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High Performance, Low Cost Polyurethane Thermoset Resin Solutions for Filament Winding
TSE INDUSTRIES, INC. A Passion for Polymers.™
ENVIRONMENTALLY PREFERABLE COMPOSITE SOLUTIONS
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Thermoset polyester extensively uses both styrene monomer & MEKP, both volatile solvents, posing an increased risk of fire in processing and storage areas.!
• Styrene monomer is classified as a suspected carcinogen. It can cause CNS issues & lead to fatal cardiac sensitization (IARC). Styrene is classified as a hazardous air pollutant. Emissions are strictly regulated as a VOC.!
• Human lungs contain enzymes that convert styrene into styrene oxide, which has developed tumors in the lungs of mice.!
• MEKP is a severe skin irritant, requiring careful treatment as a hazardous waste. It must be disposed of at an RCRA approved facility.!
• Styrene monomer may be regulated even more tightly in the near future, making permits more difficult to obtain. This could limit production and force several large industries to scramble for alternatives (spa, tub, RV, boat, etc.).!
A New Strategic Approach is Needed Now!
Current Polyester Scenario
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Potential for worker exposure lawsuits.!
• Expensive ventilation and incineration equipment required.!
• Hazardous waste handling adds expense.!
• Yield losses are high due to styrene loss.!
The Use of Styrene is Vulnerable to Legislative Changes
Additional Impact of Styrene & MEKP Usage
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Current Epoxy Resins use BPA (Bisphenol Epichlorohydrin) to achieve cross-linking and to raise Tg’s / HDT’s.
• BPA can leach from epoxy resins, possibly causing severe adverse human health effects (based on more than 100 scientific papers): • Endocrine disrupting chemical • Liver enzyme damage • Damage to brain and reproductive organs • Damage to embryonic development • Linked to breast cancer • Low doses linked to increased risk of prostate cancer
• A 2005 bio-monitoring study detected BPA in 95% of U.S. Citizens.
• California bill introduced to ban BPA in certain toys and child care products.
• EPA conducting search for an alternative to BPA for use in pipes and pipe linings.
A New Strategic Approach is Needed Now!
Current Epoxy / BPA Scenario
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Polyurethane is an extremely versatile chemistry that allows creation of both thermoplastics & thermosetting plastics, ranging from very soft to hard and rigid.
• As with polyesters, two liquid components are used, plus catalysts, fillers and reinforcements. The two basic components for most common polyurethanes are Isocyanates and Polyols.
• No styrene monomer, MEKP or solvents are used. Some Isocyanates are regulated, but handling and disposal is much less hazardous and much less expensive than for styrene and MEKP.
• Polyurethanes generally have higher tensile and impact strength vs. polyesters, but lower stiffness. Optimization of the fiberglass reinforcement can close the stiffness gap.
Polyurethane Background
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• VOC-Free!!
• BPA-Free!!
• Styrene-Free! !
• Ultra low emissions!!
• 100% Solids! !
• Safer for your workers!!
Polyurethane Advantages: Environmentally Preferred
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Polyesters & Vinyl Esters (anhydride epoxy resins) have an 8 hour cure time (3-4hrs with amine- cured epoxies).!
• Polyurethane takes just 1 hour to cure!!
• That’s up to an 800% increase in production with anhydride epoxy resins! Up to 400% with amine-cured epoxies! !
Think about what you gain by switching to TSE-‐EcoWind PU composite resin...
• Increased Produc-on by Up To 800%! -‐ Make up to 8 +mes the product in the same amount of +me!
• Reduced Labor Costs -‐ With up to 8 +mes the produc+on, you could reduce hours and lower labor costs!
• Reduced U-li-es -‐ With a cure +me of just 1 hour, you're saving 7 hours of electricity or gas each cycle!
This Means More Profit for You!
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Polyurethane Advantages: Drastically Shorter Cure Times = More Profit!
