Chinaplas Seminar, Shanghai, 2016 Innovation that works .../media/chemicals/kl-media... · production line • Dry blending, ... raffia tape at same MB level • Reduce tape breakage

Chinaplas Seminar, Shanghai, 2016

Innovation that works for you Vistamaxx™ performance polymer in compounding

• Introduction of ExxonMobil Chemical

• Vistamaxx in compounding

• New possibilities for PP modification • An innovation for masterbatch

industry

• Introduction of Vistamaxx™ performance polymers

• Question and answer

Agenda

Welcome!

ExxonMobil Chemical

5 Vistamaxx™ performance polymers

Upstream Downstream

Refining & Supply

Fuels, Lubricants & Specialties Marketing

Exploration Development Production

Chemical

Integration Manufacturing End-use

Exxon Mobil Corporation

• Long-term strategy built on ExxonMobil core competencies • Capture full benefits of integration across ExxonMobil operations • Constant focus on cost management, operational excellence • Selectively invest in advantaged projects • Build proprietary technology positions

ExxonMobil Chemical business strategies


ExxonMobil continually invests for the future to bring new products to our customers

Vistamaxx™ performance polymers plant at the expanded Singapore facility

• Utilizes the latest catalyst and processing technologies

• Capacity to produce 300,000 tons-per-year

Production

Introduction to Shanghai Technology Center

• YE2015 employment of approximately 380 people • Campus style collocation of technology

organization • with sales, marketing and supply chain

functions • State-of-the-art laboratory facilities

• Product and application testing facilities • ~5,000 m2 process hall

• Full-service center for Asia customers • Technical product support for EM Polyolefins,

Specialty Elastomers & Plasticizers • Provide customers with innovative technical

solution in product applications and processing • Fully equipped labs including Advanced

Characterization techniques • Capture full value of ExxonMobil Chemical

premium products

ExxonMobil Chemical’s state-of-the-art technology center in Asia

Expanding the possibilities for polypropylene modification

Vistamaxx™ performance polymers

• hPP/RCP modification

• ICP modification • What is stress whitening issue?

• Quantitative stress whitening test method

• Vistamaxx™ performance polymers effectively reduce stress whitening

• Vistamaxx™ performance polymers help achieve balance of properties in ICP compounds

Agenda


Maintaining clarity of RCP

0

20

40

60

80

100

0 5 10 15

Haze

, %

Test

bas

ed o

n A

STM

D1

003

Modifier, wt.%

Haze of RCP/ modifier blends (2 mm)

Vistamaxx 6202Vistamaxx 3000Exact 9371

Unlike plastomer, Vistamaxx performance polymers maintain clarity when blended with RCP

Utilize Vistamaxx 3000 series grades for your most demanding clear applications


Exact 9371

5 wt.% modifier in RCP at RT

B

BD

DB

D

Failu

re M

ode

Test

bas

ed o

n AS

TM D

3763

RCP Vistamaxx 6202 Vistamaxx 3000 Exact 9371

Modifier/%

Exact 9371


B

BD

DB

D

Failu

re M

ode

Test

bas

ed o

n AS

TM D

3763


Modifier/%

Exact 9371


B

BD

DB

D

Failu

re M

ode

Test

bas

ed o

n AS

TM D

3763


Modifier/%

Improve impact resistance with as little as

5% Vistamaxx performance polymers

Note: D = Ductile DB = Ductile Brittle BD = Brittle Ductile B = Brittle Exact = Exact™ plastomer

Superior RCP impact performance improvement


Addition of Vistamaxx performance polymers improves impact performance

as long as temperatures stay above the glass transition temperature (Tg Vistamaxx 6202 = -28°C)

Impact strength - Notched Izod at 0 ℃, J/m Vistamaxx 6202, % 0% 10% 30% 50% 70%

RCP 22 C 52 C 713 NB 820 NB 631 NB

C = complete failure; P = partial failure, NB = No break

• 50 / 50 blend of Vistamaxx 6202 / RCP blends exhibit ductile behavior down to -20°C

