Wacker VAE
Transcript of Wacker VAE
CREATING TOMORROW'S SOLUTIONS
VINNAPAS® VAE DISPERSIONSIDEAL BINDERS FOR INTERIOR PAINTSSTATE OF THE ART TRENDS.Dr. Udo Kotschi, WACKER POLYMERS, April 2011
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 1
AGENDA
• Who are we?
• Raw materials and manufacturing process
• VINNAPAS® VAE Dispersions are the preferred technology for environmentally friendly paints in Europe
• Trends• Requirements / Eco-labels
• VINNAPAS® VAE Dispersions for conventional and environmentally friendly interior paints
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 2
• Founded in 1914 by Dr. Alexander Wacker • Headquartered in Munich
WACKER CHEMIE AG
WACKER Group (2009)
• Sales: €3.72 billion
• EBITDA: €607 million
• R&D: €164 million
• Investments: €740 million
• Employees: 15,618
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 3
WACKER: HIGHLY INTEGRATED OPERATIONS BASED ON THREE KEY RAW MATERIALS
Raw material
CONSTRUCTIONAUTOMOTIVEPAINTS & COATINGSTEXTILESPRINT & PAPER, PERSONAL CARE
CONSTRUCTION (TILE ADHESIVES, DRY-MIX MORTARS, EIFS)
FOOD, LIFE SCIENCES, HOUSEHOLD
SOLAR MODULES
HYPERPURE SILICON WAFERSSEMICONDUCTORS
AUTOMOTIVE, FOOD
Upstream Downstream Customers’ industries
SOLAR CRYSTALS
SILICON METAL
SILOXANE
PYROGENICSILICA
SILICONES
SILICON WAFERS
PVAcVAM
DISPERSIBLE POLYMER POWDERS
COATINGS, ADHESIVES, NONWOVENS
ETHYLENE
STARCH/DEXTROSE
MICROBIAL FERMENTATION
THERAPEUTIC PROTEINS, FOOD INGREDIENTS
VAE
POLYSILICON
VAM = Vinyl acetate monomer, VAE = Vinyl acetate ethylene, PVAc = Polyvinyl acetate, EIFS = Exterior insulation and finishing system
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 4
* including internal sales
** balance of internal sales/ "other" € -127 million
Group sales in 2009: €3.719 billion
A WELL-BALANCED PORTFOLIO
*Total divisional sales in 2009 (incl. internal sales): €3.846 billion**
SILTRONIC
WACKER SILICONES
WACKER POLYMERS
WACKER POLYSILICON
WACKER BIOSOLUTIONS(formerly WACKER FINE CHEMICALS)
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 5
Production Dispersion Technical CenterProduction Powder
Adrian
ShanghaiDubai
Moscow
Sao Paulo
Melbourne
Zhangjiagang
Beijing
Singapore
India
Ulsan
Cologne
AllentownBurghausen
Calvert CityNanjing
Silicone
Ethylene
Acetic Acid
VAE PowdersDispersion
VAM
Key Markets
Ethylene
AceticAcid
VAE PowdersDispersion
VAM
Key Markets
Ethylene
Acetic Acid
VAE PowdersDispersion
VAM
Key Markets
US Europe ASIA
WACKER OWNS MORE THAN 50% OF THE WORLD’S VAE TECHNOLOGY PRODUCTION CAPACITY
WACKER POLYMERS production set up
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 6
FOR OPTIMUM SERVICE CLOSE TO OUR CUSTOMERS –OUR TECHNICAL CENTERS
Technical Centers located in• Australia (Melbourne)• Brazil (Jandira)• China (Shanghai; Beijing)• Germany (Burghausen)• Russia (Moscow)• Singapore • USA (Adrian; Allentown)• United Arab Emirates (Dubai)• India (Mumbai)
Service• Customer support for technical questions• New product developments based on leading-
edge technology and expertise• Formulations developed for local climates and
country-specific standards
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 8
RECIPE COMPONENTS OVERVIEW
• Water
• (Main) monomers (vinyl acetate, ethylene, vinyl chloride, acrylics, vinyl esters etc.)
