Today's KNOWLEDGE Share : Carbon Fiber Production Part1/5

Today's KNOWLEDGE Share

Insights into carbon fiber production (Part 1/5)!

Oxidation - the beginning of carbon fiber production

Large piles of PAN precursor mark the beginning of carbon fiber production with PAN precursor, the main precursor valued for its high strength and heat resistance. The oxidation process consists of several stations where the fiber is continuously oxidized and cleaned of anything that is not carbon. After the fifth oxidation oven, the fiber finally emerges from the ovens completely dark and chemically refined.

Safety is our top priority: Our ovens are equipped with advanced fire protection systems to minimize the risk of fire. Even in the event of yarn breakage, our sophisticated systems ensure that each yarn is returned to the process without waste.

source:Teijin Carbon America,Inc

#carbonfiber #carbonfiberproduction #oxidation

Today's KNOWLEDGE Share : BASF additional production capacity for expandable polystyrene (EPS)

Today's KNOWLEDGE Share

BASF Ludwigshafen announces additional production capacity for expandable polystyrene (EPS) granules by 50,000 tonnes/year.

BASF is strengthening its styrene value chain at the Ludwigshafen site by increasing annual production capacity for Neopor by 50,000 tonnes. The increase is aimed at meeting the growing market demand for grey insulation materials. The new production facility is scheduled to be commissioned in early 2027.

 

Neopor is a graphite-containing expandable polystyrene (EPS) granule developed by BASF as a raw material for the production of energy-saving thermal insulation for building envelopes. The graphite content gives the material a grey colour and improves the thermal insulation performance of the sheets by 30% compared to white EPS. Neopor insulation sets new standards for new and refurbished buildings.

 

"BASF's sustainability assessment ranks Neopor as a 'pioneer' in the highest category and is part of BASF's 'solutions for a sustainable future'," said Stephan Kothrade, member of the Board of Executive Directors and Chief Technology Officer of BASF SE. "Our goal is to be the chemical company of choice for our customers and help them achieve a green transition. Neopor is a great example of how we can achieve this goal."

 

BASF expects that the demand for energy-efficient building renovation materials will increase significantly in the coming years. The EU's goal is to make the European construction industry climate neutral by 2050. To achieve this ambitious goal, all EU member states implement the European Building Energy Efficiency Directive, which places high demands on improving building energy efficiency.

 

“Well-insulated building envelopes are essential for reducing greenhouse gas emissions and achieving climate targets. This is also a prerequisite for the rational use of modern heating technology. Our polystyrene insulation materials play an important role in this regard,” said Klaus Ries, Head of Business Management Europe at BASF Styrenics.

 

“Over their decades-long service life, they significantly reduce CO2 emissions and energy consumption for heating/cooling buildings. This is not only good for the climate, but also saves energy costs. Neopor with graphite has excellent insulation values and is easy to process, cost-effective and recyclable. Neopor is one of the most environmentally friendly insulation materials.

souce:BASF/echemi.com

Today's KNOWLEDGE Share : Issues with color masterbatches in Injection Molding

Today's KNOWLEDGE Share

Understanding Common Issues with Color Masterbatches in Injection Molding

The use of color masterbatches is prevalent in injection molding. However, over the years, I have frequently encountered several issues that typically result in surface defects on the molded parts.

These issues can be categorized into three main scenarios:

1. Incompatible Carrier Materials

Sometimes, masterbatches (e.g., with 50% pigment and 50% carrier) use a high-flow carrier like LLDPE, even when the host polymer to be colored is not LLDPE-based.

Issue: The incompatible high-flow carrier is pushed to the surface by hydrodynamic forces. For instance, small amounts of LLDPE in a nylon part can readily create blisters or delamination.

2. Neglecting to Dry the Masterbatch

In nylon or polyester parts, even when the masterbatch uses the correct carrier (same as the host matrix to be colored), users often neglect to dry the masterbatch, drying only the bulk resin to be molded.

Issue: Users may assume that the small amount of masterbatch added doesn’t need drying. However, a very wet, small amount of carrier can cause surface blooming, silver streaks, and potentially significant hydrolytic degradation issues in sensitive materials like PET or PBT.

3. Improper Dispersion of Masterbatch

Even when the masterbatch uses the correct carrier and is properly dried before feeding into the hopper, part issues can still arise.

Issue: The problem often stems from less than perfect dispersion of the masterbatch in the injection molding machine screw. These screws are not always ideally designed and may lack the ability to fully disperse the pigment, leading to color issues due to inhomogeneous color concentrate.

