Bioinspired Approach to 3D Print Recyclable Materials: ETH Zürich

Fused deposition modeling (FDM), often simply referred to as 3D Printing, has been hailed as the future of manufacturing. However, the bad mechanical performance of parts produced by FDM compared to conventionally manufactured objects has limited its use to prototyping. Therefore, despite its promise of mass customization, FDM 3D Printing has not been adopted by industry for production. 

Commercial 3D Printing of Complex Parts

Researchers at ETH Zürich have developed a bioinspired approach to 3D print recyclable materials using cheap desktop printers that outperform state-of-the-art printed polymers and rival the highest performance lightweight materials. This will finally enable the manufacturing of complex parts that mimic natural structural designs on the mass market. 3D Printing, particularly FDM, makes it possible to produce unique complex parts quickly and at a low cost by sequentially depositing beads of a molten polymer. However, the available polymers are relatively weak and the printed parts show poor adhesion between the printed lines. Because of these limitations FDM has not yet been successfully implemented in commercial products. Traditionally, people increased the performance of polymers by including strong and stiff fibers such as glass or carbon fibers into the material. Although the resulting materials exhibit very high strength and stiffness, the energy- and labor-intensive fabrication process as well as the difficulty to recycle state-of-the-art composites represent major challenges today.

3D Printing with Single Recyclable Material

• To combine the mechanical properties of fiber-reinforced composites with the freedom in design that comes with 3D printing, methods have been developed to include carbon fibers into the printed objects. 
• However, this approach requires expensive specialized equipment, and still is restricted with the possible geometries with materials that cannot be recycled. 
• For the first time, researchers from the Complex Materials group and the Soft Materials group at ETH, were able to print objects from a single recyclable material with mechanical properties that surpass all other available printable polymers and can compete even with fiber-reinforced composites.

Inspiration by Nature

The researchers were inspired by two materials that can be found in Nature – spider silk and wood – during the development of these structures. Spider silk gets its unrivalled mechanical properties from the high degree of molecular alignment of the silk proteins along the fiber directions. 

• First, it was possible to reproduce this high alignment during the extrusion from an FDM nozzle by using a liquid crystal polymer (LCP) as an FDM feedstock material, resulting in unprecedented mechanical properties in the deposition direction. 
• Second, the anisotropic fiber properties were utilized by tailoring the local orientation of the print path according to the specific loading conditions imposed by the environment. This design principle is inspired by the ability of living tissue like wood to arrange fibers along the stress lines developed throughout the loaded structure as it grows and adapts to its environment.

Recyclable 3D Printed LCP Structures

• The recyclable 3D printed LCP structures are much stronger than the state-of-the-art 3D printed polymers and do not require the labor- and energy-intensive steps involved in current composite manufacturing technologies. 
• Thus, the technology is expected to be a game-changer in several structural, biomedical and energy-harvesting applications where high-performance lightweight materials are required. 
• Additionally, because the research has been conducted using a readily available polymer and a commercial desktop printer, it should be easy for the broader additive manufacturing and open source communities to adopt this new material and digitally design and fabricate strong and complex lightweight objects from LCPs.

Source: ETH Zürich

Covestro’s Bio-based Raw Materials for Rigid PU Foam Reduce CO2 Emissions

In industrial and commercial construction, in public facilities and logistics buildings, energy efficiency, sustainability and compliance with climate protection targets will become increasingly important alongside cost-effectiveness. These and other challenges are the topic of this year's industrieBAU (Industrial Construction) Day on trends and future topics in industrial construction, which the industrieBAU magazine is organizing on September 27 at the Kasino Hotel in Chempark Leverkusen.

Reducing Energy Consumption and CO₂ Emissions

Rigid polyurethane (PU) foam is a very high-performance insulating material and is ideal for reducing energy consumption and CO₂ emissions in buildings as well as conserving fossil resources. In German industrial and commercial buildings made of sandwich panels, the insulating material now has a market share of around 80 percent. Covestro is supporting the event with a lecture and as a platinum sponsor and is inviting the participants to visit its technical center for polyurethane building products.
Sustainable insulating material for industrial and commercial buildings Sandwich panels consist of two metallic cover layers and a core of PU or even more fire-resistant polyisocyanurate (PIR) hard foam. "They have been used for many years for large-area and efficient thermal insulation of industrial and commercial buildings and facilitate fast, modular and cost-effective construction of buildings," says Stefanie Rau, marketing manager for the construction industry in the Europe, Middle East and Africa region.
Rigid PU foam is also used in insulation boards. They have flexible covering layers and are used to insulate pitched and flat roofs and floors as well as internal and external walls. "In flat roof applications, they are gaining increasing market share, which is due to their high compressive strength, water resistance and the associated low maintenance costs," explains Stefanie Rau. Both products are manufactured in a continuous process on double-belt lines.