• Functional monomers
• Stabilizers
• Initiator system
• pH adjust (buffer)
• Defoamer
• Biocide
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 9
EMULSION POLYMERIZATION PROCESS
• Monomers, surfactants / stabilizers, and water are the main components of the vinyl acetate/ethylene dispersions
• Functional monomers can be added for a variety of purposes, including stabilization or crosslinking
• pH and buffers are important variables in emulsion polymerization, influencing both kinetics and stability
• Additives like defoamers and biocides have specific functions, and are used in small quantities bearbeiten
• The right choice and amount are critical for handling and the final performance
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 10
EFFECT OF MONOMERS, FUNCTIONAL MONOMERS AND STABILIZING SYSTEMS ON COHESION & WATER RESISTANCE
Source: Wacker Chemie AG
S
VAC
VC
BA
E EHA
MMA
M
AA
MAANMA
PVAL
HECSurfa.Coh
esio
n
Hig
hLo
w
Influence on water solubility
Low High
Monomer
Func. Monomer
Stab. System
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 11
FUNCTIONING OF SURFACTANTS / EMULSIFIERS
Repulsion
Hydrophobic anionic, orcationicgroup
Surfactant
Polymer particle
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Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 12
EMULSION POLYMERIZATION PROCESS OVERVIEW
• The process and apparatus used depend on the kind of monomers
• Ethylene → gas• Open vessel does not work → Autoclave• Apparatus is under ethylene pressure
• Vinyl acetate / ethylene dispersions (VAEs) are sometimes also called “pressure polymers”
• Removal of the residual monomers and other volatileingredients by different chemical and/or physical measures
• Result: dispersion of polymer VAE particles in water
CREATING TOMORROW'S SOLUTIONS
VINNAPAS® VAE DISPERSIONS ARE THE PREFERRED TECHNOLOGY FOR ENVIRONMENTALLY FRIENDLY PAINTS IN EUROPE
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 14
GLASS TRANSITION TEMPERATURE (Tg)
Ethylene is the ideal internal softener for vinyl acetate polymer dispersions!
Influence of vinylic comonomers on glass transition temperature of vinyl acetate copolymers
°°°°C
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 15
MINIMUM FILM FORMING TEMPERATURE (MFFT)
• The process of film formation only occurs over a defined temperature. This temperature is called “minimum film forming temperature.”
• Above this temperature, the dispersion builds a homogeneous, crack-free film
• The MFFT depends on
• Tg of the polymer
• Polymer type
• Coalescing agents
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 16
VINNAPAS® VAE DISPERSIONS HAVE OUTSTANDING COALESCING PROPERTIES
Tg / MFFT correlation
MFFT [°°°°C]
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 17
• In VAE, water functions as a coalescing aid (hydroplastification!)
• High scrub resistance
• No additional coalescing agent
• No migration (no fogging)
• Film formation at low temperatures (<5 °C)
VAE DISPERSIONS VERSUS STYRENE ACRYLICDISPERSIONS Tg / MFFT CORRELATION
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 18
• Many different regulations to limit VOC in architectural coatings (governmental / labeling)
• Blue Angel / TÜV-Siegel / EU Ecolabel / VOC Decopaint Directive
• Indoor air quality (dangerous substances – construction products directive CPD) / SREP for interior wall paints
• Manufacturing without APEO’s
• Low-Formaldehyde (<10 ppm)
• Odorless
• Free of sensitizing additives (CIT …)
• What is next?
TRENDENVIRONMENTALLY FRIENDLY INTERIOR PAINTS
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 19
ENVIRONMENT
UV
NOxVOC
Ground-level ozone → summer smog
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 20
HUMAN HEALTH / OVERALL COMPETITIVENESS
• Zero VOC paints contain no solvents or plasticizers
• Therefore no fogging of active substances like solvents or plasticizers
• No black precipitations
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 21
CHALLENGES
• Rising crude oil prices / energy prices
• Raw material availability
• Value of sustainability is recognized in the coatings industries
• Interior wall paints are recognized as the most suited segment for renewable raw materials (IRA report 2009)
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 22
Sustainability Sustainable development is to meet the needs of present generations without jeopardizing the ability of future generations to meet their own needs (source: EU)
Since 1999: Dow Jones Sustainability Index
• Topics for decorative coatings
• VOC reduction / co-solvents
• Low formaldehyde
• APEO absence
• Low energy consumption
• Low carbon footprint
• Higher efficiency (less binder)
• Longer lifetimes
• Eco-friendly packaging
• Renewable raw materials
MEGA TREND SUSTAINABLE DEVELOPMENT –DECORATIVE PAINTS
EnvironmentViable
Tolerable
Sustainable
Equitable
Society
The aim is to balance economic, environmental and social goals.