Understanding and addressing these common issues can significantly improve the quality of injection molded parts. Ensuring compatibility of carriers, proper drying of materials, and optimal dispersion techniques are crucial steps in achieving defect-free products.

credit:Vito leo

#plastics #injectionmolding #plasticmasterbatch

Today's KNOWLEDGE Share :Neste and Braskem announce agreement on supply of renewable and recycled feedstocks

 Today's KNOWLEDGE Share

Neste and Braskem, the largest producer of thermoplastic resins in the Americas, have reached an agreement for the supply of renewable and recycled feedstocks for polymers and chemicals production. Braskem products based on these feedstocks are expected to be available on the market starting from the fourth quarter of 2024. These products will be sold mainly in South America and included in Braskem’s Wenew product portfolio. 

“This is a very important moment for the industry. We're introducing a new solution that will adhere to the industry’s high quality standards while ensuring sustainability right from the start of the value chain. This partnership with Neste is a significant milestone in our journey towards a circular economy,” stated Fabiana Quiroga, Director of Circular Economy at Braskem in South America. 

Braskem will sell polymer resins and chemicals made from Neste’s more sustainable feedstock Neste RE™: the recycled feedstock, produced leveraging plastic waste via chemical recycling, and the renewable feedstock produced by processing renewable raw materials such as used cooking oil (UCO). 

“We are excited to welcome Braskem as our partner in advancing the transformation of the plastics and chemicals industry towards more sustainable solutions,” emphasizes Jeroen Verhoeven, Commercial Director for Polymers and Chemicals at Neste. “We are looking forward to seeing our Neste RE solution in action in South America, reducing the dependence on virgin fossil feedstock in the production of polymers and chemicals.”

An ISCC PLUS (International Sustainability and Carbon Certification) certified mass balance approach will be applied to integrate the new feedstocks into Braskem's existing processes. This will give customers further reassurance regarding the uninterrupted chain of custody and the sustainable sourcing of the materials.

An innovative solution with clear climate benefits

By combining chemically recycled and renewable solutions, Braskem builds upon two of the most promising solutions to reduce the use of virgin feedstock and to promote sustainability in chemicals and plastics value chains. 

Chemical recycling enables the recycling of those types of plastic waste that are otherwise difficult to recycle, for example multi-material or colored plastics. In this sense, Neste’s chemically recycled feedstock can contribute to increasing recycling and therefore help reduce the amount of plastic waste entering the environment. 

Neste's renewable feedstock, on the other hand, can help reduce greenhouse gas (GHG) emissions when replacing fossil feedstock in the manufacturing of plastics and chemicals. It is produced using renewable raw materials such as waste and residue oils and fats like used cooking oil or residues from vegetable oil processing. 

source:Neste Corporation

Today's KNOWLEDGE Share : PA6-based WRAS-certified Solutions for Drinking Water Applications

Today's KNOWLEDGE Share

DOMO Introduces PA6-based WRAS-certified Solutions for Drinking Water Applications

DOMO Chemicals announces the successful achievement of the first PA6-based Water Regulation Approved Scheme (WRAS)-certified solutions, demonstrating that the material is suitable for drinking water contact applications. 

Eliminates Risk of Galvanic Corrosion and Scale Formation:

With increasing urbanization, one of today’s key challenges is to provide sustainable access to quality water. An optimal way to do this is to provide advanced polyamide technology for metal replacement and high-end polymers for the water management industry. This helps to ensure greater sustainability, lower system and maintenance costs, and easier and safer handling of water.  

"Our new range of TECHNYL® SAFE C can effectively replace brass and other metals in water distribution, filtration and irrigation, sanitary and small appliance components requiring WRAS approval up to 85°C," said Paolo Rossi, Industrial Consumer Goods Application Development manager, DOMO Chemicals. "The portfolio has been developed to provide a specific property profile compared to current best-in-class materials and to meet the regulatory requirements for contact with drinking water set out in BS6920-1:2000 and/or 2014, which define compliance with WRAS." 

DOMO's metal replacement materials eliminate the risk of galvanic corrosion and scale formation, and provide significant system savings compared to the high cost of processing and machining new brass alloys and the high environmental impact of foundry end products. 

Water management applications have very specific requirements, such as good mechanical properties retention after long-term water contact with chlorine (disinfectants) even at warm temperatures, as well as long-term dimensional stability and oxidative degradation resistance. The most common applications in this field are water filtering, water softeners and metering systems, submersible pumps, shut-off valves, fittings, faucets, cartridges, boiler components like hydro-block manifolds, along with balancing and other small home appliance parts. 

