Wacker VAE

CREATING TOMORROW'S SOLUTIONS

VINNAPAS® VAE DISPERSIONSIDEAL BINDERS FOR INTERIOR PAINTSSTATE OF THE ART TRENDS.Dr. Udo Kotschi, WACKER POLYMERS, April 2011

VINNAPAS® VAE – DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 1

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


• Founded in 1914 by Dr. Alexander Wacker • Headquartered in Munich

WACKER CHEMIE AG

WACKER Group (2009)

• Sales: €3.72 billion

• EBITDA: €607 million

• R&D: €164 million

• Investments: €740 million

• Employees: 15,618

VINNAPAS® VAE DispersionsDr. Udo Kotschi, WACKER POLYMERS, April 2011, Slide 3

WACKER: HIGHLY INTEGRATED OPERATIONS BASED ON THREE KEY RAW MATERIALS

Raw material

CONSTRUCTIONAUTOMOTIVEPAINTS & COATINGSTEXTILESPRINT & PAPER, PERSONAL CARE

CONSTRUCTION (TILE ADHESIVES, DRY-MIX MORTARS, EIFS)

FOOD, LIFE SCIENCES, HOUSEHOLD

SOLAR MODULES

HYPERPURE SILICON WAFERSSEMICONDUCTORS

AUTOMOTIVE, FOOD

Upstream Downstream Customers’ industries

SOLAR CRYSTALS

SILICON METAL

SILOXANE

PYROGENICSILICA

SILICONES

SILICON WAFERS

PVAcVAM

DISPERSIBLE POLYMER POWDERS

COATINGS, ADHESIVES, NONWOVENS

ETHYLENE

STARCH/DEXTROSE

MICROBIAL FERMENTATION

THERAPEUTIC PROTEINS, FOOD INGREDIENTS

VAE

POLYSILICON

VAM = Vinyl acetate monomer, VAE = Vinyl acetate ethylene, PVAc = Polyvinyl acetate, EIFS = Exterior insulation and finishing system


* including internal sales

** balance of internal sales/ "other" € -127 million

Group sales in 2009: €3.719 billion

A WELL-BALANCED PORTFOLIO

*Total divisional sales in 2009 (incl. internal sales): €3.846 billion**

SILTRONIC

WACKER SILICONES

WACKER POLYMERS

WACKER POLYSILICON

WACKER BIOSOLUTIONS(formerly WACKER FINE CHEMICALS)

Source: Wacker Chemie AG


Production Dispersion Technical CenterProduction Powder

Adrian

ShanghaiDubai

Moscow

Sao Paulo

Melbourne

Zhangjiagang

Beijing

Singapore

India

Ulsan

Cologne

AllentownBurghausen

Calvert CityNanjing

Silicone

Ethylene

Acetic Acid

VAE PowdersDispersion

VAM

Key Markets

Ethylene

AceticAcid


VAM

Key Markets

Ethylene

Acetic Acid


VAM

Key Markets

US Europe ASIA

WACKER OWNS MORE THAN 50% OF THE WORLD’S VAE TECHNOLOGY PRODUCTION CAPACITY

WACKER POLYMERS production set up


FOR OPTIMUM SERVICE CLOSE TO OUR CUSTOMERS –OUR TECHNICAL CENTERS

Technical Centers located in• Australia (Melbourne)• Brazil (Jandira)• China (Shanghai; Beijing)• Germany (Burghausen)• Russia (Moscow)• Singapore • USA (Adrian; Allentown)• United Arab Emirates (Dubai)• India (Mumbai)

Service• Customer support for technical questions• New product developments based on leading-

edge technology and expertise• Formulations developed for local climates and

country-specific standards


VINNAPAS® VAE TECHNOLOGYRAW MATERIALS & PRODUCTION PROCESS


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


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


EFFECT OF MONOMERS, FUNCTIONAL MONOMERS AND STABILIZING SYSTEMS ON COHESION & WATER RESISTANCE


S

VAC

VC

BA

E EHA

MMA

M

AA

MAANMA

PVAL

HECSurfa.Coh

esio

n

Hig

hLo

w

Influence on water solubility

Low High

Monomer

Func. Monomer

Stab. System


FUNCTIONING OF SURFACTANTS / EMULSIFIERS

Repulsion

Hydrophobic anionic, orcationicgroup

Surfactant

Polymer particle

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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”

• Removal of the residual monomers and other volatileingredients by different chemical and/or physical measures

• Result: dispersion of polymer VAE particles in water


VINNAPAS® VAE DISPERSIONS ARE THE PREFERRED TECHNOLOGY FOR ENVIRONMENTALLY FRIENDLY PAINTS IN EUROPE


GLASS TRANSITION TEMPERATURE (Tg)

Ethylene is the ideal internal softener for vinyl acetate polymer dispersions!

