1 / 19

Keltan ® EPDM Innovative and Surprising after all these years Herman Dikland

Keltan ® EPDM Innovative and Surprising after all these years Herman Dikland. Content. Historical perspective Catalysis Technology Applications Keltan ® history Keltan ® Innovations Keltan ACE™ technology REX technology New product development Concluding remarks.

ezhno
Download Presentation

Keltan ® EPDM Innovative and Surprising after all these years Herman Dikland

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Keltan® EPDMInnovative and Surprising after all these yearsHerman Dikland

  2. Content • Historical perspective • Catalysis • Technology • Applications • Keltan® history • Keltan® Innovations • Keltan ACE™ technology • REX technology • New product development • Concluding remarks

  3. Historical Perspective

  4. Historical perspective … Ziegler-Natta Catalysis • Von Pechmann, linear PE, a laboratory curiosity (1906) • ICI, high-pressure polyethylene (~ 1935) • Ziegler, Max-Planck ‘Kohlenforschung’ low-pressure linear PE (~ 1953): ‘Mülheimer Chemie'. • Natta, Polytechnico di Milan, stereoregular PP (~ 1953) • Less successful alternatives: Standard Oil (Mb catalyst) and Philips Petroleum (Cr catalyst) • Ziegler and Natta Nobel Prize winners in 1963 • Increased industrial importance starting in early sixties • It took more than 40 years…

  5. Historical perspective … Ziegler-Natta Catalysis • PP and EPDM development • Research communities • Dissemination of knowledge • Industrial relevance • PE and PP ahead of EPDM • Catalyst efficiencies improved orders of magnitude • New production technologies developed • Economies of scale developed • Early introduction of advanced catalyst systems Source: M.A. Rappa and K. Debackere A.P. Sloan School of Management (1990)

  6. Historical perspective … Advanced Catalysis • Metallocene catalysts: Metal sandwiched between two cyclopentadiene (Cp) ligands • First invented in 1951 (!): simple ferrocenes, Cp2Fe • Natta published results on Cp2TiCl2 with TEA co-catalyst in 1957 • Accidental discovery by Kaminsky of Cp2ZrCl2 with MAO co-catalyst • MAO activates, scavenges, stabilizes and prevents bi-metallic deactivation… • After Kaminsky’s breakthrough • Focus on commercialization • Improving MAO:metal ratio’s • Development of alternative co-catalysts • Increasing catalyst productivity • Over 1 billion USD has been spent in polyolefin catalyst research by Dow and Exxon

  7. Historical perspective … Technology • 1960 – 1980 • First EPDM plants erected in the early sixties • Typical plant scale 5 – 15 ktpa • Slurry and solution processes • 1980 – 2000 • Debottlenecking • Implementation of deep cooling technology • New finishing technology • 2000 – 2010 • New large scale facilities (60 – 100 ktpa) • Gas phase technology (†) • Dry finishing technology • Post-reactor modification technology

  8. Historical perspective … Applications • Initial target application for EPDM was in tires • Poor building tack • Poor abrasion resistance • Poor dynamical properties • Today, #1 synthetic rubber for non-tire, non-latex applications • Excellent wheatherability • Excellent processability and filler tolerance • Broad temperature performance window (-40 °C up to 140 °C) • Excellent cost:performance ratio • Gradual replacement of NR, SBR and CR in standard rubber applications • Hardly any substitution by other materials. Exceptions: • Plastomers and reactor TPO (W&C and PP impact modification) • TPVs in automotive sealing systems

  9. Historical perspective … Applications • 70’s: Automotive sealing systems NR/CR/SBR • 80’s: Window gaskets PVC/SBR/caulks • 80’s: Coolant hoses CR/NBR • 80’s: Bull eyes SBR • 80’s: Petroleum additives Poly(methacrylates) • 90’s: Roof sheeting PVC/bitumen • 90’s: Exhaust mounts NR/CR/VMQ • 90’s: Potable water seals SBR • 00’s: V-belts CR • 00’s: Wastewater seals SBR

  10. Historical perspective … Applications • 10’s: Ongoing substitution • Windshield wipers NR/CR • Engine mounts NR • Grass infill NR reclaim • Ultra-low density insulation sponge PVC-NBR/LDPE • Continued growth • With automotive build and GDP • Topped with continued inter-material substitution • More than 1000 ktpa global demand

