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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
The Dow Chemical Company
Dr. Olaf Henschke
Colin Li Pi Shan, Varun Thakur, Jaap Den Doelder
Dow Elastomers R&D
December 7, 2016
Innovations in Rubber Design, London, UK
EPDM Materials by Design
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
EPDM by Design
Dow’s commitment and sustainability to the rubber industry New Materials Research and Development Focus on Automotive Sealing Systems
2
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Dow’s Sustainability Journey
3
Our Aspiration:
To advance the well-being
of humanity by helping
lead the transition to
a sustainable society
and planet.
2005 EH&S Goals
Journey to EH&S
Excellence
2015
Sustainability
Goals
Product Solutions
to World Challenges
2025
Sustainability
Goals
Thought Leadership
and Actions
Footprint and EH&S Culture
Handprint
Blueprint
1995 2006 2016 2025
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Delivering Sustainable Impact
Leading the
Blueprint
Engaging
Employees for
Impact
Increasing
Confidence
in Chemical
Technology
Valuing Nature Advancing
a Circular
Economy
4
Dow is a thought leader in delivering sustainable impact for global challenges
World-leading
Operations
Performance
Delivering
Breakthrough
Innovations
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
1963 – The First EPDM
5
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Old Assets Dominate EPDM Industry Capacity
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1963-1970 1971-1980 1981-1993 1994-2010 2010-2014 2017
As
se
t C
ap
ac
ity
Asset Start-up Year
Industry Asset Capacity vs. Age by Technology
Almost 50%
of current assets
are 25 years old
Source: Estimates based on public information
Advanced Molecular Catalyst
Metallocene
Ziegler-Natta
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Delivering Industry-leading Efficiency
Source: Nexant and IHS
Dow
Technology
8.25 MJ/kg
Industry
Ziegler-Natta
19.11 MJ/kg
vs.
7
Production Energy Sources
Total MJ/kg
EPDM
Low & High
Pressure Steam
Electricity
(Direct &
Refrigeration)
Fuel
Gas + + =
Raw Material
Extraction Refining Use End of Life
Data per tests conducted by Dow. Additional information available upon request. Properties shown are typical, not to be construed as specifications. Users should confirm results by their own tests.
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Maintaining Our Commitment to Industry Growth
Sadara Chemical Company
ENGAGE™ & AFFINITY™ GA
Polyolefin Elastomers
U.S. Gulf Coast
Shale Gas Investments:
2015-2017 Start-ups
• Propane Dehydrogenation Unit
• Next-generation NORDEL™ EPDM
• High Melt Index Elastomers
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
1960 – present
Moving Beyond Traditional Catalyst Technology
1997 – present 2015 and beyond Ziegler-Natta
Metallocene
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• Ultra-high efficiency • Broad molecular weight • Increased filler acceptance • Faster curing • Expanded portfolio and
capabilities
• Low efficiency • De-ashing needed • Low reactor temperature
• High efficiency • No de-ashing required • High-temperature stability • Less gels
Advanced Molecular
Catalyst
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
0 2 4 6 8 10
Time, min
20
25
30
35
40
45
50
55
60
100000 1000000 10000000
Ph
as
e A
ng
le ( )
G* (dyn/cm2)
3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0
Log Molecular Weight
• High efficiency, high temperature operation
• Expanded molecular design
• Oil extension
• New tailored products
More Long Branching Higher
Molecular Weight
Catalyst and Process Advancements
More Diene
Low hLCB
High hLCB
90 Mu
+150 Mu 50 Mu Fast Curing
MD
R T
orq
ue
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Designing a New Product*
High-throughput
Catalyst Screening
Identify and select
molecular catalyst to
produce target
molecular
architecture.
Product
Hypothesis
Understand and
develop EPDM
molecular target
based on future
application and
customer needs.
Modeling and
simulation
Simulate and predict
effects of molecular
structure on melt
rheology.
Application
Prototyping
Develop prototype
for application
development.
Molecular
Screening
Produce small-scale
samples for
hypothesis testing.
*Clayfield, T.; Li Pi Shan, C.; Den Doelder, J.; Han, T.; Polymers by Design – High Throughput Development in EPDM; IRC 2015 Nuremberg, 2015.
