TOP 10 - ELASTOMERS FOR SUSTAINABILITY

 

The top entries for the second staging of ERJ’s new Elastomers for Sustainability initiative has now been decided by our judging panel led by leading experts in the field of polymer science & technology.

E4S is an industry-first sustainability initiative, designed to highlight significant advances for end-user sectors including automotive, tires, automotive components, construction, consumer, industrial and medical.   

The judging process has culminated in the following Top 10 of materials-science-based developments, based on their potential to enhance the environmental profile of the elastomer/rubber industry.   

Position	Entrant	Project	Score
1	ExxonMobil, Specialty Elastomers & Butyl Business	Higher performance tire innerliners with new specialty elastomer	585
2	JSR Elastomer Europe	New hydrogenated SBR for ultra-high strength	570
3	Arlanxeo	Sustainable EPDM compounding based on Eco EPDM rubber	548
4	Trinseo Europe	ISCC certification of synthetic rubber production	500
5	Trinseo Europe*	Highly-functionalized S-SBR grade	495
6	ETB*	Bio-butadiene from ethanol for tire production	490
7	Continental*	Eco-rubber hose	489
8	Kordsa / Continental	Ecofriendly dip technology (Cokoon) of textile tire reinforcement for tires	480
9	Asahi Kasei*	New-generation SBR technology	477
10	Isogran	Rice-husk silica	470

*Top 10 project in inaugural E4S rankings in July. Original score reduced by around 10%, then amended upwards depending on significance of any recent update to the project provided.

See also report in the latest issue of ERJ magazine. The table will be revised and updated withinm six months, with new projects that score higher than any of the current entries. Click the E4S Programme link to enter a project for the next Top 10, which will be published in ERJ July/Aug 2021 issue. 

 

THE TOP 10 PROJECTS

 

1. ExxonMobil Chemical

Higher performance tire innerliners with new specialty elastomer

Review
This new speciality elastomer has been developed to enhance the barrier performance of tire innerliners and, in turn, extend the battery range of electric vehicles.  
An alternative to traditional halobutyl/natural rubber blends, Exxpro 3563 is a fully saturated elastomer produced by the carbocationic polymerisation of isobutylene and para-methyl styrene followed by halogenation. 
The fully saturated backbone enables “exceptional” chemical and oxidation stability, while increased chain stiffness and better packing-density with benzylic bromide groups presents a highly effective barrier to oxygen molecules.
Compared to conventional innerliners, the new elastomer delivers: a 20-50% improved air retention; 12% improvement in in-use rolling resistance; On target inflation pressure loss rate (IPLR) of <1.8% for global EV OEM leaders; and an increase of 3-7% in EV battery range.

Judges' comments

- I like the idea of a lower permeation polymer for this application. Clearly TPMS has helped this sector greatly but this will do more. 
- Pushing the IPLR towards 1.5% is the industry goal. This is a commercial product that is being evaluated for tire introduction already.
- This is a commercial product that is being evaluated for tire introduction already. 

 

2. JSR Elastomer Europe

New hydrogenated SBR for ultra-high strength

Review
Through a combination of unique polymerisation and hydrogenation technology, JSR has achieved a “50%" improvement of wear resistance compared to our conventional grade while keeping a good balance between the rolling resistance and wet grip indicator. A key project focus was to increase the durability of tires and reduce road-wear particles.
The hydrogenated polymer can control the number of crosslinking points to achieve a uniform cross-linked structure that improves wear resistance.  
The single bond after hydrogenation allows free rotation leading to high polymer entanglement, which contributes to high modulus and enhanced wear resistance. 
As for the rolling resistance, the new polymerization technology shows a 30% improvement compared to E-SBR. 

Judges' comments

- Application of materials science in a seemingly novel way to deliver significant gains in the sustainability of tires
- HSBR apparently improves all aspects of the magic triangle by dispersing the crosslinks more evenly. Would like to see more evidence as to why this approach works and would like to see it used commercially to back up the claims.
- Opens a pathway to the reduction of tire wear, which would have a positive impact on reduction of TRWP and fuel efficiency

3. Arlanxeo

Sustainable EPDM compounding based on Eco EPDM rubber

Review
Arlanxeo targeted to develop and introduction of EPDM compounds based on EPDM rubbers incorporating bio-monomers as well as bio-based processing oils, plasticisers and sustainable fillers such as rice hush ash, carbon black from pyrolysed tires and micro-cellulose.
Now has three commercial Keltan Eco EPDM grades in its product portfolio: one for static profiles and TPV applications; a more amorphous grade for e.g. dynamic profiles; a super amorphous grade eg for sponge profiles.
Life cycle assessment shows that by using the high ethylene EPDM grades, CO2 footprint reduction of up to 85% can be achieved, compared with convention fossil-based EPDM.
The project also envisages the development of a bio-propylene for the Keltan Eco production as well as the use of other sustainable oils and fillers – and the potential role of such materials in new mobility, electrical vehicle and new power train technologies.

