LANXESS' GF-filled PA 66 Durethan AKV 35 H2.0 Replaces Metal in Audi's Engine Oil Pans

Compared with steel sheet or die cast aluminum, polyamides provide tremendous opportunities for reducing weight in the production of automotive engine oil pans. This is demonstrated by the 1.8 and 2.0-liter turbocharged gasoline engines used in the Audi A3, A4 and A6 as well as in the Volkswagen Passat for example. Their engine oil pans are made of Durethan AKV 35 H2.0, a polyamide 66 from LANXESS, and weigh roughly one kilogram less than a steel component solution. They are around 50 percent lighter than an oil pan made of aluminum. "Not only do weight savings of this magnitude appreciably reduce the vehicles' fuel consumption and CO₂ emissions, they also improve the handling because this weight is saved in the area of the front axle," said Frank Krause, an expert for oil-bearing polyamide engine parts at LANXESS. The oil pans are manufactured by POLYTEC PLASTICS Germany GmbH & Co KG based in Lohne, Germany.

Great design freedom

There is a general trend toward compact engines with increasingly smaller and more complex installation spaces. This results in oil pans with geometries that could only be produced with great effort in steel sheet. With deep parts, in particular, steel bumps up against its limits due to the unfavorable draw ratios. Polyamide can shine in these cases with great design freedom. In addition to the potential weight savings, its primary advantage over aluminum is that it can be used to produce ready-to-assemble injection-molded parts. Oil pans made of die cast aluminum, on the other hand, must undergo post-molding treatment, such as deburring or machining of the flanges to make them plane. This work quickly adds up to a large portion of the production costs.

Audi's engine oil pan made of LANXESS's PA 66

Integrated functionality reduces component costs

Other advantages of polyamide over metal are the opportunities that injection molding offers for reducing costs by the integration of functions. In the case of the engine oil pan for turbocharged engines, for example, the sockets for the oil level sensor and the oil drain plug are molded directly into the component. "It is precisely when many functions can be integrated that significant costs savings over aluminum construction can be achieved because separate welding and mechanical work steps and the associated logistical workflows can be eliminated," explained Krause. Possible candidates for integrated functionality in engine oil pans include sockets for oil cooling and filtration, cheeks for expanding the volume of oil, oil return lines or reinforcing elements in the area of the transmission support.

Tailored high-tech plastic

Durethan AKV 35 H2.0 is filled with 35 percent glass fibers. Despite this reinforcement, it can be used to produce low-warpage oil pans whose flanges remain tight. The plastic's high toughness, stiffness and strength contribute to the ability of the oil pans to safely withstand stone impacts and bottoming out on a high curb. The thermal stabilization of the polyamide ensures the high dimensional stability of the components under typical sustained thermal loads.

Source:LANXESS

Applied CleanTech's Sewage Recycling System Transforms Human Waste into Consumer Plastics

Applied CleanTech transforms human fecal matter into a variety of end products. Applied CleanTech's Sewage Recycling System turns the solids in sewage streams into a fertile source of energy and other consumer end products such as paper, envelopes and plastics.

Because ACT extracts — rather than digests — the bio-solids in raw sewage, its process reduces total sludge formation by up to 50%. Other advantages of ACT's Sewage Recycling System include a 30% reduction in wastewater treatment plant costs(and such costs, in turn, represent 30% of sewage processors' operating costs) and a 15% increase in plant capacity.

ACT's automatic recycling process also enables a reduction of accompanying odor problems during the treatment process, improves general plant maintenance and results in cleaner water. The company monetizes the 30% reduction in energy costs borne by the sewage operator by selling carbon credits.

The immediate product that comes out of ACT's recycling efforts is Recyllose™, which is a feedstock that has high cellulose content and low moisture. Recyllose is low in lignin, a tough substance that binds the cell walls in plants and is a hurdle in the race to create an efficient cellulosic ethanol because it's so difficult to degrade. These properties make it economical for sewage facilities that serve populations as small as 10,000 people to produce Recyllose.

ACT's sewage recycling system is already in commercial use as it serves some 100,000 people with facilities in Israel and the United States. Just since the beginning of 2012, ACT has received contracts worth roughly $3.5 million. This is just scratching the surface as we calculate the addressable market to be at least $10 billion annually.

Competitors will have to tread carefully in emulating ACT's recycling process. Management has protected the intellectual property that arose throughout nine years of research by filing some 35 patents which are categorized in seven patent families.

Source:Applied Clean Tech

Bioplastic Production Capacity to Reach 5.6 Mn Tons by 2016, Expects European Bioplastics

An above-average positive development in bioplastics production capacity has made past projections obsolete. The market of around 1.2 million tons in 2011 will see a fivefold increase in production volumes by 2016 — to an anticipated almost 6 million tons. This is the result of the current market forecast, which the industry association European Bioplastics publishes annually in cooperation with the Institute for Bioplastics and Biocomposites from the University of Hannover.