Improve RCP impact performance at low temperature


0

200

400

600

800

1000

1200

1400

0 5 10 15

Flex

ural

Mod

ulus

/MPa

Te

st b

ased

on

ASTM

D79

0

Modifier, wt.%

Flexural Modulus of RCP/modifier blends

Vistam axx 6202

Vistam axx 3000

Exact 9371

• Mechanical performance of Vistamaxx performance polymers are similar to plastomers

• Improved flexibility, reduced tensile strength

0

5

10

15

20

25

30

35

0 5 10 15Ult

imat

e te

nsile

str

eng

th/M

Pa

Test

bas

ed o

n A

STM

D63

8

Modifier, wt.%

Ultimate tensile strength of RCP/modifier blends

Vistamaxx 6202Vistamaxx 3000Exact 9371

Mechanical properties with RCP


Blends of Vistamaxx performance polymers with above 30% in PP have significantly improved softness and flexibility

Create unique products at high concentrations

Flexural Modulus

0

400

800

1200

1600

0 10 30 50 70

Flex

ural

Mod

ulus

, MPa

Te

st b

ased

on

ASTM

D79

0

HPP RCP

Dry-Blending Hardness

0

20

40

60

80

0 10 30 50 70

Vistamaxx 6202, wt.%

Har

dnes

s, S

hore

D

Test

bas

ed o

n AS

TM 2

240

HPP RCP

Dry-Blending

Vistamaxx 6202, wt.%

Reduce Stress Whitening

• ICP is a two-phase system with hPP as matrix and EP rubber as dispersed phase • In injection molding or other converting processes, hPP shrinks more in comparison to

EP rubber phase, and hence the EP rubber particles are under compressive stress • Under impact conditions, the EP rubber particles release the compressive stress by

voids, cavitation, or crazes, and hence stress whitening

ICP challenge: stress whitening/blush

hPP

Ethylene-Propylene Rubber

19

Increasing stringent requirements for lower stress whitening in ICP applications

• Rigid packaging • Luggage shells • Automotive parts • Small appliance • Toys • Furniture • Material handling

Ways to reduce stress whitening

Industry trends

Solution Challenge

HDPE, LLDPE Incompatible to ICP

Polybutene Naturally expensive

Nucleating agent No significant improvement*

Vistamaxx™ performance polymers + PE Your next best solution as shown in this study!

*only can reduce stress from molding pressure due to faster de-molding, no impact on material property for blush resistance


Process • Dry blending for 30 minutes • Sample plaque made by injection molding process for property test

Design boundary • Vistamaxx performance polymers from 0 to 30% • LLDPE 6101XR from 0 to 30% • Binary blend, ICP/ LLDPE and ICP/ Vistamaxx polymers • Tri-blend, ICP/ LLDPE/ Vistamaxx polymers

Material selection

Technical study

Grades MFR 230°C/2.16 kg g / 10 min

Density g / cm3

ExxonMobil™ ICP PP7033E3 8 (test based on ASTM D1238)

0.9 (test based on ExxonMobil method)

ExxonMobil™ LLDPE 6101XR 20 (MI 190°C/2.16 kg) (test based on ASTM D1238)

0.924 (test based on ExxonMobil method)

Vistamaxx 6202 20 (test based on ExxonMobil method)

0.863 (test based on ASTM D1505)

Vistamaxx 3000 8 (test based on ExxonMobil method)

0.873 (test based on ASTM D1505)


ExxonMobil test method • Equipment: Gardner ambient impact tester,

colorimeter • Test specimens: injection molded 10cm disc

(thickness: 3mm) • Impact condition: 1.8kg; 12.7cm

Quantified by measuring the L value of color using a colorimeter

• L is the measurement of whiteness • The degree of whitening is recorded as ΔL • ΔL= LA - LB

The quantitative measurement of whitening

LA

LB

The lower ΔL, the less stress whitening


• Impact discs are molded from dry blending ExxonMobil™ ICP PP 7033E3 with LLDPE 6101XR and Vistamaxx 3000 at respective ratio

• Pictures of sample are after impacted with Gardner impact tester

Visual comparison of impact whitening

Pure ICP 70 / 15 / 15 70 / 0 / 30 70 / 30 / 0 55 / 22.5 / 22.5

ICP / LLDPE / Vistamaxx polymers

85 / 7.5 / 7.5

Tests performed in Shanghai Technology Center (STC) following ExxonMobil test methods, some of which are based on certain versions of industry standards (ASTM/ISO). Color was tested in STC using ExxonMobil test method OMP STC 136