Judges’ comments

- The full LCA on biobased (sugar cane derived) EPDM versus conventional EPDM is compelling. Three grades on the market already. One has been turned into footballs for the World Cup in 2018. 
- I like this idea a lot. The proposal gets a little lost though. Is this about the polymer, the fillers or the plasticiser. It wants to tick every box. Focus on the new technology and build a story around that. 
- Among the many positives are the steps to build on all the achievements to date, eg targeting bio-propylene and automotive end-uses.
- The broad-based development of bio-EPDM compounds containing additives also from renewable sources is impressive. There are other bio-bases polymer lights on the Christmas tree, but the broad scope here is impressive. It is now necessary to move up the stairs.
 

4. Trinseo Europe

ISCC certification of synthetic rubber production

Review
Focused on Trinseo’s synthetic rubber manufacturing site in Schkopau, Germany, company will certify the coprocessing of traditional and sustainable feedstock in existing production units under the mass balance approach. 
The project promotes the use of more sustainable key raw materials in the manufacturing of synthetic rubber – including increased use of recycled and/or bio-based feedstock. 
Mass balance certification for the entire ‘chain of custody’ is awarded by the ISCC [International Sustainability & Carbon Certification] following third-party auditing. 
The pay-back is that companies can keep track of the total amount of sustainable feedstock throughout a complex value chain and ensure an appropriate allocation to the finished goods. 
Following a recent audit TÜV Nord and registration through the ISCC certification scheme, Trinseo can now deliver mass balance certified S-SBR and E-SBR synthetic rubber products.

Judges’ comments

- Important scheme to drive forward the use of renewable and recycled elastomer materials
- Would like to see more reference to materials-science or the formulation/testing work behind delivering the certified materials
- Innovative approach. Hopefully the benefits outweigh the extra costs/work for participants using a certified sustainable product/procedure 
 

5. Trinseo Europe

Highly-functionalized S-SBR grade

A Top 10 project in the inaugural E4S ranking in ERJ July/August issue.

Review
Functionalised SSBR with enhanced filler-polymer interaction is now the way to go for tire tread rubber. New grade Sprintan 918S featuring Trinseo’s proprietary functionalisation technology is at the leading-edge: offering advanced wet-grip and rolling-resistance properties in tires, including those for electric vehicles (EVs).

The optimised styrene/vinyl-group microstructure – in combination with functionalisation – is said to enhance wet braking performance at a relatively low glass transition temperature. This, in turn, improves wear performance. Since its recent introduction to the market, the material is said to be generating strong interest for EVs, UUHP/UHP summer, all-season and even winter tread applications.Judges' comments

Judges’ comments

- Company has provided good additional information about how the functionalisation works and how the improved processing they have achieved helps to maintain dispersion. 
Previous comments
- With a view to electric mobility, this product definitely has significant market potential.
- Innovative product that could have a significant effect on fuel reduction, which is important. Question over whether this can succeed commercially where so many others have not… 
 

6. ETB

Bio-butadiene from ethanol for tire production

A Top 10 project in the inaugural E4S ranking in ERJ July/August issue.

Review
The project targets the construction of standalone bioethanol-to-butadiene plants and those integrated into fossil-based butadiene production sites. To deliver this, the team developed a new catalyst system to increase the energy-efficiency and bio-butadiene yield of the Lebedev process.

The result could be a significant enhancement of sustainability indices across the synthetic rubber production chain – with clear benefits also for the ethanol industry. Commercialisation steps include an engineering project for demo plant in The Netherlands, with first commercial scale batches expected within two to three years.  

Judges' comments
- Ethanol-to-butadiene via updated, lower-energy Lebedev process – with a more efficient catalyst than before.
- A process development based on very good chemistry. With large-scale application could be beneficial for industry.  
- Interesting approach, though market opportunities are hard to estimate at this stage of development.
 

7. Continental

Eco-rubber hose

A Top 10 project in the inaugural E4S ranking in ERJ July/August issue.

Review: Project updated from inaugural E4S ranking in ERJ July/August issue. Continental has built on its development of a bio-EPDM based garden hose, with the new EcoLite Garden Hose, using 100% post-industrial recycled TPV.

