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Wacker VAE
Wacker VAE
Wacker VAE
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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 1
WACKER CHEMIE AG
WACKER Group (2009) Sales: EBITDA: R&D: Investments: Employees: 3.72 billion 607 million 164 million 740 million 15,618
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 2
Downstream
SILICONES
Customers industries
CONSTRUCTION AUTOMOTIVE PAINTS & COATINGS TEXTILES PRINT & PAPER, PERSONAL CARE HYPERPURE SILICON WAFERS SEMICONDUCTORS SOLAR MODULES COATINGS, ADHESIVES, NONWOVENS CONSTRUCTION (TILE ADHESIVES, DRY-MIX MORTARS, EIFS) AUTOMOTIVE, FOOD FOOD, LIFE SCIENCES, HOUSEHOLD
SILICON METAL
STARCH/ DEXTROSE
THERAPEUTIC PROTEINS,
FOOD INGREDIENTS
VAM = Vinyl acetate monomer, VAE = Vinyl acetate ethylene, PVAc = Polyvinyl acetate, EIFS = Exterior insulation and finishing system
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 3
A WELL-BALANCED PORTFOLIO
Group sales in 2009: 3.719 billion Total divisional sales in 2009 (incl. internal sales): 3.846 billion**
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 4
WACKER OWNS MORE THAN 50% OF THE WORLDS VAE TECHNOLOGY PRODUCTION CAPACITY
WACKER POLYMERS production set up
Burghausen
Beijing
Calvert City
Dubai India
Nanjing
US
Acetic Acid VAE VAM Key Markets Dispersion Powders
Europe
Silicone Acetic Acid VAE VAM Key Markets Dispersion Powders
ASIA
Ethylene
Singapore
Acetic Acid VAE VAM Key Markets Dispersion Powders
Ethylene
Ethylene
Sao Paulo
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 5
Service
Customer support for technical questions New product developments based on leadingedge technology and expertise Formulations developed for local climates and country-specific standards
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 6
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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 8
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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 9
EFFECT OF MONOMERS, FUNCTIONAL MONOMERS AND STABILIZING SYSTEMS ON COHESION & WATER RESISTANCE
VC High S
MMA
PVAL AA VAC
Cohesion
Polymer particle
--
- -
Repulsio
n
-
- --
- -
-- -- -
- -
Surfactant
Hydrophobic
--
- -
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 11
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 Result: dispersion of polymer VAE particles in water Removal of the residual monomers and other volatile ingredients by different chemical and/or physical measures
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 12
VINNAPAS VAE DISPERSIONS ARE THE PREFERRED TECHNOLOGY FOR ENVIRONMENTALLY FRIENDLY PAINTS IN EUROPE
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 14
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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 15
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 16
VAE DISPERSIONS VERSUS STYRENE ACRYLIC DISPERSIONS Tg / MFFT CORRELATION 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)
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 17
TREND ENVIRONMENTALLY FRIENDLY INTERIOR PAINTS Many different regulations to limit VOC in architectural coatings (governmental / labeling) Blue Angel / TV-Siegel / EU Ecolabel / VOC Decopaint Directive Indoor air quality (dangerous substances construction products directive CPD) / SREP for interior wall paints Manufacturing without APEOs Low-Formaldehyde (<10 ppm) Odorless Free of sensitizing additives (CIT ) What is next?
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 18
ENVIRONMENT
UV NOx VOC
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
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 20
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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 21
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 23
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. Fridolin Stary, senior v.p./corporate R&D, said at a recent press briefing at Burghausen, GermanyWackers main manufacturing sitethat 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.
