development of high density polyethylene/rice husk composites hieu nguyen, thanh tran and loan doan...
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DEVELOPMENT OF HIGH DENSITY POLYETHYLENE/RICE HUSK COMPOSITES
Hieu Nguyen, Thanh Tran and Loan Doana, Thai Nguyen and Long Truongb, Son Do and Thao Voc and Thoi Hod
a Da Nang University of Technology - The University of Danang - Vietnamb Plastics and Rubber Technology Center - Vietnam
c HCM City University of Technology - Vietnamd International Polymer Consultant - USA
Houston, 2011
International Polyolefins Conference 2011
Outline
• Introduction
• Review of natural fibers/polyolefin composite technologies
• Preliminary results of rice husk/HDPE composite
• Conclusions/ Path Forward
Green composites
Competitive price/performance
Environmentally safe (Recycling or incineration at end-of-life with energy recovery)
Renewable resource
Natural fibresSpecific mechanical properties (high strength/low density)
Widely applicable
Low machine wear
Safe working condition (vs. Glass fibre)
Low density
Green composites: Composites of the future
Global Production of WPCGlobal Production of WPC
Global Production of WPC by Countries in 2009 (%)
66.7
13.3
11.3
6.7
2.0
US
China
Europe
Japan
Other
Plastic Information EuropePlastic Information Europe
Global production of WPC: 3.3 Billion lbGlobal production of WPC: 3.3 Billion lb
Market of Wood Plastic Composite in US
0
500
1000
1500
2000
2500
2002 2004 2006 2008 2010 2012 2014
Year
Mill
ion
Do
llar
Source: Freedonia IncSource: Freedonia Inc
Market in US in 2010 about $2 Billion. Annual growth rate of about 20%Market in US in 2010 about $2 Billion. Annual growth rate of about 20%
Natural fibers as fillers for green composites
Availability of major biomass sources in Vietnam in 2006
Natural fibers
RICE HUSKRICE HUSK
Rice’s Statistics
• Rice feeds 50% of world population• World rice production in 2007 :1430 B lb• Rice contains 20wt% of rice husk• Rice husk available in 2007 is 286 B lb• About one pound of rice husk available for
each pound of polyolefin produced world wide!
W (B lb) China (B lb) India (B lb) VN (B lb) US (B lb)
286 82 62 16 4
Estimated Rice Husk Available in 2007
Cost rice husk:-Get it free from rice mill-Cost of rice husk
-Cost of transportation -Plus cost of grinding
How the rice husk is used in Vietnam?
Dumping on the river Burning openly
Mainly using for
daily cooking
Using for daily cooking (Cookstoves)
Polluting the
air, water, land…
Disposal cost
Dumping in rivers
Our Vision of Using Rice Husk in Future
+
Review of Natural Fibers/Polyolefin Composite TechnologyReview of Natural Fibers/Polyolefin Composite Technology
Which polymers should be used as matrices for rice husk composites?
Bio-Polymers
Polyolefins
PET
PU, PSABS, PC
PVC
“Green Peace” Triangle
Polyolefins continue to substitute these polymers
EnvironmentalFriendliness
Components Chemical Wt %
Base resins PP, HDPE 50-80
Natural fibers Wood (100-200 micron 20-50
Compatibilizer MAH -HDPE/MAH -PP 2-4
Processing aid Fatty acid esters, waxes 1-4
Other additives AO, UV, FR, Fungicide, Neutralizer 0.1-0.3
Summary of WPC TechnologiesSummary of WPC Technologies
Optimat Ltd and MERL LtdD Gardener
Optimat Ltd and MERL LtdD Gardener
http://www.umaine.edu/adhesion/gardner/5502002/wpc ext over 3-11-02.pdf http://www.umaine.edu/adhesion/gardner/5502002/wpc ext over 3-11-02.pdf
Flexural Strength of PP + 40wt% Filler
0
10
20
30
40
50
60
70
1
Filler Type
Fle
xura
l S
tren
gth
(M
Pa)
Unfilled
glass
talc
CaCO3
wood
Flexural Modulus of PP + 40wt% Filler
0
5
10
15
20
25
30
35
40
1
Filler TYpe
Fle
xura
l M
od
ulu
s (1
00 M
pa)
Unfilled
glass
talc
CaCO3
wood
Key Mechanical Properties of WPCKey Mechanical Properties of WPC
Reinforcing effectiveness: Glass>Talc>Wood>CaCO3Reinforcing effectiveness: Glass>Talc>Wood>CaCO3
English et al English et al
Fiber Cellulose (%)
Lignin (%) Silica (%)
Rice straw 28-36 12-16 9-14
Rice Husk 38-45 15-22 19
Soft wood 40-45 26-34 <1
Hard wood 38-48 23-30 <1
Composition of Some Selected Natural Fibers
Rice husk has much higher silica and lower lignin content than woods
Potential Advantages of Rice Husk