The addition of Vistamaxx™ performance polymers

• can effectively reduce stress whitening

• gives synergistic effect with LLDPE to reduce stress whitening more

Significant reduction of stress whitening

02468

101214

100 0 0

7030 0

857.57.5

701515

603010

5522.522.5

Col

or, Δ

L Te

st b

ased

on

Exx

onM

obil

Met

hod

62023000

02468

101214

100 0

8020

7030

Col

or, Δ

L Te

st b

ased

on

Exx

onM

obil

Met

hod

6202

3000

Vistamaxx polymers in ICP with LLDPE Vistamaxx polymers in ICP

ICP Vistamaxx

ICP LLDPE

Vistamaxx


AFM study on compatibility

• EP polymer shows well dispersed distinguished phase in ICP

• LLDPE alone in ICP has lumps of polymers undispersed

• Adding Vistamaxx™ performance polymers in ICP with LLDPE, a more homogeneous phase is observed

10 x 10 µm scan size

Pure ICP

ICP + LLDPE + Vistamaxx

ICP + LLDPE

Blend properties analysis

• Both Vistamaxx™ performance polymer grades show better stress whitening reduction and impact performance than LLDPE

• The synergistic effect of Vistamaxx polymers upgrade ICP/ LLDPE blend to achieve more balanced properties


Stress whitening, ΔL Test based on ExxonMobil Method

Hardness, Shore D Test based on TPE 0189

1 HDT, °C Test based on ISO 75

2 FM, MPa Test based on ISO 178

Tensile strength at yield, MPa Test based on ISO 572

3 NI at 23°C, KJ/m2

Test based on ISO 180

3 NI at -20°C, KJ/m2


ICP

70% ICP + 30% LLDPE

70% ICP + 30% Vistamaxx polymers

70% ICP + 15% LLDPE + 15% Vistamaxx polymers

0

15

0

65

90

1200

25

22

60

15

Elongation at yield, % Test based on ISO 572

Vistamaxx 6202 blend

1 Heat Deflection Temperature, 2 Flexural Modulus (1% Secant), 3 Notched Izod

3NI at 23°C, KJ/m2


0 Hardness, Shore D Test based on TPE 01 65

1HDT, °C Test based on ISO 75

90

2FM, MPa Test based on ISO 178

1200

25

Elongation at yield, % Test based on ISO 572

22

Tensile strength at yield, MPa Test based on ISO 572

3NI at -20°C, KJ/m2


60

15

Vistamaxx 3000 blend

0

15

Stress whitening, ΔL Test based on ExxonMobil Method


Case sharing: suitcase

Customer requirements

• Develop a reliable solution for high end suitcase

• Compatible with PP ICP & PE

• Significant reduction of stress whitening

• Decrease scrap rate during production

• Easy to adopt, no additional process and cost

• Deliver required properties

• Improve impact performance when blended with polypropylene

• Excellent compatibility with PP ICP & LLDPE

• Provide a solution to stress whitening reduction

• Achieve lower scrap rate at production line

• Dry blending, no additional process

• Tailor made properties

ExxonMobil solutions

Vistamaxx performance polymers provide a reliable solution to stress whitening in PP ICP

• Reduce stress whitening for better aesthetic parts and less defect ratio

• Improved toughness for higher durability and provide downgauge possibility

• Enable ICP with LLDPE to achieve more balanced cost and performance challenges

Significant reduction of stress whitening

Properties in ICP blend LLDPE Vistamaxx Vistamaxx + LLDPE

Stress whitening reduction + ++ +++

Impact strength - ++ +

Stiffness / hardness / HDT - --- --

Specific gravity - + Tailorable

Compatibility - ++ ++

MFR No improvement Tailorable Tailorable

An innovation for the masterbatch industry



Higher filler loading and better processing in AFMB compounding


• Individual filler particles and agglomerates are clearly visible in both samples and easily distinguished from polymer phase

• Filler dispersion is more uniform in Vistamaxx™ performance polymer carrier than in LLDPE carrier