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Our patented, dripless applicator virtually eliminates resin waste and saves you money! • On average, current systems waste approximately 5% of the material being applied.
Our patented, near dripless applicator virtually eliminates waste, slashing it to about 0.25%!
• Do the math: • Multiply the number of pounds of resin you use each month by 4.75%. • Now, multiply that number by your cost per pound of resin.
• That’s about how much you’ll save each month on resin using our applicator! • Now, add those savings to your additional income from increasing production by up to
800%, plus your savings from lower labor costs, plus your savings from a lower utility bill!
Are you getting an idea of the impact that TSE-EcoWind can have on your bottom line?
Polyurethane Advantages: TSE’s Applicator Reduces Waste & Saves Money!
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Polyurethanes are less brittle and have better impact and fatigue resistance. • Similar tensile and flexural strengths. • Superior abrasion resistance.
• Improved burst strength before and after fatigue testing: • Pressure Vessels in Epoxy and Polyurethane
• Water Heaters in Polyester and Polyurethane
Test Condi-on Epoxy Polyurethane Ambient Burst Test 880 PSI 1250 PSI Burst test aDer 250,000 Pressuriza-on cycles.
800 PSI 1240 PSI
Hot Water Burst Test 725 PSI 1237 PSI
Test Condi-on Polyester Polyurethane Average Burst 465 PSI 550 PSI Low Burst 425 PSI 520 PSI Max cycles -ll failure 250,000 +2 Million
Polyurethane Advantages vs. Polyesters & Vinyl Esters
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Polyurethane Resins Offer Step Change Process & Product Improvements
• Improved mean burst strength of 18%-40% while decreasing resin usage.
• Improved burst strength consistency
• Improved structural and burst performance allows redesign of thicknesses of the laminate to further reduce glass and resin consumption.
• Temperature resiliency: lower limit is -40 to -50F; Upper limit is approximately 205F (Tg of 300F /150C).
Polyurethane Performance Improvements: The Numbers
TSE INDUSTRIES, INC. A Passion for Polymers.™
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• Improved impact resistance due to improved elongation and tensile strengths.
• PU resins provide significant improvement in adhesion to fiberglass roving.
• 40% improvement in POST-hot cycle (250,000 cycles) strengths.
• No reduction in burst strength after POST-hot cycle.
• UV protection improved. (Based on 1 year side-by-side test in water/UV environment).
Polyurethane Resins Offer a ‘Groundbreaking Change’ Towards Improved Products & Enhanced Processes
Polyurethane Performance Improvements: The Numbers
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Isocyanates Are Classified (N120) by the EPA as Reportable Only On An Annual Basis
• Flash points of Isocyanate and Polyol are close to 400 ºF. • Volatility is extremely low, i.e., only 1 / 1,800,000 of the vapor pressure of water. • Reacted waste is non-hazardous. • Health & Safety information on MSDS:
• Polymeric Isocyanate – The ingredients of this product are not classified as carcinogenic by ACGIH or IARC, not regulated as carcinogens by OSHA, and not listed as carcinogens by NTP
• Polymeric Isocyanate - This material is not a hazardous waste under RCRA 40 CFR 261. Small quantities should be treated with a decontaminant solution. The treated waste is not a hazardous material under RCRA 40 CFR 261
Polyurethane Health & Safety
TSE INDUSTRIES, INC. A Passion for Polymers.™
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TSE is the Best Choice for a Strategic Polyurethane Partner!
• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance requirements.
• TSE not only provides Resin Technology solutions, but groundbreaking Process Technology to ensure a seamless fit for Polyurethane-based resin systems into your existing processes.
• On-site training for the Process Technology and in proper handling of chemicals.
• TSE R&D has proven experience converting both styrene ester and epoxy resins systems to polyurethane systems.
• TSE provides its patent pending, dripless impregnator roller applicators for glass wet out and higher application speeds, ensuring additional savings through waste reduction.