• Abundant resource of rice husk (286 Blb /year world wide)• Rice husk is agricultural waste product (low cost / help the
environment/reduce dependence on oil )• Rice husk is “greener” than wood• High silica content:
– High mildew and fungi resistance– Better fire retardant than wood/polyolefin composite– Lower water absorption than wood /polyolefin composite
Sample Composition(%)
Flexural Strength(MPa)
Flexural Modulus
(MPa)
Impact Strength(KJ/m2)
A PP/RH (70/30) 26 1600 4
B PP/RH (60/40) 23 1800 2.5
C PP/RH/MAPP (56/40/4) 35 1700 3.5
D PP/RH/POE/MAPP(56/30/10/4)
28 1300 5.0
E PP/RH/POE/MAPP(46/30/20/4)
17 800 15.0
PP Profax SM2400 1300 6.5
PP/Talc SM2400/10% Talc 1800* 3*
Reported Key Mechanical Properties of PP/Rice Husk Composites
PP= Profax SM 240 (d=0.9g/cc, MFR=25g/10min, POE=Engage 8150, MAPP=Licomont AR504A, B, C, D, E: Data from M. Mustapa et al (Simposium Polymer Kebangsaan Ke-V) (2005)* Estimated value
Samples B and D have comparable key mechanical properties with PP+10% Talc
Development of Rice Husk /HDPE CompositeDevelopment of Rice Husk /HDPE Composite
Experimental
Ingredients Weight (%)
Rice husk 38 - 58
HDPE 38 - 58
MAPE 4
Rice husks (RH): Long An province, Vietnam (particle size???).
High density polyethylene (HDPE): Sabic Asia Pacific PTE. LTD, Philippin.
Maleic anhydride-grafted polyethylene Fusabond E226 (MAPE): DuPont.
Songnox 417 (0.15 wt%): Songwon, Korea.
Calcium stearate (0.1 wt%).
Materials:
Experimental
(HDPE +MAPE)
Melt-blending (Brabender)
compression molding
Rice husks
Grinding Drying
Processing
Composite samples
T = 160oC = 10 min = 54 rpm
Tensile test: ASTM D638
Bending test: ASTM D790
Notched impact test: ASTM D256
Water absorption
Results: Tensile strength and modulus
30 40 50 602.6
2.7
2.8
2.9
Ten
sile
Mod
ulus
(G
Pa)
Rice husk content (Wt.%)30 40 50 60
16
18
20
22
24
Ten
sile
str
engt
h (M
Pa)
Rice husk content (Wt.%)
RH content polar RH/ apolar HDPE interfacial area tensile strength .
RH fillers have higher stiffness than the polymer matrices tensile modulus of
the composites with rice husk content.
30 40 50 602.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
Bend
ing m
od
ulu
s (G
Pa
)Rice husk content (Wt.%)
30 40 50 60
10
20
30
40
Ben
ding
str
engt
h (M
Pa)
Rice husk content (Wt.%)
RH content bending strength and then .
Bending modulus of the composites with rice husk content.
Results: Bending strength and modulus
30 40 50 605
6
7
8
9
Imp
act
tou
gh
ness (
KJ/m
2 )
Rice husk content (Wt.%)
Results: notched impact toughness
RH fillers is more brittle than HDPE matrix impact toughness of the
composites decreased as rice husk content increased.
Results: Water absorption
0 100 200 300 4000
1
2
3
4
Wa
ter
ab
so
rptio
n (
wt%
)
Time (h)
58 Wt.% RH composite 48 Wt.% RH composite 38 Wt.% RH composite Commercial WPC (from USA)
RH content water absorption
Water absorption of 38 wt.% RH composite is lower to that of
commercial composite sample for decking application.
Conclusions
RH can improve significantly modulus of pure HDPE and composites.
Impact toughness, tensile and bending strength of the composites decrease much
at high amount of rice husk.
RH/ HDPE composite have comparable key properties with commercial WPC
Successful development of rice husk/polyolefin composites:
Production of low cost composite for construction materials
Generate economic development for the rural areas
Reduction of environmental pollution
Path Forward
• Identify target applications for RH/HDPE• Optimize composite composition/additives to meet
the performances for the applications– Mechanical properties– Processability– Processing stability: discoloration/Mw degradation /Bubble
formation– Durability (water absorption/fire retardant, mildew
resistance, UV stability, etc)
Acknowledgements
2010 International Polyolefin Conference/PMAD for warding a scholarship toThanh Tran
The following companies for providing resins and additives
-The Dow Chemical Company-Dupont Company-Chemtura-BASF-Songwon
2010 International Polyolefin Conference/PMAD for warding a scholarship toThanh Tran
The following companies for providing resins and additives
-The Dow Chemical Company-Dupont Company-Chemtura-BASF-Songwon
for your attention
Merci
Danke
Thank you
Arigato
Cám ơn