a sustainable solution for extrusion coating applications ......ldpe-2 ldpe ec grade braskem...
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1 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
A Sustainable Solution for Extrusion Coating applications with Tubular LDPE
Presented by:
Roger MalmegrimTechnical Services
Performance Products
16TH TAPPI EUROPEAN PLACE CONFERENCE
17th TAPPI European PLACE Conference
20-22 May 2019Crown Plaza Hotel Porto
Portugal
2 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Introducing the Green PE Technology
New LDPE EC Tubular grade
Product Properties
Processability
Conclusions
Structure
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3 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
The Biopolymersand Our
positioning
4 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
BIO-BASED
BIODEGRADABLERECYCLABE
FOSSIL-BASED
Bioplastics Bioplastics
BioplasticsConventional Plastics
e.g.: bio-PE, PET, Bio-EVA1
Nearly all conventionalplastics e.g. PE, PP, PET e.g.: PBAT, PBS, PCL
e.g.: PLA, PHA,Starch Blends
BioplasticsBioplastics are Biobased, Biodegradable or Both.
Source: European Bioplastics1: EVA can be reused, but it’s not recyclable yet
Confidential information and restricted use by Braskem, being prohibited its reproduction, except with prior and express authorization of Braskem.
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5 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Chemically identical to “regular” PEor drop-in solution;
Renewable Source: Sugar Cane
Locking carbon in a very stable molecule (less than 1% degradation in landfills after 100 years) means reductionof Global Warming;
Every carbon atom in I’m green™ PEwas absorbed from atmosphere during sugarcanegrowth;
Every bit as recyclable as “regular” PE – can bemixed;
Our positioning:
Confidential information and restricted use by Braskem, being prohibited its reproduction, except with prior and express authorization of Braskem.
Renewable and Recyclable
6 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Green PE CycleSugarcanecaptures CO2
Production of ethanoland renewable energy
Production of Green Ethyleneand Green Polyethylene
Packaging made fromGreen Polyethylene
Green Polyethylene helpsreduce greenhouse gases
and is 100% recyclable
100%Recyclable
(at same condition as
fossil PE)
Green PE Carbon footprintfrom Cradle to Braskem’s gate
1mtof I’m green™Polyethylene
3.09mtCO2.eq
captures
LCA Study conducted by ACV Brasil/2017 (from cradle to Braskem factory gate)
Confidential information and restricted use by Braskem, being prohibited its reproduction, except with prior and express authorization of Braskem.
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7 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Carbon Footprint ComparisonCarbon footprint (t CO² eq./t polymer)
(1) LCA Study conducted by ACV Brasil/2017 (from cradle to Braskem factory gate)(2) Plastics Europe
-3,09(1)
+1,83(1)
Conventional PE (Braskem)
+1,93(2)
Conventional PE (Europe)
Braskem’s I’m green™ PE
Confidential information and restricted use by Braskem, being prohibited its reproduction, except with prior and express authorization of Braskem.
8 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
LDPE Extrusion Coating Tubular ‐ Methods to achieve objective
ExtrusionCoatingProduct
Process(polymerization
process conditions)
Post ReactorModification
Resin
Blend
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9 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Comparative Examples Tubular vs. Autoclave LDPE
New
Material Description Producer Technology Melt Indexg/10min
Densityg/cm³
LDPE-1 LDPE film grade Braskem Tubular 4.0 0.922
LDPE-2 LDPE EC grade Braskem Autoclave 4.0 0.924
LDPE-3 LDPE EC grade Braskem Autoclave 8.0 0.919
LDPE-4 New LDPE EC grade Braskem Tubular 4.7 0.918
LD-5 EC Tub Comparative Examples Commercial LD grade Tubular 3.9 0.919
LD-6 EC Tub Comparative Examples Commercial LD grade Tubular 5.0 0.920
