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Dr Sven Thiele Dr Christian Döring Daniel Heidenreich
Synthetic Rubber –A Critical Raw Material For Low Rolling Resistance
High Performance Passenger Car Tires
Trinseo Deutschland GmbH
Dr. Sven Thiele, Dr. Christian Döring, Daniel Heidenreich
Trinseo Deutschland GmbH
56th Annual General Meeting of the International Institute of Synthetic Rubber Producers (IISRP) at Cape Town, South Africa, 20‐23 April, 2015
1 Introduction
AGENDA
1. Introduction
2. Functionalization Technologies
3. TRINSEO New Polymer Grade Development
4. TRINSEO Growth & Market Expansion
5 Conclusion/Summary
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5. Conclusion/Summary
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• Trinseo was founded on a unique combination of strong capabilities strong market
Fast Facts
INTRODUCTION: TRINSEO
capabilities – strong market positions, production assets, and leading technology
• More than 2,100 employees, based in 27 countries
• 66 manufacturing plants at 19 manufacturing sites around
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the world
• Part of Dow Chemical until 2010
• Leader in our key products: plastics, latex, and rubber
Trinseo Portfolio Overview
Performance Materials DivisionBasic Plastics and
Feedstocks Division
INTRODUCTION: TRINSEO
Bu
sin
esse
s an
d
Bu
sin
esse
s an
d
Key
K
ey P
rod
uct
sP
rod
uct
s
LatexStyrene Butadiene (SB) LatexStyrene Acrylate (SA) Latex
Rubber
Polystyrene (PS)Acrylonitrile Butadiene Styrene (ABS)Styrene Acrylonitrile (SAN)Polycarbonate (PC)FeedstocksSolution Styrene Butadiene Rubber (SSBR)
Lithium Polybutadiene Rubber (Li-PBR)Emulsion Styrene Butadiene Rubber (ESBR)Nickel Polybutadiene Rubber (Ni-PBR)
Performance PlasticsConsumer Essential MarketsAutomotive Plastics
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Bra
nd
sB
ran
ds
En
d
En
d U
ses
Use
s
LOMAX™ MaxCoat™ ProForte™ FOUNDATIONS™ MaxFoS™ EVEREST™ HPL™ MaxForte™ ProWeb
ENVERSA™ SPRINTAN™
CALIBRE™ MAGNUM™STYRON™ STYRON A-TECH™ TYRIL™ STYRON™ C-TECH
EMERGE™ INSPIRE™VELVEX™CELEX™PULSE™
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INTRODUCTION: Synthetic Rubber & TRINSEO
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1937 IG Farben ‐ Schkopau – world first large scale production
of synthetic rubber “BUNA N & BUNA S”
2000 Dow Chemical Company
New production plant for “Anionic Solution Polymerization”
June 2010 Styron Deutschland GmbH
June 2014 Trinseo Deutschland GmbH
ESBR, 4865, 29%EPDM, 1295, 8%
IR; 776; 5%SSBR; 1378; 8%
INTRODUCTION: Global SR Capacity
CR, 404, 2%
IIR, 1243, 7%
, ,
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BR; 4042; 24%SBC, 2269, 13%
NBR, 737, 4%
TRINSEO Activity Fields
Total 2012 Synthetic Rubber Production = 17.000 kT IISRP 2012 Report
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General Rubber
HIPS3,3 %
Footwear1,9 %
ABS0,9 %
Hoses0,3 %
INTRODUCTION: Synthetic Rubber Applications
Tires
Goods24,8 %
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TRINSEO supplies synthetic rubber in all application areas!
LMC Report 2012
Tires68,8 %
3000
3500
nt
North America S & C America Europe & Eurasia
Middle East Africa Asia Pacific
INTRODUCTION: World Energy Consumption / Transport Sector
500
1000
1500
2000
2500
3000
Million tonnes
oileq
uivalen
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0
500
1990 1995 2000 2005 2010 2013 2015 2020 2025 2030 2035
in
Source: BP, Energy outlook 2015, report from February 2015
World energy consumption by the transport sector rose by 56% in 23 years(1990-2013) !
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INTRODUCTION: CO2 Emission Limits
2000 in g (CO2)/km 2015 in g (CO2)/km
Passenger vehicle emissions:
EU 170 130
Mexico 225 160
Canada 205 160
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2 http://www.edf.org/documents/5301_Globalwarmingontheroad.pdf
The international council of clean transportation, Policy update March 2014.