The worldwide production capacity for bioplastics will increase from around 1.2 million tons in 2011 to approximately 5.8 million tons by 2016. By far the strongest growth will be in the biobased, non-biodegradable bioplastics group. Especially the so-called 'drop-in' solutions, i.e. biobased versions of bulk plastics like PE and PET that merely differ from their conventional counterparts in terms of their renewable raw material base are building up large capacities. Leading the field is partially biobased PET, which is already accounting for approximately 40 percent of the global bioplastics production capacity. Partially biobased PET will continue to extend this lead to more than 4.6 million tons by 2016. That would correspond to 80 percent of the total bioplastics production capacity. Following PET is biobased PE with 250,000 tons, constituting more than 4 percent of the total production capacity.

"But also biodegradable plastics are demonstrating impressive growth rates. Their production capacity will increase by two-thirds by 2016,"states Hasso von Pogrell, Managing Director of European Bioplastics. Leading contributors to this growth will be PLA and PHA, each of them accounting for 298,000 tons (+60 percent) and 142,000 tons (+700 percent) respectively.

"The enormous growth makes allowance for the constantly increasing demand for sustainable solutions in the plastics market. Eventually, bioplastics have achieved an established position in numerous application areas, from the packaging market to the electronics sector and the automotive industry", says von Pogrell.

A disturbing trend to be observed is the geographic distribution of production capacities. Europe and North America remain interesting as locations for research and development and also important as sales markets. However, establishment of new production capacities is favored in South America and Asia. "European Bioplastics invites European policy makers to convert their declared interest into concrete measures. "We are seeing many general supportive statements at EU level and in the Member States", says Andy Sweetman, Chairman of European Bioplastics. "There is, however, a lack of concrete measures. If Europe wants to profit from growth at all levels of the value chain in our industry, it is high time the corresponding decisions are made."

For a more in-depth impression of the world of bioplastics, visit the 7th European Bioplastics Conference on 6 and 7 November in Berlin. With over 400 experts on hand, the European Bioplastics Conference is the leading industry event in Europe.

Bangkok Metro to Use ICCO's Fire-resistant Pultruded Profiles as Third Rail Covers

One of the European leaders in pultruded composite material profiles is going to provide 20 kilometers of the Thailand capital with third rail covers. ICCO COMPOSITES produces top contact third rails up to 4 and 6 meters long which comply with safety and resistance requirements. Delivery is planned for early 2013 and should be open to the public on 2015.

Maximum underground safety

ICCO COMPOSITES pultruded profiles (especially designed for the top contact third rail) comply with all local security requirements and provide fire-resistant solutions for an even better safety.

Totally insulating, these profiles show many fire-resistant features and benefits: fire-resistant, low smoke emission, UV resistant, etc.

"The fact that one quarter of our activity is dedicated to the railway industry enables us to have a perfect knowledge of the market and business demand as regards safety issues. We can comply with our customers' most important safety requirements and have been able to develop the main of our activity to answer to our customer needs. To date, one customer out of three is using the whole range of our methods of production (pultrusion, machining and finishing, molding), from design to finishing" says ICCO COMPOSITES Sales Manager Bertrand VIEILLE.

Up to 200kms of third rail for ICCO COMPOSITES

ICCO COMPOSITES has already worked on Alger, Athens, Taipei, Almaty and Milan projects and will soon cross the 200 km border line with this third rail order. Bertrand Vieille says "ICCO COMPOSITES establishes a partnership rather than a customer/supplier relationship with its customers. Our work experience in the railway industry together with our wide and global know-how (pultrusion, machining and finishing, molding) enable our customers to have one single partner who is experienced with their range of activity. We perfectly know the railway industry requirements and can comply with them to deliver a competitive finished product".

SABIC's Novel LEXAN™ FST3403 PC Copolymer Meets Fire Safety Standard for Rail Seat Backs

SABIC's Innovative Plastics business recently announced new LEXAN™ FST3403 (flame-smoke-toxicity) polycarbonate (PC) copolymer, the first thermoplastic solution for rail seating applications to meet the strictest fire safety requirements under the CEN/TS 45445 standard. Now commercial a full two years before this European standard goes into effect, new high-performance.

LEXAN FST3403 copolymer — developed specifically for seat back shells and side covers — achieved the highest possible hazard level rating (HL3) under CEN/TS 45445-2 R5. In addition to its exceptional heat release, smoke density and toxicity performance, documented by independent laboratory testing, the LEXAN FST copolymer delivers high flow properties for injection molding large parts with excellent aesthetics and impact strength. Today's new product launch demonstrates SABIC's commitment to meeting evolving public safety standards with tailored thermoplastic solutions that support the needs of transportation industry customers.

"SABIC's proactive focus on developing advanced materials technology for rail industry customers will give them a significant head start in developing compliant seating components for a first-to-market competitive advantage," said Ilknur Gur, general manager, Specialty Business in Europe, Innovative Plastics. "Our new LEXAN FST3403 copolymer enables customers to continue using thermoplastics in their seat back shells and side covers instead of having to revert to traditional metal or thermosets that can inhibit design flexibility and potentially add weight and costs from secondary operations. This industry-leading technology greatly simplifies and accelerates compliance with the new European standard."

