Top 10 Elastomers for Sustainability - ARLANXEO entry

TOP 10 - ELASTOMERS FOR SUSTAINABILITY

Company: ARLANXEO

Location: Geleen, The Netherlands

Project: Sustainable EPDM compounding based on Keltan Eco EPDM rubber

Main materials technologies involved
Keltan Eco EPDM: World's first bio-based EPDM
Sustainable rubber- and TPV compounding ingredients, like bio-PE, bio-based processing oils and plasticizers and sustainable fillers such as rice hush ash, carbon black from pyrolyzed tires and micro-cellulose.

Main goal or objective of the development project
Conventional EPDM rubbers are 100% based on fossil fuels. ARLANXEO targeted to develop and launch new EPDM products based on bio-monomers which have a much lower carbon footprint. Furthermore, ARLANXEO aimed to develop EPDM compounds but also EPDM based TPVs with the highest sustainable content possible.

Technical challenges addressed by the project team
- Receiving the bio-ethylene in our plant in Triunfo for production of Keltan Eco EPDM
- Setting up the testing and certification of these bio-EPDMs (proof that the C2 is originating from sugar cane)
- Selecting the right sustainable compounding ingredients to achieve acceptable compounding properties
- Experimentally producing TPVs with acceptable properties based on Keltan Eco EPDM
- Achieving highest sustainable content as possible for both the conventional rubber compounds as well as for the TPV but also realizing acceptable (physical) properties

What is the commercial status of the technology or product?
ARLANXEO has 3 commercial Keltan Eco EPDM grades in its product portfolio:
- Keltan Eco 5470: a medium Mooney, crystalline grade for e.g. static profiles and TPV applications
- Keltan Eco 8550: a higher Mooney, more amorphous grade for e.g. dynamic profiles
- Keltan Eco 6950: a medium Mooney, super amorphous grade for e.g. sponge profiles
Blends of Keltan Eco 5470 and Keltan Eco 8550 are also very suitable for coolant hoses.
Keltan Eco 6950 was used in the World cup soccer ball for World championships in 2018.

Please describe the contribution of the technology or product to sustainability
ARLANXEO did a thorough Life Cycle Assessment (LCA) using third party assessment and including the support of Braskem, who supplies the bio-ethylene.
By using the high ethylene EPDM grade, a 85% reduction of the CO2 footprint is realized per mt of EPDM (compared with high ethylene grades based on fossil oil) !!
An amorphous EPDM grade, based on bio-ethylene from sugar cane, gives a 50% reduction of the CO2 footprint.

Scope for further enhancements to the technology or product
Keltan Eco EPDM is now based on bio-ethylene, produced from sugar cane.
Next step would be also to have bio-propylene for the Keltan Eco production.
With respect to rubber compounds and TPVs:
- review of other sustainable oils and fillers is on the agenda
- And other sustainable alternatives for polypropylene with respect to TPVs
Essentially, these Keltan Eco based TPVs combine a renewable origin with recycling via melt processing. Bio-based TPVs score very good in a cradle-to-cradle approach and further lowering the carbon footprint.

Any further comments to further highlight the contribution of this development project to environmental sustainability?
ARLANXEO is investigating new venues to further improve the sustainability of its products. ARLANXEO also reviewed the effect and impact of New Mobility, Electrical Vehicles and changing power trains on its rubber portfolio. ARLANXEO sees risks as well as opportunities wrt
- Tyres
- Electrification
- Thermal Management
- Lightweight
- Noise, Vibration, Harshness

These are the main areas in which ARLANXEO focusses its innovation activities specifically for the automotive industry and markets.