Water Regulation Approved Scheme

WRAS approval is a simple way of demonstrating that a material is of a suitable quality and standard and has been tested to demonstrate compliance with BS6920. 

Any water fitting which, when installed, will carry or receive water from the public water supply in the UK must comply with the Water Supply Regulations or Scottish Byelaws.These require that a water fitting must not cause waste, misuse, excessive consumption or contamination of the water supply and must be "of an appropriate quality and standard.” Non-metallic materials and components are only tested for their effect on water quality.  

The new TECHNYL® SAFE C solutions complement the existing WRAS-certified TECHNYL® SAFE portfolio of water and food contact, based on PA66 and PA6.10. 

source: DOMO Chemicals/omnexus.specialchem.com

Today's KNOWLEDGE Share : Carbon Fiber reinforced Bio based PA 10.10 Grade

Today's KNOWLEDGE Share

Xenia Launches 50% CF Reinforced Bio based PA 10.10 Grade

This new carbon-fiber reinforced material, based on PA10.10, delivers exceptional strength and durability while being 100% bio-based.

This new material not only represents a step forward in performance but also aligns with Xenia®’s commitment to sustainability.

Suitable for High Temperature Applications:

With up to 50% carbon fiber reinforcement, XECARB® 31 ensures increased stiffness, making it ideal for structural applications that demand superior mechanical strength.

Furthermore, this new compound is well-suited for environments that require higher operating temperatures without compromising performance, thanks to its high melting point.

The PA10.10 base polymer ensures significantly reduced moisture absorption, improving long-term durability. Its excellent cold impact resistance makes it suitable for applications frequently exposed to low temperatures, such as outdoor environments and high-altitude settings. The combination of lightweight construction and rigidity makes the XECARB® 31 optimal for high-performance sports equipment. This material enhances product durability without adding unnecessary weight, making it ideal for competitive sports where performance is crucial.

In the industrial sector, chemical resistance and mechanical stability are key advantages for parts exposed to harsh working conditions. This includes applications where the material’s ability to withstand heat, oil, and grease ensures longevity and reliable performance.

Sourced from Castor Oil:

As a bio-based material sourced from castor oil, the PA10.10 significantly reduces dependence on fossil fuels, addressing the growing demand for eco-friendly solutions.

This new compound promotes a more circular and environmentally conscious approach to manufacturing, offering high performance without compromising on sustainability.

Source: Xenia® Materials/omnexus.specialchem.com

Honeywell And SGP BioEnergy To Develop Plant-Based Biochemicals, Reducing Industry’s Reliance On Fossil Fuels

Honeywell and SGP BioEnergy today announced they are working together to develop new, scalable technology to convert industrial hemp and other plant-based material into biochemicals that can be used to produce plastics and other everyday items, offering an alternative to chemicals produced from fossil fuels.

As part of this collaboration, Honeywell will develop the new technology that enables plant material to be used as feedstock for biochemical production on an expanded scale. SGP BioEnergy will provide the infrastructure, workforce and second-generation feedstock, including industrial hemp, for this initiative through its “READY.GROW.” program.

To ensure safe and efficient unit operations, Honeywell will provide ongoing operational support and workforce training for the team at SGP BioEnergy. The collaboration with SGP BioEnergy supports Honeywell’s alignment of its portfolio to three powerful megatrends, including the energy transition.

“Honeywell is committed to developing innovative solutions to help enable the energy transition. This cutting-edge technology will enable the production of a variety of petrochemical alternatives using second-generation feedstocks,” said Bryan Glover, chief technology and growth officer of Honeywell Energy and Sustainability Solutions. “By using hemp and other non-edible feedstocks to produce these important chemicals, Honeywell and SGP BioEnergy are helping to reduce the world’s reliance on fossil fuels without impacting the food chain.

“Advancements in the creation and use of biochemicals and biomass are bringing the world to a transformative inflection point. The global stakeholder demand is continually growing, and policies to incentivize cleaner and safer solutions are aligned among many of those stakeholders,” said Randy Delbert Letang, founder, president and CEO of SGP BioEnergy. “Honeywell’s leadership, technological renown and commitment to accelerating the energy transition made it a perfect partner for this initiative given our ‘Zero Waste Ecosystem’ model and continued efforts towards decarbonization.”

souce:honeywell

China debuts first-of-its-kind hydrogen-powered high-speed train with remarkable capabilities: 'A new green upgrade for passenger transport'

China continues to stretch its lead in the high-speed rail industry, debuting a hydrogen-powered train at InnoTrans 2024.