Economy
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 23
IMPACT OF RISING OIL PRICES ON MANUFACTURING COSTS OF POLYMER DISPERSIONS
• O-Content• No. Synthesis Steps• Energy Consumption /
step• Process yield /
byproducts
Cost comparison –relative cost advantages
35-0%4-10%
1-10%
1-10%
Source: Wacker Chemie AG
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 24
CHEMICAL WEEK MAGAZINE :: NEW CONSTRUCTION PROJECTS
1 Wacker Eyes Green Polymers Production
10:09 AM EDT | April 9, 2010 | Natasha Alperowicz in Burghausen
Wacker Chemie is developing renewable bio-based technologies to produce vinyl acetate monomer (VAM)
and ethylene vinyl acetate (EVA) precursors, and ultimately green polymers. The company is the leading
producer of VAM-based dispersible polymer powders and a leading maker of EVA-based dispersions. Fri-
dolin Stary, senior v.p./corporate R&D, said at a recent press briefing at Burghausen, Germany—Wacker’s
main manufacturing site—that Wacker has been operating a bioethanol-based pilot plant producing acetic
acid at Burghausen since last year and is ready to scale up the process as soon as the economics prove
viable. The size and timing of the scale up would depend on the price of bioethanol compared with the price
of petrochemical feedstock, Stary says. The company is also preparing to produce bioethylene. “We would
use some of the quantities of the feedstocks to produce green VAM, and from this green polymers, but so far
we have no timeline by when this would be achieved,” Stary says.
Stary: Assessing the economics but no firm timeline is set.
Wacker buys bioethanol from a local distillery, which it uses at the 500-m.t./year acetic acid pilot plant. “We
are ready to build an industrial plant but are waiting to assess whether the economics to produce biogenic
acetic acid on an industrial scale are justified,” Stary says. No decision has been made on the capacity of the
bigger plant but sources say that it could be about 10,000 m.t./year. Wacker would be willing to license the
acetic acid process to third parties, he says.
VINNAPAS® DISPERSIONS BASED ON RENEWABLE RAW MATERIALS
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 25
EthanolBarley
Cane
Grape
Potato
Wheat
Corn
Honey
Beer
Rum
Wine
Vodka
Scotch
Jim Beam
Mead
VAEVAM VAE
Vinegar
Cane
Corn
Cellu-lose
Ethylene
+ Oxygen
- Water
end use
Ethanol
POSSIBLE WACKER-BIO-ROUTEETHANOL HAS A MILLENNIUM LONG PROVEN HISTORYOF INCREDIBLE DIVERSITY AND PERSISTENT INNOVATION
CREATING TOMORROW'S SOLUTIONS
VINNAPAS® VAE DISPERSIONS FOR CONVENTIONAL AND ENVIRONMENTALLY FRIENDLY DECORATIVE PAINTS
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 27
VINNAPAS® RANGE FOR SOLVENT- AND PLASTICIZER-FREE INTERIOR PAINTS
Type EP 3360 EP 3355 EP 3888 EF 3777 EZ 3010 CEZ 18
Monomer base Vac/E Vac/E Vac/E Vac/E Vac/E Vac/E/VC
Emulsifier
SystemPVAL+E PVAL+E PVAL+E E CD+E CD+E
APEO-free yes yes yes yes yes yes
MFFT +2°C +2°C +2°C +1°C 0°C +2°C
Preservation BIT/MIT BIT/MIT BIT/MIT BIT/MIT CIT/MIT BIT/MIT
Specification
Solids Content 60 ± 1 55 ± 1 50 ± 1 56 ± 1 55 ± 1 50 ± 1
Viscosity 4000 ± 1000 1750 ± 750 800 ± 400 1000 ± 850 4300 ± 1600 12000 ± 3000
pH 4 – 6 4 – 6 4 – 6 3.5 – 4.5 4.5 – 5.5 4 – 5
Application interior interior interior interior interior interior / exterior
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 28
VINNAPAS® VAE DISPERSIONS – APPLICATIONS
• All kinds of interior applications: (with exception of silicate systems)
• Solvent-free and plasticizer-free interior paints
• Matt paints (wall and ceiling paints)
• Glossy paints
• Latex paints
• Silicone paints
• Matt and glossy full-shade paints
• Interior plasters
• Scratched plasters
• Plasters with a worm structure
• Textured coatings
• Primers
• Fillers
• Glue for glass, fabrics, and wallpapers
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 29
• Dispersion properties
• Low total VOC content
• MFFT = 0°C
• Solvent-, plasticizer-free and low-formaldehyde dispersion
• Manufactured without APEO’s
• No or low odor
• Preservation < 200 ppm BIT / MIT or < 15 ppm CIT / MIT
VINNAPAS® VAE DISPERSIONS – PROPERTIES
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 30
VINNAPAS® VAE DISPERSIONS –FORMULATION AND FILM PROPERTIES
• Good compatibility with a wide range of raw materials
• MFFT approx. 0°C
• Excellent film forming properties at low temperatures
• Good film formation without the addition of coalescing agents
• No solvents or plasticizers required
• Very high binding power
• High scrub resistance in matt paints (high PVC paints)
• Excellent gloss / blocking behavior
• Excellent thickener response
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 31
• Complies with European environmental standards and labeling
• Blue Angel
• TÜV-Siegel
• EU Ecolabel
VINNAPAS® VAE DISPERSIONS –FORMULATION AND FILM PROPERTIES
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 32
• Exterior decorative paints