LLDPE based Masterbatch

Filler Particle

Vistamaxx Phase

Vistamaxx based Masterbatch

Filler Particle

Agglomerated Particle

70% filler 80% filler

PE Phase

Better dispersion at higher filler loading

• Low melt temperature of Vistamaxx performance polymer allows for lower mixing temperature during masterbatch compounding process

• Protect heat-sensitive additives in MB compound

Lower processing temperature

Vistamaxx 6202

LLDPE

hPP

DSC melting scan



Improved tape toughness and processing efficiency, cost savings


Compared with PP-based masterbatch, Vistamaxx polymer-based masterbatch can:

• Improve tenacity and elongation of raffia tape at same MB level

• Reduce tape breakage during tape making and weaving process

AFMB with Vistamaxx and hPP blend as carrier resin provides balanced cost and performance


Vistamaxx polymer-based AFMB enhances performance

Reference Vistamaxx polymer-based Masterbatch

Tape

80% hPP/ 20% hPP-based

MB

80% hPP/ 20% Vistamaxx polymer-

based MB

MB

85% CaCO3/ 15% hPP

85% CaCO3/ 7.5% hPP/

7.5% Vistamaxx 6202

0

5

10

15

20

3

4

5

6

Elongation at Break (%)

Tenacity (g/D)

Tenacity (g/D) Elongation at Break (%)


Compared with PP-based masterbatch, Vistamaxx-based masterbatch can:

• Allow higher AFMB let down and maintain tape properties, hence achieve cost saving

• Reduce tape breakage during tape making and weaving process

AFMB with Vistamaxx and hPP blend as carrier resin provides balanced cost and performance


Reference Vistamaxx-based Masterbatch

Tape

80% hPP/ 20% hPP-based

MB

70% hPP/ 30% Vistamaxx-based MB

MB

85% CaCO3/ 15% hPP

85% CaCO3/ 7.5% hPP/

7.5% Vistamaxx 6202

Higher AFMB level for cost saving

0

5

10

15

20

3

4

5

Elongation at Break (%)

Tenacity (g/D)

Tenacity (g/D) Elongation at Break (%)


• Trends • Cost reduction, flat growth • Increased in filler and recycle material • Limited down gauging options • New legislation on the usage of plastic carry bags

• Drivers • Lower margins, stiff competition • Ban on plastics bags in some states / countries

HDPE shopper bags and garbage bags


Vistamaxx performance polymer-based MB in HDPE Shopper & Garbage bags

50

400

800

180

30

6

Avg. Tensile Strength, MPa *** Test based on ASTM D-882

Avg. Elongation at Break, % *** Test based on ASTM D-882

Avg.1% Secant modulus, MPa *** Test based on ASTM D-882

Dart Impact, g ** Test based on ASTM D-1709

Puncture Break Energy, mJ/µm Test based on ASTM D-5748

MD Elmendorf Tear, g Test based on

ASTM D-1922-06a

15µm, HDPE (77%) + C4LL (13%) + LL MB (10%) 15µm, HDPE (69%) + C4LL (11%) + Vistamaxx based MB (20%)

Sour

ce: E

xxon

Mob

il D

ata

All

mas

terb

atch

es u

sed

cont

ain

80%

CaC

O3, *

* da

rt im

pact

mea

sure

d ≤4

8g

***

show

n as

ave

rage

of M

D/T

D

Punc

ture

, AST

M D

-574

8; d

art i

mpa

ct ,

ASTM

D-1

709,

tens

ile s

treng

th/E

long

atio

n, A

STM

D-8

82; F

M, A

STM

D- 7

90A;

MD

Elm

endo

rf te

ar, A

STM

D-1

922-

06a

** d

art i

mpa

ct m

easu

red

≤48g

**

* sh

own

as a

vera

ge o

f MD

/TD

• Significantly increase CaCO3 loading via Vistamaxx based MB • Significantly increase toughness via Vistamaxx based MB


ExxonMobil Data, films produced on commercial line, 20 µm nominal thickness, all MB used contain 80% CaCO3

Increase CaCO3 content Increase recycle content

Test based on ASTM D1709

Test based on ASTM D1709

• Vistamaxx polymer based MB enhances the property profile at a lower cost • Vistamaxx polymer based MB solutions allow increased filler loading

Vistamaxx performance polymer-based MB in HDPE S&G bags

Summary

• Vistamaxx™ performance polymers as a resin carrier for masterbatch offer improved compound processing to compounders

• Vistamaxx based masterbatch improves the properties of PP raffia tape in addition to the benefit of resin carrier for the filler

• Vistamaxx performance polymer-based masterbatch optimizes cost and performance of HDPE shopper bag and garbage bag producers

Introduction of Vistamaxx performance polymers


The next generation of products building on ExxonMobil’s history of providing technically advanced solutions to the market.


