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*Research Engineer –Sustainable Biomaterials and Plastics Group

*Mica DeBolt, Beste Aydin, Alper Kiziltas and Debbie Mielewski

SPE ACCE Conference Sept. 7-9, 2016

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Outline

Background

Motivation

Objectives

Materials and Methods

Results and Discussion

Mechanical and Physical Properties

Thermal Properties

Morphological Properties

Conclusions

Acknowledgements

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Petroleum –

a limited resource

harmful to environment

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Sustainable Foams

Soy-based seat foam

Castor oil foam in the IP

Natural Fiber Reinforced Plastics Implementation of cellulose fiber

Kenaf fiber interior door panels

Wheat straw reinforced storage bin

Rice hull reinforced wire harness

Recycled Materials Seat fabric from recycled PET

MRP incorporation in foams

Under the foot the under the hood

Ford’s Sustainability Initiatives

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Oil feedstock alternatives for polyols

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CO2 = Solution?

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CO2-based polyols

Derived from waste CO2

Environmental benefits

CO2 is a byproduct of:

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Rice Husk Ash

Husks used as fuel in heat generation for drying rice

Silica-rich ash generated during combustion

Silica is a flame retardant filler

Silica has been shown to increase mechanical properties

Supplied from Radici Group

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Cellulose Filaments

Byproduct of forestry industry

Renewable resource

Filaments harvested without chemicals during pulping

process

Exceptional strength and purity, with an extraordinary high

and unique aspect ratio

Untreated cellulose filaments

Cellulose filaments treated with a coupling agent

Supplied from FPInnovation http://www.performancebiofilaments.com/product/

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Micronized Rubber Powder

Estimated that 1000

million tires end

service life

Burning = fire hazards

and environmental

pollution

Depletion of landfill

sites

Supplied from Lehigh

Technologies

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Motivation

2015 United Nations

Climate Change Conference

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Objectives

Synthesize flexible polyurethane foams using

waste CO2-based polyols

Determine potential for automotive use

Tested for :

Physical and mechanical properties

Optical images taken with Keyence digital

microscope

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Foam Formulations

Component B Type of Additive Supplier

Voranol 4701 Petroleum Polyol Dow Chemical Company

Novomer Converge

251-20/351-30 CO2 Polyol Novomer Inc

Lumulse POE (26)

GLYC Cell Opener Vantage

Tegostab B4690 Surfactant Evonik

Diethanolamine Cross Linker Sigma Aldrich

Niax a300 Catalyst Momentive

Niax A1 Catalyst Momentive

Water Blowing Agent -------

Component A

Rubinate 7304 Isocyanate (MDI) Huntsman Corporation

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Addition of CO2-based polyol

into flexible polyurethane foams

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Density (kg/m3)

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Wet Compression Set

(% Compression)

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Compression

Modulus (MPa)

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SAG Factor

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Tensile Strength (kPa) Young’s Modulus (MPa)

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Tear Resistance (N/mm)

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TGA Results Sample Code Residual Mass (%) Temp. at 10% ML (°C) Temp. at 50% ML (°C)

251-20-0% 8.8 (1.0) 305.4 (4.5) 378.6 (1.2)

251-20-10% 8.9 (0.9) 285.2 (2.8) 378.3 (4.9)

251-20-20% 9.4 (0.9) 272.6 (4.9) 371.4 (2.7)

251-20-30% 9.7 (0.4) 272.7 (3.7) 373.2 (2.7)

251-20-50% 9.6 (0.3) 260.9 (1.3) 367.2 (1.1)

351-20-0% 9.3 (0.3) 306.4 (2.9) 377.1 (0.9)

351-20-10% 7.8 (1.6) 295.2 (4.9) 389.4 (0.2)

351-20-20% 10.1 (0.3) 287.3 (2.6) 377.8 (2.1)

351-20-30% 10.3 (0.2) 275.0 (3.7) 375.1 (1.9)

351-20-50% 9.7 (0.5) 262.6 (4.0) 369.5 (1.1)

°

°

°

°

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TGA Results

Temparature (°C)

200 300 400 500 600

Ma

ss

(%

)

0

20

40

60

80

100

251-20-Control251-20-10%251-20-20%251-20-30%251-20-50%

Temparature (°C)

200 300 400 500 600

Ma

ss

(%

)

0

20

40

60

80

100

351-20-Control351-20-10%351-20-20%321-20-30%321-20-50%

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Temperature (°C)

-50 0 50 100 150

Lo

ss

Mo

du

lus

(P

a)

1e+4

1e+5

351-20-Control351-20-10%351-20-20%351-20-30%351-20-50%

Temperature (°C)

-50 0 50 100 150

Sto

rag

e M

od

ulu

s (

Pa

)

1e+5

1e+6

351-20-Control351-20-10%351-20-20%351-20-30%351-20-50%

Temperature (°C)

-50 0 50 100 150

Lo

ss

Mo

du

lus

(P

a)

1e+4

1e+5

251-20-Control251-20-10%251-20-20%251-20-30%251-20-50%

Temperature (°C)

-50 0 50 100

Sto

rag

e M

od

ulu

s (

Pa

)

1e+5

1e+6

251-20-Control251-20-10%251-20-20%251-20-30%251-20-50%

DMA Results

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Optical Images

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Converge 251-20 (top) and 351-30 (bottom)

mixed with petroleum polyol

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Converge 251-20 and Soy

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Conclusions

Improvements with CO2-based polyol

No significant change

Areas of concern

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On-going studies

Addition of rice husk ash, cellulose, and

micronized rubber tires into formulation

Compatibility of CO2-based polyol with soy-

based polyol

Decreasing wet compression set values at

higher concentrations

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Acknowledgements

Sustainable Biomaterials and Plastics

Team

Novomer Inc

Lehigh Technologies

FPInnovations

Radici Group

Hutsman International LLC

Dow Chemical Company

SPE ACCE