Influence of vinylic comonomers on glass transition temperature of vinyl acetate copolymers

°°°°C



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 HAVE OUTSTANDING COALESCING PROPERTIES

Tg / MFFT correlation

MFFT [°°°°C]



• 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)

VAE DISPERSIONS VERSUS STYRENE ACRYLICDISPERSIONS Tg / MFFT CORRELATION


• Many different regulations to limit VOC in architectural coatings (governmental / labeling)

• Blue Angel / TÜV-Siegel / EU Ecolabel / VOC Decopaint Directive

• Indoor air quality (dangerous substances – construction products directive CPD) / SREP for interior wall paints

• Manufacturing without APEO’s

• Low-Formaldehyde (<10 ppm)

• Odorless

• Free of sensitizing additives (CIT …)

• What is next?

TRENDENVIRONMENTALLY FRIENDLY INTERIOR PAINTS


ENVIRONMENT

UV

NOxVOC

Ground-level ozone → summer smog


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



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)


Sustainability Sustainable development is to meet the needs of present generations without jeopardizing the ability of future generations to meet their own needs (source: EU)

Since 1999: Dow Jones Sustainability Index

• Topics for decorative coatings

• VOC reduction / co-solvents

• Low formaldehyde

• APEO absence

• Low energy consumption

• Low carbon footprint

• Higher efficiency (less binder)

• Longer lifetimes

• Eco-friendly packaging

• Renewable raw materials

MEGA TREND SUSTAINABLE DEVELOPMENT –DECORATIVE PAINTS

EnvironmentViable

Tolerable

Sustainable

Equitable

Society

The aim is to balance economic, environmental and social goals.

Economy


IMPACT OF RISING OIL PRICES ON MANUFACTURING COSTS OF POLYMER DISPERSIONS

• O-Content• No. Synthesis Steps• Energy Consumption /

step• Process yield /

byproducts

Cost comparison –relative cost advantages

35-0%4-10%

1-10%

1-10%



CHEMICAL WEEK MAGAZINE :: NEW CONSTRUCTION PROJECTS

1 Wacker Eyes Green Polymers Production

10:09 AM EDT | April 9, 2010 | Natasha Alperowicz in Burghausen

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. Fri-

dolin Stary, senior v.p./corporate R&D, said at a recent press briefing at Burghausen, Germany—Wacker’s

main manufacturing site—that 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.

Stary: Assessing the economics but no firm timeline is set.

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® DISPERSIONS BASED ON RENEWABLE RAW MATERIALS


EthanolBarley

Cane

Grape

Potato

Wheat

Corn

Honey

Beer

Rum

Wine

Vodka

Scotch

Jim Beam

Mead

VAEVAM VAE

Vinegar

Cane

Corn

Cellu-lose

Ethylene

+ Oxygen

- Water

end use

Ethanol

POSSIBLE WACKER-BIO-ROUTEETHANOL HAS A MILLENNIUM LONG PROVEN HISTORYOF INCREDIBLE DIVERSITY AND PERSISTENT INNOVATION


VINNAPAS® VAE DISPERSIONS FOR CONVENTIONAL AND ENVIRONMENTALLY FRIENDLY DECORATIVE PAINTS


VINNAPAS® RANGE FOR SOLVENT- AND PLASTICIZER-FREE INTERIOR PAINTS

Type EP 3360 EP 3355 EP 3888 EF 3777 EZ 3010 CEZ 18

Monomer base Vac/E Vac/E Vac/E Vac/E Vac/E Vac/E/VC

Emulsifier

SystemPVAL+E PVAL+E PVAL+E E CD+E CD+E

APEO-free yes yes yes yes yes yes

MFFT +2°C +2°C +2°C +1°C 0°C +2°C

Preservation BIT/MIT BIT/MIT BIT/MIT BIT/MIT CIT/MIT BIT/MIT

Specification

Solids Content 60 ± 1 55 ± 1 50 ± 1 56 ± 1 55 ± 1 50 ± 1

Viscosity 4000 ± 1000 1750 ± 750 800 ± 400 1000 ± 850 4300 ± 1600 12000 ± 3000

pH 4 – 6 4 – 6 4 – 6 3.5 – 4.5 4.5 – 5.5 4 – 5

Application interior interior interior interior interior interior / exterior


VINNAPAS® VAE DISPERSIONS – APPLICATIONS

• All kinds of interior applications: (with exception of silicate systems)