  11. Historical perspective … Keltan® 1960 Start research activities 1965 Obtained license for Ziegler-Natta catalysts 1966 Established Keltan® trademark 1967 Start up EPT 1, Geleen 1973 Start up EPT 2, Geleen 1974 EPT 1 stop 1975-8 Debottlenecking EPT 2 1981 EPT 1 re-start 1982 First computer in EPT 1983 Introduction of promoted catalyst systems

  12. Historical perspective … Keltan® 1988 Debottlenecking EPT 1 1989 Acquisition Copolymer (Addis, US) 1991 JV DSM-Idemitsu Company (Chiba, Japan) 1996 Acquisition Nitriflex (Triunfo, Brazil) 2003 Startup EPT 3, Geleen 2004 Closure plants in Addis and Chiba 2005 Debottlenecking EPT 1-2 2005 Debottlenecking EPT 3 2007 Start up large-scale reactive extrusion line in Triunfo 2008 Implementation Keltan ACE™ technology 2009 Introduction first high-VNB products, Keltan DE8270C

  13. Keltan Innovations®

  14. Innovations … Keltan ACE™ Technology • Cutting edge advanced catalyst technology • High catalyst efficiency …………………….…….…………. …..orders of magnitude • Higher polymerization temperatures ………............. less cooling, higher solids • Higher selectivity towards a-olefins ………………………product diversification • Product differentiation opportunities ………………….…. high VNB, and more… • Sustainable benefits, in terms of • Product diversification opportunities • Investment for grass root plant • No catalyst waste products • Improved energy utilization

  15. Odor reduction (processing and end use) Bloom reduction Fogging reduction Enhanced electrical insulation Innovations … Keltan ACE™ high-VNB products Peroxide Crosslinking Peroxide curing efficiency VNB >DCPD/ENB Increased Scorch time Hperbranched structure or or Less peroxide and/or coagent Higher total loading level (Phr) while maintaining compression set properties No change in peroxide No change in filler level Lower 3rd monomer level Enhanced compound elasticity Improved processing (better flow) Less Peroxide decomposition products Lower residual peroxide in end product Higher cross link density No black scorch Lower compound cost Improved fiber/cord/fabric adhesion Less volatile emissions (VOC) Improved higher T compression set values Significantly improved compression set properties Less PP degradation In TPV application Properties related to crosslink densitiy improve (ageing, chloramine resistance) Improved heat ageing resistance (5-10 °C compared to NEN/DCPD)1 Lower post curing necessary Less stress cracking Improved snappiness

  16. Innovations … REX Technology • Ethylene-propylene copolymers are used in petroleum additive applications for more than 30 years • Viscosity Index Improvement (VII) • Soot dispersant control • Specialty products are made by post-reactor modification • In 2008 DSM started operating the largest reactive extrusion plant in its kind in Triunfo, Brazil • Key products for VII applications are • Keltan 1200A • Keltan 3200A • Keltan 1200A also suitable for • V belts, potable water applications, brake parts, food contact applications

  17. Innovations … K1200A: The Ultra-Low Viscosity Grade • High-hardness and polymer-rich formulations are difficult to process • Keltan 1200A can be used as blend partner • Compound viscosity sharply reduced • Extractables are markedly reduced (vs. traditional processing aids) • Hardness, tear and tensile properties are largely maintained • Microbial growth properties are improved • Retention of properties after high-temperature ageing is improved

  18. Innovations … New Products • Conversion of standard paraffinic oil to high quality colorless oils in oil-extended products • Keltan 4551A (former K509x100), Keltan 6531A (former K708x15) and Keltan 4331A (former K512x50) • Broadest array of products for sponge automotive sealing systems • Keltan 4703, Keltan 4903, Keltan 7341A, Keltan 6251A • Best-in-class quality products for TPV applications • Keltan 5531A, Keltan 4551A, Keltan 7341A • New product for automotive solid sealing systems • Keltan 8642A • New Keltan ACE™ grade for peroxide cure applications • Keltan DE8270C

  19. Concluding Remarks • It took 40 years to understand the value of von Pechmann’s invention • It took another 40 years to establish EPDM as #1 synthetic rubber for general purpose rubber applications • It will take another 40 years before EPDM becomes a true commodity At least

More Related