Thermoset Reduced
Thermoset Reduced Eco-footprint of Beyone 201-A-01 resins vs. epoxy resin reference ECO-footprint is the sum of all environmental impacts from an LCA (including e.g. CO2 footprint, toxicity, waste, resource consumption, land use) Eco Footprint (points) Beyone 1 Epoxy system 0,575 DSM has proposed an all-new composite system for making wind turbine blades, together with its partners 3B-the fibreglass company, Siemens Wind Power and DTU Wind Energy, featuring easy blade manufacturing, low weight, high stiffness, and excellent resistance to fatigue. The system is based on DSM’s Beyone 201-A-01, a resin that is styrenefree, cobalt-free (based on BluCure Technology, www. BluCure.com), and 40 % biobased. It has been demonstrated that this system can be used for making long blades at a record speed (through faster resin infusion and short postcure), giving an increased output per mold and an outlook for excellent process consistency. The bio-ingredients in the product formulations introduced in this article are derived from a mix of corn and corn waste material (the so-called generation 1.5). DSM wants to demonstrate that high performance levels can be achieved through using bio-ingredients (hence the introduction of these three resins). At the same time, DSM has increased its efforts to investigate routes for making the required raw materials from secondary organic sources (i.e. not competing with the food chain). DSM already has a track record of introducing new biobased products, supported by its strong roots in Life Sciences and biotechnology. 0,72 Co-creation works In order to commercialize new technologies that have the potential to revolutionize the manufacturing of wind turbine blades, it was necessary to think out of the box and form a strong channel partnership. DSM, 3B, Siemens Wind Power and DTU were able to demonstrate that through cocreation, a complex technology can be evaluated at record speed and prepared for live application in line with market requirements. Presently, the material system is under evaluation by Siemens Wind Power for its next-generation wind turbine blades. The development of Beyone 201-A-01 may turn out to be a game-changer not only for its performance in wind energy but also for the general application of biobased composite resins. Through the combination of great end-use performance, cost savings through easier processing, and improved sustainability the introduction of this material can be truly called a green revolution. Together for a brighter future with composites Building on its unique position as Life Sciences & Materials Sciences company, DSM is the leading global innovator of high performance, sustainable composite solutions. Through DSM’s Bright Science and market leadership across a number of industries including transportation, construction, infrastructure and industrial the company creates value by enhancing performance, improving health & safety, and minimizing environmental footprint. By: Thomas Wegman Marketing Manager DSM Composite Resins Zwolle, The Netherlands www.dsmcompositeresins.com www.blucure.com Great outlook for use of biobased materials in wind energy applications 36 bioplastics MAGAZINE [03/14] Vol. 9
Thermoset Biobased Epoxy Epichlorohydrin from glycerin enables biobased epoxy resins The possible ways of producing epoxy resins are very different and complex. The most common and important class of epoxy resins is derived from epichlorohydrin (ECH) and bisphenol A (BPA), a bivalent alcohol. BPA is exclusively produced from fossil feedstock. However, health and safety concerns about the use of this chemical in food contact applications have led to the development of BPA substitutes, some of which being bio-based (e.g. lignin derivatives). Epichlorohydrin has been produced from oil-based propylene for decades, but it can also be obtained from biobased glycerin, a by-product from biodiesel and oleochemicals production. Thanks to identical physicochemical properties, biobased ECH can be used as a drop in substitute for fossil ECH. The world market for epichlorohydrin is about 1.5 million tonnes, 87% of which being used for the production of epoxy resins (in Asia and especially China, this share exceeds 90%). The main use of epoxy resins is for the production of protective coatings (corrosion proof) for the marine, automotive and industrial markets. The second biggest application area for epoxy resins is the manufacture of electronic components such as printed circuit boards and encapsulated semiconductors. In third position is the field of composites, mainly for public transportation (aerospace, automotive,…) and wind-power generation. Belgian multinational Solvay is a major supplier of ECH and the world’s biggest producer of bio-based epichlorohydrin, made from glycerin. The diversified chemicals group entered the ECH market in the early 1960s, growing its annual ECH production capacity to 210,000 tonnes nowadays. Solvay produces propylene-based ECH at its plant in Rheinberg/ Germany and a mix of propylene and bio-based ECH in Tavaux/France. Its plant in MapTa Phut/Thailand is entirely dedicated to biobased epichlorohydrin (100,000 t/a) which is marketed under the brand name Epicerol ® . In contrast to some other ECH producers, Solvay is not downstream integrated and does not produce epoxy resins. “Epicerol revolutionized the way of ECH production,” Thibaud Caulier, Senior Business Development Manager at Solvay explains to bioplastics MAGAZINE. “Epicerol not only uses 100% renewable carbon and reduces the carbon footprint of ECH production,” he says. “It is environmentally friendly in many other respects.” The whole production process consumes less energy and chlorine. The chemical reactions involved are more selective than in the propylenebased process, which significantly reduces the generation of chlorinated by-products. Another distinctive feature of Epicerol is that it does not release liquid effluents in the environment. In 2013, AkzoNobel and Solvay signed a three-year agreement whereby AkzoNobel will progressively increase the use in their coatings of bio-based epoxy resins produced with Epicerol, aiming to reach by 2016 20% of their equivalent ECH demand as bio-based material. In March 2014, a joint panel was organized at the World Biomarkets conference in Amsterdam, with Kukdo Chemical (epoxy supplier of AkzoNobel) and EY besides Solvay and AkzoNobel. Kukdo is committed to develop bio-based epoxy resins based on Epicerol. EY is bringing its competencies in order to implement a chain of custody that keeps track along the chain of the use of Epicerol in AkzoNobel coatings. Solvay is actively seeking to establish further supply chain partnerships in other epichlorohydrin market segments. Besides thermoset resins, Epicerol can also be used for rubber products. This shall be covered in a separate issue of bioplastics MAGAZINE. MT www.solvay.com Chemistry of epichlorohydrin manufacturing (simplified) Propylene CI 2 HCI OH HO OH Bio sourced Glycerine CI Allyl Chloride HCI HCIO NaOH CI OH CI Dichloropropanol Brine O Epichorohydrin CI H 2 O bioplastics MAGAZINE [03/14] Vol. 9 37