• Solvent-free and plasticizer-free interior paints

• Matt paints (wall and ceiling paints)

• Glossy paints

• Latex paints

• Silicone paints

• Matt and glossy full-shade paints

• Interior plasters

• Scratched plasters

• Plasters with a worm structure

• Textured coatings

• Primers

• Fillers

• Glue for glass, fabrics, and wallpapers


• Dispersion properties

• Low total VOC content

• MFFT = 0°C

• Solvent-, plasticizer-free and low-formaldehyde dispersion

• Manufactured without APEO’s

• No or low odor

• Preservation < 200 ppm BIT / MIT or < 15 ppm CIT / MIT

VINNAPAS® VAE DISPERSIONS – PROPERTIES


VINNAPAS® VAE DISPERSIONS –FORMULATION AND FILM PROPERTIES

• Good compatibility with a wide range of raw materials

• MFFT approx. 0°C

• 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


• Complies with European environmental standards and labeling

• Blue Angel

• TÜV-Siegel

• EU Ecolabel

VINNAPAS® VAE DISPERSIONS –FORMULATION AND FILM PROPERTIES


• 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 – APPLICATIONS


� High scrub resistance

• Tested in a matt paint

according to RR 53 523 09

• PVC = 45 - 85%

VINNAPAS® VAE DISPERSIONS –KEY PERFORMANCE IN PAINTS / BENCHMARKING

Water x

Dispex N 40 5

Natrosol plus 430 2

Rheolate 208 2

NaOH 10% 1

Addid 800 1

Kronos 2300 71

Mistron 754 G 71

Omyalite 90 142

Omyacarb 2 GU 261

Arbocel BE 600/30 PU 40

Parmetol DF 12 2

Dispersion x

Total 1,000


EN ISO 11 998DIN 53 778 part 2

EQUIPMENT FOR THE DETERMINATION OF SCRUB RESISTANCE









RESULTS OF THE DETERMINATION OF SCRUB RESISTANCE




PVC [%]

Loss

of T

hick

ness

[µm

]

High scrub resistanceScrub resistance of VINNAPAS® EP 3888 and VINNAPAS® EZ 3010as a function of the PVC (RR 53 523 09 test procedure)


Excellent film forming properties at low temperaturesScrub resistance of VINNAPAS® EP 3888 as a function of the PVC and temperature (RR 53 523 09 test procedure)


PVC [%]

Loss

of T

hick

ness

[µm

]



Excellent hiding power



Hiding power VINNAPAS® EP 3888 versus SA

Con

tras

trat

io

Spreading rate in m2/liter

6,0 6,5 7,0 7,5 8,0 8,5 9,0 9,5




EQUIPMENT FOR THE DETERMINATION OF SHEEN RESPECTIVELY GLOSS

• EN ISO 13 300

• Mat < 10 units at 85°

• Dead mat < 5 units at 85°




She

en (

85)

Low sheen in matt paintsSheen (Gloss 85) as a function of the PVC

PVC [%]


• Excellent color strength

• Excellent color stability, even in matt interior paints

After 6 weeks on the window


Competitor binder VINNAPAS®

EP 3888


• 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® CEZ 18 – APPLICATIONS


• MFFT < 0°C

• Excellent film forming properties at low temperatures

• No solvents or plasticizers required

• High binding power

• Low VOC

• No or low odor

• Manufactured without APEO’s

VINNAPAS® CEZ 18 –KEY PERFORMANCE IN INTERIOR PAINTS


• Excellent resistance against saponification

• Excellent weathering resistance

• Excellent durability

• Low dirt pick-up

• Low chalking

VINNAPAS® CEZ 18 –KEY PERFORMANCE IN EXTERIOR PAINTS


• 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 ofthermal insulation systems

VINNAPAS® CEZ 18 – KEY PERFORMANCE IN PLASTERS


• 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

ONGOING MONITORING OF DIFFERENT VINNAPAS® CEZ 18 EXTERIOR COATINGS ON OUR TEST FENCE


THANK YOU!!

Documents

Wacker VAE