LD-7 EC Tub Comparative Examples Commercial LD grade Tubular 5.0 0.918
10 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Molecular Weight Distribution (MWD): LDPE EC Tubular vs. Autoclave
High molecular weight fraction
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
2.0 3.0 4.0 5.0 6.0 7.0
dWf/dLogM
Log M (g/mol)
LDPE‐3 EC (MI 8) ‐ Autoclave(Braskem)
LDPE‐4 New EC (MI 4.7) ‐ Tub(Braskem)
LDPE‐1 Typical Film (MI 4) ‐Tub (no modification)
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11 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Rheological Comparison of Tubular vs. Autoclave LDPE
• (η0) High viscosity at low shear rate
1E+02
1E+03
1E+04
0.01 0.10 1.00 10.00
│ɳ ̽│ , Pa.s
Angular Frequency, (rad/s)
Melt Viscosity as a Function of Angular Frequency (ω) 170°C
LDPE‐4 New EC (MI 4.7) ‐ Tub(Braskem)
LDPE‐3 EC (MI 8) ‐ Autoclave(Braskem)
LDPE‐2 EC (MI 4) ‐ Autoclave(Braskem)
New tubular LDPE:Extrudability (high shear rates)
comparable to 8 MI autoclave LDPE
Melt Index
g/10min
Density
g/cm³
G'(G"=500 Pa),
(170 °C), [Pa]
η0(zero viscosity ),
(170 °C), [Pa.s]
4.0 0.924 9.49E+03 119
4.7 0.918 8.45E+03 114
8.0 0.919 4.23E+03 107
LDPE‐2 EC ‐Auto
LDPE‐4 New EC ‐Tub
LDPE‐3 EC‐ Auto
12 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Resin system: Rheology attributes @190°C
‐2
0
2
4
6
8
10
12
0 2 4 6 8 10 12 14 16 18 20
Melt Strength [cN
]
Melt Extensibility [cm/s]
Determination Melt Strength vs. Melt Extensibility (190°C)Rheotens curves
LDPE‐4 New EC (MI 4.7) ‐ Tub (Braskem)
LDPE‐3 EC (MI 8) ‐ Autoclave (Braskem)
Commercial LD‐5 EC (MI 3.9) ‐ Tubular
Commercial LD‐6 EC (MI 5) ‐ Tubular
Commercial LD‐7 EC (MI 5) ‐ Tubular
Commercial LD-5 EC MI 3.9 tub
LDPE-3 EC MI 8 autoclave
LDPE-4 New EC MI 4.7 tub
Commercial LD-6 EC MI 5 tub
Commercial LD-7 EC MI 5 tub
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13 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Effect of Processing Temperature on Neck‐in
Neck In (NI) = (Die width ‐ Coating width) / 26770
78
8588
93.5
89.5
20
30
40
50
60
70
80
90
100
305°C 315°C 325°C
Neck‐In (mm)
Melt Temperature
LDPE EC (MI 8) ‐ Autoclave
New LDPE EC (MI 4.7) ‐ Tub(Braskem)
Blend 70:30 (LDPE EC Auto /New EC‐Tub)
Set maximun speed 450m/min, 12 g/m², Die Gap 0,63 mm, die width 990mm, Air gap 346 mm
14 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Effect of Processing Temperature on Draw‐Down
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
305°C 315°C 325°C
Minim
um Thickn
ess (m)
Melt Temperature
Minimum Thickness vs. Melt Temperature
LDPE EC (MI 8) ‐ Autocalve
New LDPE EC (MI 4.7) ‐ Tub(Braskem)
Set 450m/min, Die gap 0,63 mm, Air gap 346 mm
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15 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
Conclusions
Our new LDPE EC (Tub MI 4.7 g/10 min) presents:
The presence of higher molecular weight fraction in the resin ensures high melt strength
Viscosity behaviour of our new tubular LDPE EC (MI 4.7 g/10min) is between autoclave materials with MI 4 and 8 g/10min.
Good optical properties and low gel level
Stable processing under given conditions at 450 m/min, constant coating weight 14 g/m² and melt extruder temperature at 325°C.
Good performance in extrusion coating machines, but the NI is still slightly above NI of known standards LDPE EC (A/C MI 8.0 g/10min)
LDPE EC ( Tub MI 4.7 g/10min) showed better draw-down than A/C MI 8.0 g/10min at higher melt temperature (315 °C and 325 °C).
Our Green LDPE EC tubular technology is a sustainable solution with better higher carbon footprint compared to others technology, gives > 95 % biobased carbon content calculated by C14 method.
16 Roger Malmegrim, Braskem - A Sustainable Solution for Extrusion Coating with Tubular LDPE - 17th TAPPI European PLACE Conference 2019 Porto – Session 8 - Paper 2
“Thank you” “Muito obrigado”
Presented by:
Roger MalmegrimTechnical ServicesPerformance [email protected]
16TH TAPPI EUROPEAN PLACE CONFERENCE