Review
The strength of the original Eco-rubber garden hose project-entry is that it has delivered a pipeline taking a bio-ethylene monomer from sugar cane to a fully commercial product. The R&D work involved led to the development of an optimised bio-EPDM compounds able to match the performance of convention petroleum-derived polymer. The garden-hose project is linked a broader programme at Continental; targeting similar products containing up to 95% of renewable and reclaimed/recycled feedstock and materials – including that from end-of-life tires and other rubber products. 

Judges' comments

- Neat, focused compound development work with clear sustainability objectives
- Convincing development to this project with a product on the market and others that might soon follow
Previous comments
- Commercialisation is key to achievements in sustainability. This project seems to succeed in this point
- Sugar cane to EPDM rubber is really an Arlanxeo innovation. I like the potential in many other applications.

 

8. Kordsa Technical Textile / Continental AG

Ecofriendly dip technology (Cokoon) of textile tire reinforcement for tires

Review
New tire-cord fabric adhesive system to replace standard resorcinol-formaldehyde adhesive systems. The novel chemical composition is in its early commercialisation period.
Standardisation of the materials technology also reduces overlaps in R&D work and approval costs and minimises complexity for tire makers and textile converters.
With an open-source platform and royalty-free patent pool, the technology can be deployed without supply-chain conflicts among producers, customers and competitors. 
Continental has produced 250,000 tires with Cokoon dip technology in 2020. Some 24 external companies have signed NDAs and tested dipped cord samples. 

Judges' comments

- Great project concept, involving a wide number of suppliers and manufacturers in the adoption of a new, more sustainable chemistry.
- Pool approach is innovative and might find followers on other fields or even other industries
- If this is all open source, why not disclose some aspect of the chemistry in the application. Is it more sustainable: how can I judge this? Get the scientists to write (project entry form) next time.

 

9. Asahi Kasei

New-generation SBR technology

A Top 10 project in the inaugural E4S ranking in ERJ July/August issue.

Review
The company’s sixth generation functionalised SBR is said to show 20% lower rolling resistance than the previous grade and reduced wear. For this, Asahi developed a special functional group to enhance filler-polymer interaction – to improve wear resistance and rolling resistance – and a new polymerisation technology to optimise the polymer structure for advanced abrasion resistance while maintaining processability. The advanced SBR is currently being tested by customers worldwide, with plans to commercialize some grades in 2021. Next target is to improve the wear resistance by a further 20% and to increase the stability of the polymer in the compound.

Judges' comments

Previous comments
- Top marks for rolling-resistance and wear reduction through functionalisation of SBR to stick to rubber molecules
- Market-oriented development. What is positive is the progress being made here, even if not ‘a step outside the box’.

 

10. Isogran

Rice-husk silica

Review
Backed by Singapore-based agribusiness group Wilmar International, this project centres on the conversion of waste from rice-husk ash to silica and active carbon, particularly for the development of a high dispersible silica (HDS) for tire applications.
The HDS is said to perform similarly to conventional silica but with a carbon footprint of -0,82 kgCO2e/kg, compared to 2.06 kgCO2e/kg for the conventionally made product.
The product is commercially available, with the project team now developing a HDS with a surface area of >200m²/g for applications in silicone, health & personal care, agriculture, food & feed, paints and inks.

Judges’ comments

- Project involving major Singapore-based agribusiness group Wilmar International aims to deliver a large-scale production facility could add real impetus to the development of rice-husk as a significant filler option.
- I have been watching this space for many years and the reality is that this project needs more detail to explain why it will work - unlike other rice husk ash products, which have failed in the past to gain commercial acceptance.

 

About the E4S Top 10 ranking

Since early 2020, companies and individuals have been invited to supply E4S entries via an online link on the ERJ website. To decide the rankings, the expert judging panel assessed each project on the basis of: Quality of the presentation; level of innovation; USP; Commercial potential; and Contribution to sustainability. Along with ratings for overall strength and weakness, the system allowed for a maximum score of 700 points.

The expert panel comprises: 

Prof James Busfield, professor of materials & national teaching fellow director of industrial engagement & head of the soft matter group, Queen Mary University of London.

Dr. Christoph Sokolowski, lead on ‘sustainability’ issues within the German rubber industry association the WDK (Wirtschaftsverband  der deutschen Kautschukindustrie), based in Frankfurt am Main, Germany.

Martyn Bennett, who has recently founded UK-based consultancy Midsomer Science, after a career spanning over 30 years at Avon Rubber plc, most recently as chief scientist and head of its ARTIS consultancy service. 

Ji?í Brejcha, head of Brejcha Rubber Consulting, and former materials development specialist at Trelleborg Wheel Systems, and before that Mitas, Prague, Czech Republic.