Microcrystalline regions

Amorphous regions

• Based on ExxonMobil Chemical’s proprietary metallocene technology

• Semi-crystalline polymer with tunable amorphous content

• Compatible with other polyolefinic materials, e.g., PE & PP

• Produced in the Singapore facility with a 300,000 ton per year capacity

Amorphous Content

Crystallinity Density Hardness Flex Modulus

Vicat Softening Point


Vistamaxx™ performance polymers Enable customers to bring innovative, cost-effective solutions to market.

43

Grade slate Typical values

Grade

MFR 230°C/2.16

kg EMCC method

g/10 min

Density1 23°C ASTM D1505, g/cm3

Hardness 15 sec ASTM D2240,

Shore D/A

Tensile Stress1 @

Break ASTM D638,

MPa (psi)

Elongation1 @ Break

ASTM D638, %

Flex Mod1,2 1% Secant

ASTM D790

MPa (psi)

Tear Strength1

Die C ASTM D624, kN/m (lbf/in)

Vicat Softening Point 200g

EMCC Method, °C (°F)

3000 8 0.873 33D 17.1 (2480) 1898 59.3

(8610) 62.3 (356)

65.6 (150)

3020FL** 3 0.874 34D 17.0 (2460) 1756 59.7

(8650) 64.3 (367)

68.3 (155)

3980FL** 8 0.878 40D 17.2 (2500) 1682 110

(16000) 81.3 (464)

76.7 (170)

6102/6102FL** 3 0.862 66A >6.90 (>1000) >2000 12.3

(1790) 34.3 (196)

52.2 (126)

6202/6202FL** 20 0.863 66A >5.50 (>798) >2000 12.3

(1790) 33.3 (190)

47.2 (117)

6502 48 0.865 71A >9.65 (>1400) >1900 20.5

(2980) 38.4 (220)

51.5 (125)

**FL grades pass ExxonMobil Chemical’s test for film appearance with regard to gels, as needed for performance film applications (‘A’ rating) 1. All physical properties were measured on specimens cut from compression molded plaques per ASTM D4703, Procedure A, Type I and conditioned at 23ºC

for a minimum of 40 hours per ASTM D618 prior to testing. 2. 1% secant @ break.



Polymer modification and compounding • Stationary files • Soft PP grips • Ice cream containers • Cosmetic Bottles

Filler masterbatch • HDPE shopper & garbage bags • Nonwoven packaging • Raffia bag

New possibilities in compounding

Food containers Thermoformed trays

Buckets

Storage boxes DVD cases

Shopper & garbage bag

Thank you


Backup


Test methods (PP modification)

Testing ExxonMobil Test Method based on

Hardness ASTM D2240

Ultimate Tensile Strength ASTM D638

Elongation at Break ASTM D638

Tensile Strength at Yield ASTM D638

Flexural modulus (1% Secant Modulus) ASTM D790

Notched IZOD Impact energy ASTM D256

Instrumented impact test ASTM D3763

Haze ASTM D1003

Tests performed in STC follow ExxonMobil test methods, some of which are based on certain versions of industry standards (ASTM/ISO).