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Design Challenge Understanding what the industry does with our materials…
Fast and efficient High Quality Sustainable Supply
High Productivity Defect Free
Class A Reliable
12
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Weatherseals -Keeping the noise out of the car…
DOW RESTRICTED
Primary Door/Body Seal
Secondary Door Seal
Trunk Seal
Encapsulated
Quarter-window
Hood Seal
Glass Run ChannelSunroof
Belt Line Seal
Other:
Roof Line
Windshield
Rear Window
13
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Tailoring a Branched EPDM
New capability and predictive design tools enabled polymers with tailored
branching rheology and high melt elasticity*
Homogeneous Long Chain
Branching (hLCB)
T-TypeMacromonomer, vinyl chain
incorporation
• Uniformly distributed long chain branches
• Gel free
• Metallocene/post-metallocene chemistry 1.0E-01
1.0E+00
1.0E+01
1.0E+02
1.0E+03
1.0E+04
0.001 0.01 0.1 1 10 100 1000
Pred
icte
d Ta
n D
elta
Shear Rate (1/s)
No hLCB
med hLCB
high hLCB
Increased melt elasticity
Melt elasticity is a key requirement for foaming
*Li Pi Shan, C.; Clayfield, T.; Den Dolder, J.; “Homogeneous long-chain branched EPDM development with high Mooney viscosity”; RubberWorld Magazine, Vol 250, No. 2, 2014.
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Designed Performance
Design challenge to produce
molecular structures with a combined
rheological and mechanical
performance.
Multi-dimensional approach allows
more accurate modelling with the use
of polymerization kinetic models of
Dow’s Advanced Molecular Catalysts.*
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
3 3.5 4 4.5 5 5.5 6 6.5 7
dw
/ d
Lo
g(M
)
Log (M)
Nordel 5565
Overall Fit
Flory Site 1
Flory Site 2
GPC Data
Overall FitMw = 172,992Mw/Mn = 3.03
Site 1: 53%, Mw = 74,550Site 2: 47% , Mw = 284,000
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
37 43
76 78
0
10
20
30
40
50
60
70
80
90
NORDEL 6565 Prototype Incumbent
10 Minutes 2.5 Minutes 180 C Cure Time:
100C
, 22 h
r. C
om
pre
ssio
n S
et (
%)
Product Grade
Mooney
Viscosity
(ML1+4 @
125°C)
C2
(Mass %)
ENB
(Mass %) MWD
Crystallinity
(Mass %) Form
NORDEL™ IP 5565 65 50 7.5 Medium < 1 Bales
NORDEL 6565 XFC 65 55 8.5 Broad < 1.5 Bales
Features & Benefits:
Improved Performance for Dense and Microdense WS
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Features Benefits
High diene Fast curing/property build
Medium viscosity Fast processing/extrusion
High branching Excellent shape retention
Molecular wt. distribution High filler acceptance
Low gel levels Excellent surface quality
Data per tests conducted by Dow. Additional information available upon request. Properties shown are typical, not to be construed as specifications. Users should confirm results by their own tests.
Formulation: 347 phr total, N550, CaCO3, Sunpar 2280, sulphur cure
Faster cure, faster property build
10% higher line speeds
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
One-Stop Shop - First All Dow Weatherstrip
Incumbent EPDMs
NORDELTM 6555 OE (sponge)
NORDELTM 6565 XFC (dense, microdense)
NORDELTM 6535 XFC
European OEM Quality, Class A Sponge and Dense Profiles Corner Molds
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Leading the Way
• Dow continues to deliver sustainable
impact for EPDM, the elastomers
industry, and the plastics industry
at large
• World-leading operations performance
• Breakthrough innovations
‒ Advanced Molecular Catalyst offers
even greater efficiency and improved
performance across a broader range of applications
‒ New offerings for sponge and dense
EPDM options for automotive sealing
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® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
The Dow Chemical Company
Thank You
® ™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use
conditions and applicable laws may differ from one location to another and may change with time, Customer is
responsible for determining whether products and the information in this document are appropriate for Customer's use
and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other
government enactments. The product shown in this literature may not be available for sale and/or available in all
geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow
assumes no obligation or liability for the information in this document. References to "Dow" or the "Company" mean the
Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN;
ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY EXCLUDED.
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