VinylSUM: A Research Network to

Improve the Sustainability of PVC

N.L. Thomas, M. Gilbert & S.G. Patrick,

IPTME, Loughborough University, UK
 Outline of Presentation
™Introduction
¾Who we are
¾Objectives
¾Where we fit in
™Activities
¾Meetings & Workshops
¾Research Projects
™Expansion of Network
¾Associate Membership Scheme
¾Future Plans
 Introduction
™EPSRC funded April 2004 – March 2007
™Organised by the Institute of Polymer
Technology and Materials Engineering (IPTME),
Loughborough University
™Dr Noreen Thomas is Principal Investigator
with Professor Marianne Gilbert as co-
investigator and Mr Stuart Patrick as
coordinator/administrator.
 Industrial Partners
™Ineos ChlorVinyls
™Hydro Polymers
™British Plastics Federation
™European Council for Plasticisers and
Intermediates (ECPI)
™European Stabiliser Producers Association
(ESPA)
 Academic Partners

™IPTME, Loughborough University

™Prof Adisa Azapagic, CEAS, Manchester University
™IRC, Bradford University
™Wolfson Centre, Brunel University
™Biocomposites Centre, Bangor University
 Additional Members

™The Natural Step (TNS) and the PVC

Stakeholder Council (chaired by Jonathon
Porritt)
™COSTdown (Recycling)
™Dutch PVC Network
 Objectives
™To establish a forum for an industry-wide discussion of
research required to improve the sustainable use of PVC
™To review research to date, and identify knowledge gaps
™To develop an approach for a full evaluation of
sustainability on a life cycle basis, and set up a modus
operandi in which the whole industry works together to
achieve the objectives for sustainable use which can then be
applied to other polymers
™To become a source of impartial information to all
stakeholders
 Vinylsum.org.uk
™ About Us
™ Members Area – Minutes of meetings, Presentations
™ Associate Members - Summary of Results from Research
Projects, Technical reports, Updated literature review
™ Research Projects – Detailed Results of current project
™ News
™ Events
™ Literature
™ Links
 Literature Review I – PVC Research
™General PVC references, recent reviews
™Additives: stabilisers, plasticisers & issues
™Fire retardants and smoke suppressants
™Nanocomposites and related topics
™Polymerisation
™Resins and compounds
™Processing and products
™Recycling and waste treatments
™Life cycle analysis/Sustainability
 Literature Review II - Sustainability
™Review of Life Cycle Assessments Available
on PVC
™Review of Environmental Issues Associated
with PVC
™Review of Recycling and Waste Treatment
Issues and Methods
Improving Sustainability of PVC through
Novel Materials, Processes and Life
Cycle Methodologies
N L Thomas, M Gilbert, B Haworth (IPTME)
A Azapagic, Manchester University

Supported by INEOS ChlorVinyls,

Hydro Polymers, BPF and ECPI
 Processes + Materials = Products
POLYMERISATION NANOCOMPOSITES
(WP1) (WP2) PVC PRODUCTS

Processing

Use
Incorporation of
Non-aqueous Additives during Stabilization Plasticiser Smoke Re-use &
Polymerisation Migration Suppression Processing Recycling
Polymerisation
(WP1&WP2)

LIFE CYCLE SUSTAINABILITY OF PVC (WP3)

 Research Workers on the Project
™Polymerisation – WP1
™Prof Brian Brooks – Emeritus professor, Chemical
Engineering, Loughborough
™Dr Styliani Georgiadou – RA (IPTME)

™Nanocomposites – WP2
™Dr David Hitt – RA (IPTME)
™Mr Fabio Papini – PhD student (IPTME)
™Mr Xiaoran Zheng – PhD student (IPTME)

™Life Cycle Sustainability of PVC – WP3

™Dr Shahriar Amini – RA – University of Manchester
 Novel Sustainable Processes for making PVC

The aim of the project is to address some of the environmental

and sustainability issues associated with PVC production by achieving
™ Energy savings
™ Reduction of emissions
™ Elimination of water contamination during polymerisation
™ Use of smaller quantities of sustainable additives

These objectives will be achieved by the development of

Ö novel non-aqueous polymerisation processes
Önovel PVC nano-composites with sustainable additives
Non-aqueous Polymerisation
A polymerisation process that does not require water has substantial
environmental benefits, particularly regarding energy savings.
 Non-aqueous Polymerisation

SEM pictures showing Grain Morphology and Surface Detail of PVC

polymerised by the Non-aqueous Process.
 Nanocomposite Development by In-situ Polymerisation

In situ polymerisation facilitates the dispersion of the nanoparticles.