Further reduction of emission limits anticipated!
2000 2012 2015 2020
g (CO2)/ km
g (CO2)/ miles
g (CO2)/ km
g (CO2)/ miles
g CO2)/ km
g CO2)/ miles
INTRODUCTION: CO2 Emission Limits
EU 170 273 130 209 95 153
Mexico 225 361 160 257
Canada 205 330 160 257
2014 2017 2020
g (CO2)/ k
g (CO2)/ il
g CO2)/ k
g (CO2)/ il
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1 http://www.edf.org/documents/5301_Globalwarmingontheroad.pdf
Almost 1/3 of total CO2‐emission caused by passenger Cars & Light Trucks.1
km miles km miles
EU 175 282 147 234
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http://www jatma or jp/english/lab
INTRODUCTION: Tire Labels
http://www.jatma.or.jp/english/labeling/outline.html
http://www.etrma.org/public/activitiestyreg.asp http://www.inmetro.gov.br/
Volentary & active since 2010
Mendetory & active since 2012
Mandetory as of 2016
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http://www.kotma.or.kr/
http://www.nhtsa.gov/
?
Mendetory & active since 2012
Proposal since 2010 Introduction in discussion for 2016
-> 20-30 % of total driving resistance corresponds to rolling resistance of tires-> Tire tread causes 65-70% of tire rolling resistance
INTRODUCTION: European Label & Fuel Efficiency
http://www.etrma.org/public/activitiestyreg.asp
http://www.etrma.org/public/activitiestyreg.asp
http://www.etrma.org/public/activitiestyreg.asp
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Difference of Class A and G amounts to ~10% or 0.66 L/100 km
Fuel Consumption in L/100 km
VCD, http://www.vcd.org/rollwiderstand.html
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INTRODUCTION: European Label & Tire Safety
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Basis: Braking distance at 80 km/h. After 28 m F class tire has a speed of 50.5 km/h
VCD, http://www.vcd.org/rollwiderstand.html
Braking distance in m
67.3%70%80%
Summer Tires Size 205/55 R16
April 14 (all) March 2015 (all) March 2015 (Premium)
INTRODUCTION: RR & Wet Grip / Tire Label Statistics
0.5% 1.5%
12.8%9.7%
50.8%
0.6% 1.4%
9.2%12.0%
48.8%
1.4% 2.7%
16.4%18.6%
0%10%20%30%40%50%60%70%
Trinseo Deutschland GmbH
A all all A A‐B
A A A‐B all all
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Data from: www.reifen.com (April 2014 and March 2015), tire size 205 55 R16 (lower middle class), tires compared: 2014: 195; 2015: 498 (Premium: 220)
best fuelefficiency (A or B)
best grip on wet road (A or B)
best rating
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70%
Comparison of label classification of different tire sizes
175/65 R14 (small car) 205/55 R16 (lower middle class)
225/45 R17 (upper middle class) 215/65 R16 (compact SUV)
INTRODUCTION: RR &. Wet Grip / Tire Label Statistics
0.0% 0.0% 1.6% 1.6%
26.7%
0.6% 1.4%
9.2%12.0%
48.8%
0.0% 0.3%
16.2%
2.9%
59.0%
0.0% 0.7%
7.2% 7.2%
30.4%
0%
10%
20%
30%
40%
50%
60%
70%
Trinseo Deutschland GmbH
A all all A A‐B
A A A‐B all all
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Data from: www.reifen.com (March 2015), tires compared: Size 175/65 R14: 191; Size 205 55 R16: 498; Size 225/45 R17: 339; Size 215/65 R16: 138
best rating best fuelefficiency (A or B)
best grip on wet road (A or B)
European tire labelling effective as of November 2012.
Minimum thresholds for rolling resistance & wet grip as of November 2014 in Europe.
INTRODUCTION: Trends for Passenger Cars in Europe
Tire manufacturers have mainly optimized tire wet grip safety standards to A-B rating.
Fuel efficiency characteristics were balanced to ratings of C-E.
Winter tires have generally a lower rolling resistance performance.
More stringent rolling resistance standards d f 2020
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are expected as of 2020.
There is a High Demand & an Improvement Potential For Fuel Efficient Tires in Europe !