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 VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 24
POSSIBLE WACKER-BIO-ROUTE ETHANOL HAS A MILLENNIUM LONG PROVEN HISTORY OF INCREDIBLE DIVERSITY AND PERSISTENT INNOVATION
CelluHoney lose Corn Wheat Barley Grape Potato Cane Ethanol Mead Jim Beam
- Water
+ Oxygen
Vodka Rum
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 25
VINNAPAS VAE DISPERSIONS FOR CONVENTIONAL AND ENVIRONMENTALLY FRIENDLY DECORATIVE PAINTS
EP 3360
Vac/E PVAL+E yes +2C BIT/MIT
EP 3355
Vac/E PVAL+E yes +2C BIT/MIT
EP 3888
Vac/E PVAL+E yes +2C BIT/MIT
EF 3777
Vac/E E yes +1C BIT/MIT
EZ 3010
Vac/E CD+E yes 0C CIT/MIT
CEZ 18
Vac/E/VC CD+E yes +2C BIT/MIT
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 27
VINNAPAS VAE DISPERSIONS PROPERTIES Dispersion properties Low total VOC content MFFT = 0C Solvent-, plasticizer-free and low-formaldehyde dispersion Manufactured without APEOs No or low odor Preservation < 200 ppm BIT / MIT or < 15 ppm CIT / MIT
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 29
VINNAPAS VAE DISPERSIONS FORMULATION AND FILM PROPERTIES Good compatibility with a wide range of raw materials MFFT approx. 0C 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 Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 30
VINNAPAS VAE DISPERSIONS FORMULATION AND FILM PROPERTIES Complies with European environmental standards and labeling Blue Angel TV-Siegel EU Ecolabel
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 31
VINNAPAS VAE DISPERSIONS APPLICATIONS 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 Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 32
VINNAPAS VAE DISPERSIONS KEY PERFORMANCE IN PAINTS / BENCHMARKING High scrub resistance Tested in a matt paint according to RR 53 523 09 PVC = 45 - 85%
Water Dispex N 40 Natrosol plus 430 Rheolate 208 NaOH 10% Addid 800 Kronos 2300 Mistron 754 G Omyalite 90 Omyacarb 2 GU Arbocel BE 600/30 PU Parmetol DF 12 Dispersion Total
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 33
EN ISO 11 998
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 34
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 35
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 36
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 37
PVC [%]
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 38
PVC [%]
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 39
VINNAPAS VAE DISPERSIONS KEY PERFORMANCE IN PAINTS / BENCHMARKING Excellent hiding power
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 40
VINNAPAS VAE DISPERSIONS KEY PERFORMANCE IN PAINTS / BENCHMARKING Hiding power VINNAPAS EP 3888 versus SA
Contrast ratio
6,0
6,5
7,0
7,5
8,0
8,5
9,0
9,5
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 42
EQUIPMENT FOR THE DETERMINATION OF SHEEN RESPECTIVELY GLOSS EN ISO 13 300 Mat < 10 units at 85 Dead mat < 5 units at 85
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 43
PVC [%]
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 44
VINNAPAS VAE DISPERSIONS KEY PERFORMANCE IN PAINTS / BENCHMARKING Excellent color strength
After 6 weeks on the window
Competitor binder
VINNAPAS EP 3888
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 45
VINNAPAS CEZ 18 APPLICATIONS 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 VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 46
VINNAPAS CEZ 18 KEY PERFORMANCE IN INTERIOR PAINTS MFFT < 0C Excellent film forming properties at low temperatures No solvents or plasticizers required High binding power Low VOC No or low odor Manufactured without APEOs
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 47
VINNAPAS CEZ 18 KEY PERFORMANCE IN EXTERIOR PAINTS Excellent resistance against saponification Excellent weathering resistance Excellent durability Low dirt pick-up Low chalking
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 48
VINNAPAS CEZ 18 KEY PERFORMANCE IN PLASTERS 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 of thermal insulation systems
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 49
ONGOING MONITORING OF DIFFERENT VINNAPAS CEZ 18 EXTERIOR COATINGS ON OUR TEST FENCE
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
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 50
THANK YOU!!
VINNAPAS VAE Dispersions Dr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 51