epdm materials dow.pdf · *clayfield, t.; li pi shan, c.; den doelder, j.; han, t.; polymers by...

® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

The Dow Chemical Company

Dr. Olaf Henschke

Colin Li Pi Shan, Varun Thakur, Jaap Den Doelder

Dow Elastomers R&D

December 7, 2016

Innovations in Rubber Design, London, UK

EPDM Materials by Design


EPDM by Design

Dow’s commitment and sustainability to the rubber industry New Materials Research and Development Focus on Automotive Sealing Systems

2


Dow’s Sustainability Journey

3

Our Aspiration:

To advance the well-being

of humanity by helping

lead the transition to

a sustainable society

and planet.

2005 EH&S Goals

Journey to EH&S

Excellence

2015

Sustainability

Goals

Product Solutions

to World Challenges

2025

Sustainability

Goals

Thought Leadership

and Actions

Footprint and EH&S Culture

Handprint

Blueprint

1995 2006 2016 2025


Delivering Sustainable Impact

Leading the

Blueprint

Engaging

Employees for

Impact

Increasing

Confidence

in Chemical

Technology

Valuing Nature Advancing

a Circular

Economy

4

Dow is a thought leader in delivering sustainable impact for global challenges

World-leading

Operations

Performance

Delivering

Breakthrough

Innovations


1963 – The First EPDM

5


Old Assets Dominate EPDM Industry Capacity

6

1963-1970 1971-1980 1981-1993 1994-2010 2010-2014 2017

As

se

t C

ap

ac

ity

Asset Start-up Year

Industry Asset Capacity vs. Age by Technology

Almost 50%

of current assets

are 25 years old

Source: Estimates based on public information

Advanced Molecular Catalyst

Metallocene

Ziegler-Natta


Delivering Industry-leading Efficiency

Source: Nexant and IHS

Dow

Technology

8.25 MJ/kg

Industry

Ziegler-Natta

19.11 MJ/kg

vs.

7

Production Energy Sources

Total MJ/kg

EPDM

Low & High

Pressure Steam

Electricity

(Direct &

Refrigeration)

Fuel

Gas + + =

Raw Material

Extraction Refining Use End of Life

Data per tests conducted by Dow. Additional information available upon request. Properties shown are typical, not to be construed as specifications. Users should confirm results by their own tests.


Maintaining Our Commitment to Industry Growth

Sadara Chemical Company

ENGAGE™ & AFFINITY™ GA

Polyolefin Elastomers

U.S. Gulf Coast

Shale Gas Investments:

2015-2017 Start-ups

• Propane Dehydrogenation Unit

• Next-generation NORDEL™ EPDM

• High Melt Index Elastomers

8


1960 – present

Moving Beyond Traditional Catalyst Technology

1997 – present 2015 and beyond Ziegler-Natta

Metallocene

9

• Ultra-high efficiency • Broad molecular weight • Increased filler acceptance • Faster curing • Expanded portfolio and

capabilities

• Low efficiency • De-ashing needed • Low reactor temperature

• High efficiency • No de-ashing required • High-temperature stability • Less gels

Advanced Molecular

Catalyst


0 2 4 6 8 10

Time, min

20

25

30

35

40

45

50

55

60

100000 1000000 10000000

Ph

as

e A

ng

le ( )

G* (dyn/cm2)

3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0

Log Molecular Weight

• High efficiency, high temperature operation

• Expanded molecular design

• Oil extension

• New tailored products

More Long Branching Higher

Molecular Weight

Catalyst and Process Advancements

More Diene

Low hLCB

High hLCB

90 Mu

+150 Mu 50 Mu Fast Curing

MD

R T

orq

ue

10


Designing a New Product*

High-throughput

Catalyst Screening

Identify and select

molecular catalyst to

produce target

molecular

architecture.

Product

Hypothesis

Understand and

develop EPDM

molecular target

based on future

application and

customer needs.

Modeling and

simulation

Simulate and predict

effects of molecular

structure on melt

rheology.

Application

Prototyping

Develop prototype

for application

development.

Molecular

Screening

Produce small-scale

samples for

hypothesis testing.

*Clayfield, T.; Li Pi Shan, C.; Den Doelder, J.; Han, T.; Polymers by Design – High Throughput Development in EPDM; IRC 2015 Nuremberg, 2015.