The zero-carbon train — made by China Railway Rolling Stock Corporation's Qingdao Sifang — travels up to 200 kilometers per hour (125 mph) and can cover 745 miles before needing a recharge.

It was unveiled at the transportation technology trade fair, held in Berlin at the end of last month, as Newsweek reported.

The four cars of the CINOVA H2 hold more than 1,000 passengers, and the train can be refueled in 15 minutes. It generates 960 kilowatts of electricity, producing no pollution and releasing only water.

"Its design emphasizes a green and sustainable approach," senior designer Liang Caiguo said. "The water emitted from the hydrogen fuel cell reaction is purified and recycled to meet passenger water needs. Additionally, the waste heat from cooling the hydrogen fuel cell is repurposed for heating the air conditioning system during winter."

Artificial intelligence helps monitor and maintain the train, as is the case for other Chinese locomotives.

Such developments in the sector which include an Italian levitating train that can run on already built tracks are vital to reducing the carbon pollution that is overheating the Earth and endangering lives, livelihoods, and communities.

If hydrogen and other low-carbon train trips can replace domestic flights, in particular, it will be great for our health, our future, and the environment.

"It effectively reduces carbon dioxide and other air pollutant emissions, showcasing significant environmental benefits, and will strongly promote a new green upgrade for passenger transport equipment on non-electrified railways," CRRC Qingdao Sifang deputy director Wang Xueliang told China Daily, per Newsweek.

The magazine noted that hydrogen trains in Europe are not nearly as fast, with one reaching a top speed of 87 mph but normally traveling around 50-75 mph. The fastest train in the world is a magnetic levitation vehicle in Shanghai, which has an eye-popping top speed of 268 mph and normal operating speed of 155 mph, allowing it to make modest 20-mile journeys in just eight minutes for $7.

source:www.thecooldown.com

Today's KNOWLEDGE Share :HAVING DESIRED EPOXY RESIN CONTENT

 Today's KNOWLEDGE Share

Why need to set optimum Epoxy Resin content for COPV applications?
The strength of composites depends predominantly on their reinforcements.I have identified from my experience in the Type 4 composite cylinder project that has been proved that the resin content directly affects the tensile strength, modulus of elasticity, Poisson's ratio and other mechanical properties of laminates.

It is mandatory to have studied the fracture analysis of the resin system and carbon fiber laminates to identify the problems in the fracture analysis and to be sorted out before proceeding to the prototype stage in the project.
Based on the manufacturing set up,production time &expected properties of the composites,need to select the right grade of epoxy resin with hardener.
Hardener plays a vital role in getting the suitable epoxy resin system.There's a deep understanding of the epoxy chemistries and its curatives are needed to select the right choice of hardener for the Type4 composite cylinders.

I have seen many failures when not selecting the suitable raw materials for the Type 3/4 COPV applications.Aliphatic,Aromatic and Anhydride based hardeners can be tried out before selecting the right matrix to meet the design requirements.If followed properly,half of your problems will not rise in the testing phase.

The more resin content and the high fiber content will cause more delamination/void in the final product.It is mandatory to stick with the right resin content throughout the process to have the uniform stress distribution in the entire carbon fiber laminate.I have witnessed more resin content will pass it on burst test and do show up failure on fatigue cyclic testing.Certain resin behavior will pass on initial tests but surely do showup the cylinder's efficiency in the end results on fatigue cyclic tests.

I always suggest my clients to have their own R& D team to conduct different resin content for example to say 30% or 35%/40% even higher or lower based on your customized epoxy resin system that suits for composite Hydrogen cylinder applications.Electron microscopy is used to scanned the the tensile strength results fracture morphology observed and analysed on each % resin system.
It is advisable to perform tensile strength and elastic modulus versus different percentage of epoxy resin content respectively and observed the results and find the optimum percentage of resin content that yield excellent results.This will give you the right understanding of your composite laminates and which resin system gives the better result.

Though fibers bear the stress,it is essential for the matrix to have optimum % content with not higher or lower thus leading to decrease in the mechanical properties of the carbon fiber cylinders.Interfacial bonding in between fiber and matrix need to planned well to avoid not infiltrate the fiber in the resin system thus lead to stress transfer failure and performance failures as well.

Muthuramalingam Krishnan