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Energy Loss Through Energy Loss Through Irreversible
Transfer of Mechanical Energy (Tire Motion on the Road)
Tire Hysteresis Energy Loss
INTRODUCTION: Options to Rolling Resistance Reduction
Friction of Filler Particlesgy g
Movement of Polymer Chains
Active Particles withhigh dispersion in rubber formulations
Prevent
Active Polymer FunctionalizationPrevent polymer chain aggregation
Hysteresis Energy Loss / Rolling Resistance
Improvement Options
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particle aggregationCapability of handling higher viscositypolymer formulations
polymer chain aggregation network formation during
polymer filler compounding
Optimized Filler Particle Separation / Improved Polymer-Filler Interaction Low Rolling Resistance
2012‐2013
Period
Patents SBR/BR
INTRODUCTION: Demand Creates Research Activities
1980 1990
1990‐2000
2000‐2010
2010‐2011
2011‐2012
GrowthFactor 9
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Number of SBR & BR related patents refelect market demand driven research actvities !
Patent search with Thomson Innovation, Dec 3, 2013
0 500 1000 1500 2000 2500 3000 3500 4000
1980‐1990
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The Magic Triangle
INTRODUCTION: Tire Property Profil
Wet Grip
Trinseo Deutschland GmbH
CONFLICTING PERFORMANCE REQUIREMENTS
19
Grip
Polyme‐risation
Termination
Chemical Modification
Expanding the Magic Triangle
INTRODUCTION: Improving The Tire Property Profil
Designed Microstructure (Random,Ta‐pered, Block)
Molecularweight
MWD
Termination
Coupling
„Variation of Monomer“ block
t t
Trinseo Deutschland GmbH
structure
Functiona‐lization
20
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Third monomer
Backbone Functionalization ω-Chain-End Functionalization
FUNCTIONALIZATION TECHNOLOGIES
Bridgestone: Eur. Patent No. 832903 B1; September 22, 1993
-(amine)modified SSBRGoodyear: US Patent No. 6664328 B1; June 06, 2003
Center Funct. or Modified C li
Bridgestone: Eur. Patent No. 0773231 B1; December 29, 1994
Backbone Functionalization
nSBR
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Michelin: US Patent No. 8344063 B2; March 30, 2010
Coupling
Postpolymerization reaction
O
OHHS
nSBR
S
O
HOBayer: Eur. Patent No. 1101789 A1; November 22, 1999
TRINSEO NEW MODIFIED SSBR DEVELOPMENT
X =
Alkyl-Li =+
Initiator Formation Step
Trinseo Deutschland GmbH
+ Styrene, 1,3-ButadienePolymerization Step
22
new functionalizedanionic initiator
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alpha-functionalized
SSBRX
active chain endse.g.
TRINSEO NEW MODIFIED SSBR DEVELOPMENT
X
Chain-End Modification/Coupling Step
X
X
XX
/ /
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New multi-functionalized SSBR
X
XX
Characteristics of Optimized New Multi-functionalized
Oil Extended SSBR (Mw > 500.000 g/mol)
Typical Polymer Properties
TRINSEO NEW POLYMER GRADE DEVELOPMENT
SPRINTANTM
SLR 4630 -Schkopau
SPRINTANTM
SLR 4633 -Schkopau
Optimized new OE-
SSBR
Styrene [wt%] 25 21 28
Vinyl [wt%] 62 62 60
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Tg [°C] -28.0 -27.1 -24.9
Mooney ML1+4 [MU]
55.8 78.9 56.6
Oil [wt%] 27.3 23.3 27.3
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Silica Test FormulationComponent
SSBR
High-cis BR
Ultrasil 7000GR
phr
80
20
80
TRINSEO NEW POLYMER GRADE DEVELOPMENT
Silane Si75
Dusantox 6PPD
Antilux 654
Zinc oxide
Stearic acid
TDAE Oil
Sulfur
Aggregate: Brabender 350S Mixing: Two step process
6.9
2
1.5
2.5
1.0
20
1.4
Trinseo Deutschland GmbH
TBBS
DPG
1.5
1.5
25
NH
NH
NH
Diphenyl guanidine (DPG)
130127
Performance of New vs. Commercialized OE-SSBRSilica Formulation
TRINSEO NEW POLYMER GRADE DEVELOPMENT
70
90
110
100100
100100
100
112
101
86
117
105
115
106
98
127
107
Perform
ance [%]
Trinseo Deutschland GmbH
DIN AbrasionHeat build‐up (HBU)
Wet Grip Indicator Rolling
Resistance Indicator 1
Rolling Resistance Indicator 2
SPRINTAN™ 4630 ‐ Schkopau
SPRINTAN™ 4633 ‐ Schkopau
new funct. OE‐SSBR(Tan deta @ 60°C)
26
(Rebound Resilience@ 60°C)
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Schkopau, October 15, 2012Additional capacity of 50.000 MT SSBRAdditional volume satisfied increasing request on functionalized SSBR.