The TSE Advantage
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Pipes & Piping Systems Tanks & Pressure Vessels Elastomeric Lined FW Pipes
Filament Wound Products TSE 1 Specialty Chemicals & Resin Manufacturing Facility in Clearwater, FL
® TSE-EcoWind Complete Polyurethane Solution
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Products ! Process !
Pipes and Piping Systems! • TSE-‐EcoWind® P200G – High Performance Filament Winding resins for General pipe and piping system applicaKons
• TSE-‐EcoWind® P200HE – High ElongaKon, High Performance Filament Winding Resin for pipes and products requiring a higher degree of flexibility and elongaKon!
• Patented TSE Applicator technology for high speed filament winding processes incorporaKng opKmal applicaKon of polyurethane onto the glass/carbon fiber reinforcement)
• Turnkey Filament winding Process SoluKons and process consultancy for Polyurethane soluKons in Pipes, Piping Systems, Tanks, Pressure vessels, Water Heaters etc.
• Well equipped Research & Development Lab to develop custom applicaKon soluKons. !
Tanks and Pressure Vessels (with internal liners, i.e. water so_eners) !
• TSE-‐EcoWind® T210
Miscellaneous Filament wound products (i.e. water heaters!
• TSE-‐EcoWind® M100!
Elastomeric Liners (internal or external) for Pipes, Rollers!
• TSE-‐EcoWind® L85
® TSE-EcoWind Complete Polyurethane Solution
TSE INDUSTRIES, INC. A Passion for Polymers.™
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ACE Award Presentation, October 2014, CAMX Orlando!
TM
® Winner: ACE Award, CAMX Orlando 2014
TSE INDUSTRIES, INC. A Passion for Polymers.™
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The TSE EcoWinder Resin Applicator TM
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Pipes wound using TSE-EcoWind Polyurethane Thermoset Resin systems
displayed at the 2013 JEC Americas Innovation Showcase held in Boston.!
JEC Americas 2013 – Innovation Award Ceremony! ®
Winner: JEC Americas 2013 Innovation Award
TSE INDUSTRIES, INC. A Passion for Polymers.™
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TSE-EcoWind PU Filament Winding system was a Finalist at the 2013 Polyurethanes Technical Conference conducted by the American Chemistry Council in September.!
TSE’s presentation of its innovation in polyurethanes for filament winding applications at the Polyurethane Technical Conference 2013 held Sept. 23-25 in Phoenix, AZ.!
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Finalist: 2013 Innovation Award American Chemistry Council
Polyurethanes Technical Conference
TSE INDUSTRIES, INC. A Passion for Polymers.™
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TSE-EcoWind® Polyurethane Filament Wound pipes was a finalist at the 2013 JEC Europe Innovation Showcase held at Paris.!
JEC Europe 2013 – Innovation Showcase!
Winner: JEC Europe 2013 Innovation Award Paris, March 2013
TSE INDUSTRIES, INC. A Passion for Polymers.™
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TSE-EcoWind Polyurethane Resin System: • Reduces Cure Time from 8Hrs to Just 1Hr Meaning Up to an 800% Increase in Production, Increasing Profits While Reducing Labor and Utilities!
• High-Speed, Patented Applicator Virtually Eliminates Resin Waste, slashing it from 5% down to About 0.25%, Saving You BIG Money!
• Environmentally Preferable Solution - VOC, BPA & Styrene-Free! 100% Solids.
• Produces Products as Strong as Steel, but Lighter with Better Burst Strength.
• Seamless Conversion and On-Site Training from TSE Professionals.
• TSE-EcoWind Resins. Great for the environment, your workers, & your bottom line!
Conclusion
TSE INDUSTRIES, INC. A Passion for Polymers.™
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Thank you! For more information, contact!Mark D’Souza!
Composite Research & Development Manager!727-540-1306!
5260 113th Avenue North, Clearwater, Florida 33760!TEL: 1-800-237-7634 | FAX 727-230-8090!
www.TSE-Industries.com | www.TSE-EcoWind.com!