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http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.alibaba.com/countrysearch/US/hdpe-pellets.html&ei=l0KEVePZI8TIsAW50YfAAg&psig=AFQjCNFHcwBf-N2c3-9NMdH9jtZMI7bUlQ&ust=1434817545286138


Design Challenge Understanding what the industry does with our materials…

Fast and efficient High Quality Sustainable Supply

High Productivity Defect Free

Class A Reliable

12


Weatherseals -Keeping the noise out of the car…

DOW RESTRICTED

Primary Door/Body Seal

Secondary Door Seal

Trunk Seal

Encapsulated

Quarter-window

Hood Seal

Glass Run ChannelSunroof

Belt Line Seal

Other:

Roof Line

Windshield

Rear Window

13


Tailoring a Branched EPDM

New capability and predictive design tools enabled polymers with tailored

branching rheology and high melt elasticity*

Homogeneous Long Chain

Branching (hLCB)

T-TypeMacromonomer, vinyl chain

incorporation

• Uniformly distributed long chain branches

• Gel free

• Metallocene/post-metallocene chemistry 1.0E-01

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

0.001 0.01 0.1 1 10 100 1000

Pred

icte

d Ta

n D

elta

Shear Rate (1/s)

No hLCB

med hLCB

high hLCB

Increased melt elasticity

Melt elasticity is a key requirement for foaming

*Li Pi Shan, C.; Clayfield, T.; Den Dolder, J.; “Homogeneous long-chain branched EPDM development with high Mooney viscosity”; RubberWorld Magazine, Vol 250, No. 2, 2014.

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Designed Performance

Design challenge to produce

molecular structures with a combined

rheological and mechanical

performance.

Multi-dimensional approach allows

more accurate modelling with the use

of polymerization kinetic models of

Dow’s Advanced Molecular Catalysts.*

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

3 3.5 4 4.5 5 5.5 6 6.5 7

dw

/ d

Lo

g(M

)

Log (M)

Nordel 5565

Overall Fit

Flory Site 1

Flory Site 2

GPC Data

Overall FitMw = 172,992Mw/Mn = 3.03

Site 1: 53%, Mw = 74,550Site 2: 47% , Mw = 284,000

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37 43

76 78

0

10

20

30

40

50

60

70

80

90

NORDEL 6565 Prototype Incumbent

10 Minutes 2.5 Minutes 180 C Cure Time:

100C

, 22 h

r. C

om

pre

ssio

n S

et (

%)

Product Grade

Mooney

Viscosity

(ML1+4 @

125°C)

C2

(Mass %)

ENB

(Mass %) MWD

Crystallinity

(Mass %) Form

NORDEL™ IP 5565 65 50 7.5 Medium < 1 Bales

NORDEL 6565 XFC 65 55 8.5 Broad < 1.5 Bales

Features & Benefits:

Improved Performance for Dense and Microdense WS

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Features Benefits

High diene Fast curing/property build

Medium viscosity Fast processing/extrusion

High branching Excellent shape retention

Molecular wt. distribution High filler acceptance

Low gel levels Excellent surface quality

Data per tests conducted by Dow. Additional information available upon request. Properties shown are typical, not to be construed as specifications. Users should confirm results by their own tests.

Formulation: 347 phr total, N550, CaCO3, Sunpar 2280, sulphur cure

Faster cure, faster property build

10% higher line speeds


One-Stop Shop - First All Dow Weatherstrip

Incumbent EPDMs

NORDELTM 6555 OE (sponge)

NORDELTM 6565 XFC (dense, microdense)

NORDELTM 6535 XFC

European OEM Quality, Class A Sponge and Dense Profiles Corner Molds

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Leading the Way

• Dow continues to deliver sustainable

impact for EPDM, the elastomers

industry, and the plastics industry

at large

• World-leading operations performance

• Breakthrough innovations

‒ Advanced Molecular Catalyst offers

even greater efficiency and improved

performance across a broader range of applications

‒ New offerings for sponge and dense

EPDM options for automotive sealing

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The Dow Chemical Company

Thank You


21

NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use

conditions and applicable laws may differ from one location to another and may change with time, Customer is

responsible for determining whether products and the information in this document are appropriate for Customer's use

and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other

government enactments. The product shown in this literature may not be available for sale and/or available in all

geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow

assumes no obligation or liability for the information in this document. References to "Dow" or the "Company" mean the

Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN;

ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE

EXPRESSLY EXCLUDED.

epdm materials dow.pdf · *clayfield, t.; li pi shan, c.; den doelder, j.; han, t.; polymers by...

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