TRINSEO RUBBER GROWTH & MARKET EXPANSION
Wirtschaft / 15.10.2012... 91 Million Euro were invested, ... .
With 32 Jobs created new, this makes 2.8 Million per workplace. ...
Schkopau, February 18, 2014Acquisition of additional SSBR capacity from JSR
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Schkopau future„We are assessing currently, if neodym-polybutadiene manufacturing may be a future option“ …
Ralf Irmert Managing Director Trinseo Deutschland GmbH, KGK online 08/2014
from JSR
BATCH NON OIL EXTENDED
TRINSEO Synthetic Rubber Product Capabilities
TRINSEO RUBBER GROWTH & MARKET EXPANSION
SPRINTANTM SLR – 4602Sty 21%, Vinyl 63%, Mooney 65
Coupling Rate 25
SSBR
SPRINTANTM SLR – 4601Sty 21%, Vinyl 63%, Mooney 50
SPRINTANTM SLR – 3402Sty 15% , Vinyl 30%,
Mooney 62
functionalized for carbon black
SPRINTANTM SLR – 4502Sty 20% , Vinyl 54%,
Mooney 60
Experimental GradeSty 45% , Vinyl 9%,
Mooney 70
2000
20092011 2013/142010
Trinseo Deutschland GmbH
Experimental GradeSty 28%, Vinyl 58%
Mooney 60
functionalized for silica & carbon black
improved functionalized
28
Experimental GradeSty 20%, Vinyl 54%
Mooney 65
2014-16 2014-16
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OIL EXTENDED SSBR
TRINSEO Synthetic Rubber Product Capabilities
TRINSEO RUBBER GROWTH & MARKET EXPANSION
SPRINTANTM SLR 4633
SE SLR -
SSBR
Experimental Grade
SPRINTANTM SLR -4630Sty 25%, Vinyl 63%, Mooney 55
non-functionalized
20052005 Batch mode
Experimental GradeSty 40%, Vinyl 24%, Mooney 80;
22.5% TDAE
2013-16
SPRINTANTM SLR-6430Sty 40%, Vinyl 24%, Mooney 67
Experimental Grade
Trinseo Deutschland GmbH
SPRINTANTM SLR -4633Sty 21%, Vinyl 62%, Mooney 78
Experimental GradeSty 28%, Vinyl 59%, Mooney 80
functionalized
29
2014 2014-16
Experimental GradeSty 28%, Vinyl 58%, Mooney 65
Improved Rolling Resistanceimproved functionalized
2014-2016
Experimental GradeSty 41%, Vinyl 38%, Mooney 61
2014-16
TRINSEO Synthetic Rubber Product Capabilities
BR Grades
TRINSEO RUBBER GROWTH & MARKET EXPANSION
BR Grades
non- functionalized
SE PB 3501 - Schkopau(cont) High branching, Vinyl 9% Mooney 44
High Cis BR
SE PB 5901 - Schkopau(cont) Medium branching,
Vinyl 9% Mooney 62
SE PB 5800 - Schkopau(cont) Low branching, Vinyl
11% Mooney 51
Buna cis 132-SchkopauNon-functionalized
Mooney 45
Low Cis BR
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functionalizedNeodymium-based
Non- & FunctionalizedMooney 45/63
2013-16
Experimental GradeLow Vinyl
Mooney 63
2014-16
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CONCLUSIONS & SUMMARY
Increasing demand for low rolling resistance –high grip – high abrasion resistance tires caused by environmentally driven legislation.
Trinseo is successfully continuing stage-wise polymer grade development.
New Trinseo developmental grades address current market needs.
Trinseo provides market volume through di d ti biliti
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expanding production capabilities.
Extended TRINSEO Synthetic Rubber product portfolio indicates short implementation timeline for new SSBR grades.
ACKNOWLEDGEMENTS
T i D hl d G bHTrinseo Deutschland GmbH
Trinseo Deutschland GmbH
THANK YOU