Inorganic materials that will

be used include ultrafine:-
¾ calcium carbonate
¾ silica
¾Clays & other platy
particles
Nanocomposite Development by In-situ Polymerisation

Incorporation of nano-particles of CaCO3 into PVC

Nanocomposite Development by Melt Compounding
Addition of ultra-fine or nano-particles during dry blending
followed by melt compounding on a range of processing
equipment – including a Haake rheometer, twin-roll mill and
twin-screw extruder.

Dispersion of nano-scale additives should improve thermal

stability and help to reduce toxic smoke emissions on burning.

Other advantages are to improve mechanical properties –

particularly impact strength.
 Charpy Impact Strength of PVC
Compounds with Hydrotalcite
Hydrotalcite (phr) Charpy Impact Strength (kJm-2)

0 26.8 ± 8.8
2 134.3 ± 8.2
5 139.2 ± 9.7
10 135.3 ± 8.8
 Hydrotalcite
CO32- Ions

The Hydrotalcites
have similar structures H2O water intercalated
to the natural clay between the layer
minerals e.g..
Montmorillonite, but
with opposite charge.
Al(OH)6- octahedron

Mg(OH)6- octahedron
 Hydrotalcites as PVC Stabilisers
Basic Layer
[Mg1-x Alx(OH)2]x+

Mg1-x Alx(OH)2 Mg1-x Alx(OH)2

H2O CO3 H2O + 2HCl H2O Cl H2O Cl + CO2 + H2O

(in PVC)

Mg1-x Alx(OH)2 Mg1-x Alx(OH)2

Basic Layer
[Mg1-x Alx(OH)2]x+ Ion exchange reactions with HCl -
Hydrotalcites can act as stabilisers and
smoke suppressants for PVC
 Reducing Plasticiser Migration

Reduce migration of plasticiser in Tactoid

flexible PVC by dispersing small peeling

amount of platy nanofiller in PVC

that increases tortuosity of
diffusion path.

Intercalation
20 nm
Life cycle sustainability of PVC
Adisa Azapagic and Shahriar Amini

School of Chemical Engineering and Analytical Science

The University of Manchester
Sustainability of PVC: Project Aims
™Development of a life cycle methodology and
decision-support tool for assessing and
improving sustainability of PVC
™Development of databases to support
assessment and decision-making
™Demonstration of the methodology and decision-
support tool on a number of case studies
 Software Overview
The whole life cycle of PVC
™Materials and energy options
™Processes and technologies
™Products
™End-of-life options

Capability
™Sustainability assessment and optimisation
™Selection of the best options for improved sustainability
 Global Warming Potential (GWP 100 years) [kg CO2-Equiv.]

100

80

60

40

20

0
Scenario 1 Scenario 2
 DTI & Industrial Funded Project -
Development of Bio-based Products
for Use as PVC Plasticisers
started April 2006, Bangor
Biocomposites Centre.
 Associate Membership
™Associate membership of VinylSUM - open to all
stakeholders
™Associate members updated by newsletter (two per
year) also including an overview of results from the
current sustainability improvement Work Programmes
™Associate members are also made aware of potential
new research proposals and/or funding possibilities
covering PVC sustainability improvement and given the
opportunity to participate from the start.
™Current associates include Solvin, Braskem, ECVM,
Teknor Apex and Synthomer.
Associate Membership & Future Plans

™ Current plans to launch new research project on

reduction of smoke and HCl emissions from burning
PVC.
™ Another area is product design to save material: use of
nano-scale modifiers, PVC composites, foaming
processes.
™ Continue to work together with all stakeholders so that
the whole industry works together to achieve the
objectives for sustainable use of PVC