Combining High Performance and Attractive Aesthetics:

LEXAN FST3403 copolymer was tested by the Currenta Institute in Germany according to the requirements of CEN/TS 45445-2 R5 for seat back shells and side covers. This independent facility certified that LEXAN FST3403 copolymer complies with the requirements of HL3, the most challenging hazard level to achieve. Currenta tested the material for heat release under ISO 5660-1 and for smoke density and toxicity under ISO 5659-2.

The material also provides high flow capabilities that enable large parts, such as seat back shells, to be injection molded without marks, texture defaults, flow lines and other surface defects. It can also be molded in tooling that is typically used for PC/acrylonitrile butadiene styrene (ABS) materials. Another aesthetic benefit of LEXAN FST3403 copolymer is its ability to be custom colored, which avoids the need for secondary painting.

LEXAN FST3403 copolymer provides the sufficient impact performance and chemical resistance that are hallmarks of LEXAN PC resin. These properties help protect railcar, bus and tram seating from wear and tear.

Solvay Boosts PEEK & PAEK Production Capacity in India for Auto, Aero, Medical Sectors and more

Solvay announced recently a capacity increase of 70% at its Panoli plant, India, for the production of its high performance polymers KetaSpirepolyetheretherketone (PEEK)® and AvaSpire® polyaryletherketones (PAEK). Panoli is Solvay's largest plant worldwide for these two innovative ultra performance polymers that tower at the top of the plastics performance pyramid. Nearly half of this capacity increase has already been implemented and successfully brought on-line. The second phase of the project will be completed by mid 2013 and will allow the plant to continue to satisfy growth in demand.

The ultra-high performance of KetaSpire® polyetheretherketone (PEEK) and AvaSpire® polyaryletherketones (PAEK) along with their ease of processing provide substantial value for design engineers. The products are used in a diverse range of applications spanning many industries including aeronautic, automotive (e.g. mechanical components in cars), healthcare (medical equipment and reusable medical devices), electronics, oil & gas exploration and production, and process industries such as semiconductor manufacturing (chip testing and wafer processing).

"Solvay is delighted with the growth of its line of polyketone materials and we are very excited to be adding capacity for this business that we launched just a few years ago," commented Augusto Di Donfrancesco, General Manager of the Global Business Unit Specialty Polymers. "Our focus from the start was to deliver products with consistently high quality and performance and we believe this has been a key driver in the rapid market acceptance of our KetaSpire® PEEK resins. With AvaSpire® PAEK, we are impressed with how innovative design engineers are capitalizing on the entirely new performance dimensions offered by these materials", added Chris Wilson, Vice President for the Spire Ultra Polymers business.

With this investment, the Group reaches a new milestone in realizing its ambition to double its sales in India by 2015. Last week Solvay announced it is acquiring a controlling stake in Sunshield Chemicals, an Indian company specializing in surfactants, and some months ago it opened a major innovation centre in Savli (Gujarat State). The Group has been doing business in India since 2000 through its Novecare, Engineering Plastics and Specialty Polymers activities. With seven production sites and about 900 employees, the Group generated net sales of EUR 180 million in India in 2011.

Novamont's Bioplastic Container Aids Airline Caterer to Retain Eco Sustainability of In-fligh Meals

Swedish airline Malmö Aviation recently introduced a new catering container on its flights aimed at significantly reducing the problem of disposing of waste from their on-board catering service.

It was the airline caterer Picknick served by Omikron, packaging manufacturer, who was searching for a new sustainable solution.

The Swedish manufacturer Iggesund Paperboard supported them with suitable material for the purpose. Iggesund, specialized in coated paperboard for the premium packaging market, is a long-standing partner of Novamont.

In addition to the box, which is made from a virgin fiber-based paperboard called Invercote, the solution also includes a serving tray suitable for fresh food, made of Invercote Bio, extrusion coated with Mater-Bi®, Novamont's biodegradable and compostable bioplastic (according to EN 13432).

Produced in a modified atmosphere to ensure the food remains fresh, the serving tray — thanks to the use of Mater-Bi® — can be disposed of together with food scraps and sent to composting and anaerobic digestion plants, which transform wet waste into compost and biogas

"Using this combination of paperboard and bioplastic, both of which certified compostable to European standards, means the new box is perfect for today's recycling systems and also for future systems," said Jonas Adler, commercial manager of Invercote Bio products at Iggesund.

"This solution not only saves space but also helps protect the environment," added Malin Olin, Inflight and Lounge Manager at Malmo Aviation.

Mater-Bi® — the range of biodegradable and compostable bioplastics produced by Novamont — is rapidly becoming one of the reference materials for food packaging and catering thanks to its biodegradability and compostability. These are features that bring a highly added value when dealing with products contaminated by food scraps that would otherwise be difficult and uneconomical to recycle.

"Increasingly organizations and individuals are thinking about the 'end-of-life' issue of many products in everyday use, and therefore the creation and disposal of waste. We believe bioplastics can provide part of the solution to certain aspects of this issue as they can be composted together with organic waste," said Catia Bastioli, CEO of Novamont.