobased carbon) in plastics is a real move for decoupling step by step from the use of fossil resources that have taken millions of years for their creation, but could be used for couple of months/years (if not less) before turning to waste or CO2 emission.
Using a carbon that is already present in our next environment, with a wise use of energies, helps to reduce the long term transfer of carbon  from geosphere to atmosphere, that is eventually causing the global warming of our planet.

Scope for further enhancements to the technology or product
Main enhancement MCPP is looking for, is to increase step by step the amount of renewable carbon incorporated in its compound portfolio. This will request additional R&D at MCPP and a close partnership with our relevant and consistent suppliers, for developing innovative and sustainable solutions to the market. 
An LCA study is on-going at MCPP in order to develop quantitative value on how such initiative is benefiting to carbon footprint and other important environmental impacts. Of course, a preliminary study has already confirmed that this initiative was in the right direction to lower GHG emissions.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
Mitsubishi Chemical Performance Polymers (MCPP) is deploying this approach for the full range of product (not only elastomers) and technologies to provide a wide offer of solutions based on this renewable carbon.
Most of solutions are already on the market and we intend to bring more solutions in our mission to realize KAITEKI.

 

KRATON CORPORATION
 

Title of product or project: Kraton IMSS ™ Technology

Main materials technologies involved
The development of Kraton’s novel high-flow hydrogenated styrenic block copolymers (HSBC) and formulations enable compounds that can be injection moulded into automotive instrument panel skins.

Main goal or objective of the development project
Our goal is to offer the automotive industry an alternative to skins made by slush moulding of PVC powder.

Technical challenges addressed by the project team
We developed a material with the right balance between low enough melt viscosity to fill a long and narrow mould, with physicalmechanical properties high enough to satisfy OEM performance requirements.

What is the commercial status of the technology or product?
Kraton IMSS compounds, manufactured by licensed compounders, are in an advanced stage of validation at multiple OEMs and their Tier 1 suppliers. The first commercial car model with the Kraton IMSS technology is scheduled to start production in Q4 2020.

Please describe the contribution of the technology or product to sustainability
Compared to slush PVC, Kraton IMSS compounds offer the following benefits:
• lower part weight, contributing to decrease carbon dioxide emissions
• are reprocessable, helping to decrease landfill/incineration - both for manufacturing scraps and for vehicle end-of-life management
• do not contain phthalate plasticizers, thus improving air quality in the vehicle
• enable safer low-temperature airbag deployment, preventing harmful shard formation
• do not require topcoat application, avoiding VOC emissions and workers exposure
• lower energy consumption during transformation when compared to slush, decreasing overall environmental impact

Scope for further enhancements to the technology or product
Further enhancements include IMSS materials that can be foamed. This would allow for replacement of currently used PU thermoset foam backing, enabling a fully recyclable IP or door panel assembly.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
All-electric vehicles will contribute significantly to transportation sustainability, but their limited mileage represents a hurdle. 
Kraton IMSS™ technology helps contribute to reducing vehicle weight, supporting the growth of electric vehicles in the marketplace.
Learn more by viewing the video on Kraton's website: https://www.kraton.com/products/automotive/imssStory.php