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Upcycling of consumer waste plastic:
from bottle to bumper
Dr. Ir. Jos van GisbergenSABIC Innovative PlasticsTechnology Mgr polyester resins October 23, 2009
2
Content
– Introduction SABIC Innovative Plastics
–Responsible care: what can we affect
– Environmentally Responsible Materials, Valox and Xenoy iQ* resins
– Summary
3
SABIC Innovative Plastics
• Subsidiary of Saudi Basic Industries
Corporation (SABIC)
• Leading global supplier of
engineering thermoplastics:
– Compounded resins.
– Film and Sheet
• multi-billion-dollar company
• operations in more than 40
countries, headquarters Europe in
Bergen op Zoom (NL)
• over 9000 employees worldwide
4
Engineered resinsDiverse applications & customer base
Media & Product Security
Healthcare
Transportation
Infrastructure
Electronics
Consumer
Automotive
Film & Sheet
SABIC Innovative Plastics – Market Segments
5
ResinPellets OEMMolder
ChemicalFeedstocks
How We Fit Into The Supply Chain
Base polymers
SABIC Innovative Plasticsmanufactures high quality thermoplastic resins & compounds
6
Responsible Care: What we can affect…
Transform
Capture?
Process Efficiency
Cleaner Chemistry
Recycling
Bio-based
Design
7
Responsible care in the processes in Bergen op Zoom
Rainwater Collection Unit (realization 2006):
Separation of rainwater and waste water to reduce risks by controlled discharge and reduction of hydraulic capacity of the water treatment system & re-use opportunity.
Brine Recover Project (realization 2006-2007):
Re-use of the brine stream from resin plant by filtration and adsorption. Total waste water reduction by 14%, reduction of salt concentration of wastewater by 74%, reuse and recycle of key raw material.
Winner National Energy Globe award.
Employee and Neighborhood involvement
Open communication and specific projects, e.g. energy savings
safety awareness with employees and family, e.g. children drawing contest
8
0
50
100
150
200
250
300
350
400
t on
/ jaar
2004 2005 2006 2007 2008
Jaar
NOx emissie SABIC-IP
NOx : 50 % reduction
2500000
2700000
2900000
3100000
3300000
3500000
3700000
3900000
Nm
3/ja
ar
2004 2005 2006 2007 2008
Jaar
Water use: 15 % reduction
Responsible care in the processes in Bergen op Zoom
250000
300000
350000
400000
450000
500000
ton
/jaar
2004 2005 2006 2007 2008Jaar
CO2 emissie SABIC-IP
CO2 : 12 % reduction
Continuous effort to reduce emissions and water usage
9
Environmentally Responsible Material Solutions
SABIC Innovative Plastics focuses environmental efforts on:
Exatec* Glazingglass replacement= Less weight
Paint replacement:Lexan* SLX Film
Replacement of halogenated materials:
Flexible Noryl* resinUpcycling PET water bottles into PBT:Valox iQ* &
Xenoy iQ* Resins
Upcycled Plastics from Recycled
Materials
End-Product Energy/FuelEfficiency Improvement
Reducing MaterialToxicity
Lexan* Constant Clear Film: no freezer
door blower = reduced energy
Improved solar water heater designs
Lexan* IR sheet:reduced heat = energy savings
10
10
cradle gate grave
raws Intermediates(polymers)
pellets molding product/use end of life
ProducerResponsibility
Extended Producer Responsibility
• The further downstream (back to cradle), the more the flexibility and the better the quality but also the more technical challenging.• With Valox and Xenoy iQ resins back to intermediates (raws)
cradle #2
Polymer Product Life Cycle….Cradle to Grave Cradle
MechanicalChemicalThermal
11
PBT PolyesterIndustryToday
Oil/Gas DMT/TPA
Post Consumer PET
Valox iQ*Xenoy iQ*Resin
How Valox iQ* Resins and Xenoy iQ* Resins work
12
Upcycle iQ* PBT resin process vs Recycle process
vs
Valox iQ* and Xenoy iQ* resin: Post Consumer “UPCYCLE”,Comparable properties to regular Valox and Xenoy resin
High-end Plastic Parts
Regrind Re-compound
Heat history
Traditional: Post consumer RECYCLE,
typically a 20 – 30% drop in performance
Trading-down
Post Consumer PET
Valox IQ* and Xenoy IQ* Resin
Butane DiOl
Chemical process
Trading-u
p
Trading-u
p
13
C
O
O CH2 CH2 CH2 CH2C
O
O
n
iQ PBT
C
O
O CH2 CH2C
O
O
n
O CH2 CH2 CH2 CH2 OH H O CH2 CH2 OH H
0.87 kg
+0.41 kg
R-PET
EGBDO
1.00 kg
0.28 kg
60% massIs “green”from RPET + 40% mass is chemical
•iQ PBT utilizes 68% green input (100 x 0.87/1.28)•iQ PBT is 60% green by mass•iQ PBT also produces green Ethylene glycol
1.28 kg
iQ* PBT “Green” Content
Valox iQ* PBT resin contains 60% Post Consumer Recycle
14
AND
• Reduction of post-consumer solid waste
• Reduced CO2 emissions
• Reduced energy consumption
Each Ton of iQ* PBT:
• Saves 0.9 tons of solid waste
• Saves 2 tons of carbon dioxide
• Saves up to 8.5 barrels of oil
Valox iQ* & Xenoy iQ* Resins
The performance of Engineering Polymers
16
Eco FR + Valox iQ*:
– Non Br/Cl FR
Super High Flow + Valox iQ*:
- new additive technology
Structural + Valox iQ*:
- 40% Glass filled
- MBDC cradle-to-cradle
Valox iQ* Applications
Electrical- Pressure sensor
Electronics- Cooling fans:
Valox iQ*: the same high end applications as “normal” PBT based products
Automotive & Furniture
17
Xenoy iQ* Applications
Hydro Stable + Xenoy iQ*:
– High Impact
High Modulus Ductile + Xenoy iQ*:
– 10% MF, High Modulus Ductiletechnology
automotive
Doorhandle
Telecommunications:
iphone ecoshield
Automotive:
Bumper energy absorbers
Xenoy iQ*: the same high end applications as “normal” PBT/PC based products
18
Valox iQ* and Xenoy iQ* resins
Environmental responsible technology CAN be combined with the highest engineering plastics performance standards
and latest material innovations.
19
Raise the iQ of your Products...smart3
Valox iQ* and Xenoy iQ* resins
� Meets tough technical expectations, lower carbon footprint
� 15 minutes of use extended to 15 years
� No compromise in design, performance, manufacturing or efficiency
21
THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS SUBSIDIARIES AND AFFILIATES (“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARD CONDITIONS OF SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com . AND ARE AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN IN GOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING SELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED IN SELLER’S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN.
Each user is responsible for making its own determination as to the suitability of Seller’s products, services or recommendations for the user’s particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statement by Seller concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of Seller or as a recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right.
SABIC Innovative Plastics is a trademark of Sabic Europe Holdings BV
* Trademark of SABIC Innovative Plastics IP BV