• We do not recommend the “pure” VINNAPAS® VAE dispersions (without vinyl chloride, vinyl laurate, acrylics etc.) for exterior applications
• Please address any questions concerning the use of VINNAPAS® VAE dispersions for exterior applications directly to our Application Development & Technical Service (+49 8677 83-4094) in Burghausen
VINNAPAS® VAE DISPERSIONS – APPLICATIONS
VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 33
� High scrub resistance
• Tested in a matt paint
according to RR 53 523 09
• PVC = 45 - 85%
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
Water x
Dispex N 40 5
Natrosol plus 430 2
Rheolate 208 2
NaOH 10% 1
Addid 800 1
Kronos 2300 71
Mistron 754 G 71
Omyalite 90 142
Omyacarb 2 GU 261
Arbocel BE 600/30 PU 40
Parmetol DF 12 2
Dispersion x
Total 1,000
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 34
EN ISO 11 998DIN 53 778 part 2
EQUIPMENT FOR THE DETERMINATION OF SCRUB RESISTANCE
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 35
EQUIPMENT FOR THE DETERMINATION OF SCRUB RESISTANCE
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 36
EQUIPMENT FOR THE DETERMINATION OF SCRUB RESISTANCE
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 37
RESULTS OF THE DETERMINATION OF SCRUB RESISTANCE
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 38
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
PVC [%]
Loss
of T
hick
ness
[µm
]
High scrub resistanceScrub resistance of VINNAPAS® EP 3888 and VINNAPAS® EZ 3010as a function of the PVC (RR 53 523 09 test procedure)
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 39
Excellent film forming properties at low temperaturesScrub resistance of VINNAPAS® EP 3888 as a function of the PVC and temperature (RR 53 523 09 test procedure)
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
PVC [%]
Loss
of T
hick
ness
[µm
]
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 40
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
Excellent hiding power
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 41
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
Hiding power VINNAPAS® EP 3888 versus SA
Con
tras
trat
io
Spreading rate in m2/liter
6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 42
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 43
EQUIPMENT FOR THE DETERMINATION OF SHEEN RESPECTIVELY GLOSS
• EN ISO 13 300
• Mat < 10 units at 85°
• Dead mat < 5 units at 85°
Source: Wacker Chemie AG
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 44
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
She
en (
85)
Low sheen in matt paintsSheen (Gloss 85) as a function of the PVC
PVC [%]
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 45
• Excellent color strength
• Excellent color stability, even in matt interior paints
After 6 weeks on the window
VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING
Competitor binder VINNAPAS®
EP 3888
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 46
• All-purpose binder → interior and exterior applications
• All kinds of interior applications (including silicate systems)
• Solvent and plasticizer-free interior paints / plasters, etc.
• All kinds of exterior applications
• Exterior paints, crack-bridging paints, etc.
• Thermal insulation systems
• Special applications
• Dispersion-modified silicate paints
• Concrete paints
• Roof coating compounds
• Flame retardant systems
VINNAPAS® CEZ 18 – APPLICATIONS
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 47
• MFFT < 0°C
• Excellent film forming properties at low temperatures
• No solvents or plasticizers required
• High binding power
• Low VOC
• No or low odor
• Manufactured without APEO’s
VINNAPAS® CEZ 18 –KEY PERFORMANCE IN INTERIOR PAINTS
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 48
• Excellent resistance against saponification
• Excellent weathering resistance
• Excellent durability
• Low dirt pick-up
• Low chalking
VINNAPAS® CEZ 18 –KEY PERFORMANCE IN EXTERIOR PAINTS
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 49
• Interior / exterior applications
• Excellent resistance against saponification
• Excellent durability
• Crack-free
• Pinhole-free
• Good storage stability
• Fire protection classification B1 according to DIN 4102 (Fire Behavior of Building Materials and Elements) in respect ofthermal insulation systems
VINNAPAS® CEZ 18 – KEY PERFORMANCE IN PLASTERS
VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 50
• Different exterior coatings series based on VINNAPAS® CEZ 18 have been applied to our test fence in Burghausen (Germany) over a period of several months
• Our objective is to compare the new system with our VINNAPAS® CEZ 16 standard
• Beside classical exterior coatings, we are also testing ⇒ silicon resin emulsion paints⇒ silicate paints
• So far, the coatings performance of VINNAPAS® CEZ 18 APEO-free looks good and is comparable with our VINNAPAS® CEZ 16 standard
ONGOING MONITORING OF DIFFERENT VINNAPAS® CEZ 18 EXTERIOR COATINGS ON OUR TEST FENCE