Testing method (Stress whitening)

Testing ExxonMobil Test Method based on

Stress whitening EMCC method

Notched IZOD Impact energy ISO 180

Flexural Modulus (1% Secant) ISO 178

Hardness TPE 0189

Tensile Strength @ yield ISO 572

Elongation @ yield ISO 572

HDT (Heat deflection temperature) ISO 175


Materials (masterbatch)

Manufacturer Grade

MFR 230ºC/2.16

kg ASTM D1238

g/10 min

MI 190ºC/2.16

kg ASTM D1238

g/10 min

Density D23ºC ASTM D1505

modified g/cm³

Pour Density ASTM D1513 kg/m³

Bulk Density ASTM C110

lbs/ft³

ExxonMobil Chemical Vistamaxx™ 6202 20 0.861 _ _

Sunoco Chemicals

F180A homopolymer polypropylene (hPP) 17 -- -- _ _

ExxonMobil Chemical

ExxonMobil™ LLDPE LL 6201RQ resin -- 50 0.926 _ _

ExxonMobil Chemical

ExxonMobil PP4712E1 polypropylene homopolymer resin

2.8 -- 0.9 _ _

Huber Engineered Materials

Hubercarb® M4 Calcium Carbonate (CaCO3)

mean particle size 4.5 µm -- -- 40

Cabot Corporation

Vulcan® 9A32 carbon black (CB)

less than or equal to 19 nm particle size -- 352

Note: Values obtained from product data sheet for each material.


Test methods (masterbatch)

Test method ExxonMobil Test Method based on

MFR (230 ⁰C/2.16 kg) ISO 1133

MI (190 ⁰C/2.16 kg) ISO 1133

Differential Scanning Calorimeter (DSC) ASTM D3418



Materials (blown film study)

Note: Values obtained from product data sheet, for each material.

Manufacturer Grade

MFR 230ºC/2.16 kg ASTM D1238

(g/10 min)

MI 190ºC/2.16 kg ASTM

D1238 (g/10 min)

Density D23ºC ASTM D1505

modified (g/cm³)

Pour Density

ASTM D1513 (kg/m³)

ExxonMobil Chemical Vistamaxx 6202 20 0.861 --

Sunoco Chemicals F180A homopolymer polypropylene (hPP) 17 -- -- --

ExxonMobil Chemical ExxonMobil™ LLDPE LL 6201RQ resin -- 50 0.926 --

ExxonMobil Chemical ExxonMobil™ PP4712E1 polypropylene homopolymer resin

2.8 -- 0.9 --

Cabot Corporation Vulcan® 9A32 carbon black (CB)

less than or equal to 19nm particle size -- 352

ExxonMobil Chemical ExxonMobil™ HDPE HTA 001 HD --

9.0 (190ºC/21.6

kg) 0.952



Test methods (blown film study)

Test method ExxonMobil Test Method based on

Differential Scanning Calorimeter (DSC) ExxonMobil Method

Elmendorf tear strength ASTM D 1922-06a

Impact resistance by free-falling dart: Method A (Dart impact) ASTM D 1709

Optical microscopy ISO 18553

Puncture resistance ASTM D 5748

Tensile properties on film ASTM D 882


Disclaimer ©2016 ExxonMobil. ExxonMobil, the ExxonMobil logo, the interlocking “X” device and other product or service names used herein are trademarks of ExxonMobil, unless indicated otherwise. This document may not be distributed, displayed, copied or altered without ExxonMobil's prior written authorization. To the extent ExxonMobil authorizes distributing, displaying and/or copying of this document, the user may do so only if the document is unaltered and complete, including all of its headers, footers, disclaimers and other information. You may not copy this document to or reproduce it in whole or in part on a website. ExxonMobil does not guarantee the typical (or other) values. Any data included herein is based upon analysis of representative samples and not the actual product shipped. The information in this document relates only to the named product or materials when not in combination with any other product or materials. We based the information on data believed to be reliable on the date compiled, but we do not represent, warrant, or otherwise guarantee, expressly or impliedly, the merchantability, fitness for a particular purpose, freedom from patent infringement, suitability, accuracy, reliability, or completeness of this information or the products, materials or processes described. The user is solely responsible for all determinations regarding any use of material or product and any process in its territories of interest. We expressly disclaim liability for any loss, damage or injury directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information in this document. This document is not an endorsement of any non-ExxonMobil product or process, and we expressly disclaim any contrary implication. The terms “we,” “our,” "ExxonMobil Chemical" and "ExxonMobil" are each used for convenience, and may include any one or more of ExxonMobil Chemical Company, Exxon Mobil Corporation, or any affiliate either directly or indirectly stewarded.

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Chinaplas Seminar, Shanghai, 2016 Innovation that works .../media/chemicals/kl-media... · production line • Dry blending, ... raffia tape at same MB level • Reduce tape breakage