Covestro – A Pioneer in Alternative Raw Materials

For even more sustainable thermal insulation of buildings, Covestro now additionally uses alternative raw materials for its production, also to reduce its own dependence on fossil resources. The company is currently working intensively on a CO₂-based raw material for rigid PU foam.

In addition, Covestro and its partners have developed a unique method for obtaining the key chemical product aniline from biobased raw materials. MDI could in future be produced from this bioaniline – another important raw material for rigid PU foam.

Modern Technical Center

A few years ago, Covestro set up a modern technical center for the industrial production of polyurethane foams in order to better support it in aligning its production to current market requirements. Among other things, the plant includes continuously operating systems for the production of insulation boards and sandwich panel elements, which are used for large-area insulation solutions in industrial construction. The goal is to further improve the insulating effect and fire resistance of these products in line with customer requirements and market trends.

Digitalization for Greater Efficiency

Digitalization opens up many opportunities for the construction industry and the associated value chain to increase productivity, make processes more efficient and support sustainability. Covestro pursues a comprehensive strategic program based on three dimensions – digital business processes, digital customer experience and new digital business models.
The implementation of the program begins for Covestro with more efficient operation of its own production and ranges from a comprehensive digital approach of business customers to the development of an innovative chemical trading platform, which is currently being tested. With the new business models, "digital technical services" are particularly important to make customer production even more efficient.
Source: Covestro

 

Researchers Identify Latex Proteins to Enhance Natural Rubber Production

The Yokohama Rubber Co., Ltd., has announced that the results of joint research projects conducted since 2013 with two universities in Thailand, a major producer of natural rubber, were recently presented at The International Polymer Conference of Thailand 2018 (PCT-8). 

The joint research projects were conducted with researchers at Mahidol University and Prince of Songkla University. The research with Mahidol University succeeded in analyzing proteins contained in sap (latex), the base raw material for natural rubber, and identifying the proteins deeply involved in natural rubber biosynthesis. The research deepens the understanding of the biosynthesis of natural rubber, making it possible to accelerate research related to quality and production.

Evaluating Physical and Chemical Properties of Rubber

The research conducted at Mahidol University entailed the extraction and nano-level analysis of proteins from fresh latex and seedlings from Para rubber trees. The analysis covered more than 800 kinds of proteins contained in latex, some of which were found to be related to natural rubber biosynthesis and stress resistance. In addition, by comparing proteins from different varieties of Para rubber trees, the researchers were able to identify the proteins that promote biosynthesis and the proteins that inhibit biosynthesis. The proteins are expected to be used as biomarkers of biosynthesis.
The research at Prince of Songkla University was fundamental research on natural rubber that focused on analyzing the differences in latex related to different seasons and regions, different varieties and different processing methods. The research also evaluated the presence or absence of changes in the physical and chemical properties of rubber over long periods of time. To date, natural rubber has been a very stable material, from its composition to its physical properties, and it has been highly resistant to external factors. 

Enhancing Maintenance and Development of Natural Rubber Plantations:

Natural rubber is a raw material made from latex taken from Para rubber trees. It is one of the main raw materials used in automotive tires, accounting for about 30% of tires made. However, natural rubber’s production is concentrated in Southeast Asia, which exposes large-scale production to risks from abnormal weather and disease. Expecting tire demand to expand in the future, Yokohama Rubber regards the improvement of the quality of natural rubber and the promotion of technological development contributing to stable production as an important corporate duty. Accordingly, the Company plans to use the results of this research to promote the maintenance and development of natural rubber plantations.

The Yokohama Rubber Group has positioned “Promotion of CSR activities throughout the value chain” as one of the important issues of the Group’s corporate social responsibility (CSR) activities. Accordingly, in addition to the above joint research projects on natural rubber, the Group is engaged in activities that will contribute to sustaining farmlands. These activities have included biodiversity surveys on natural rubber plantations and promoting widespread use of an “agroforestry farming method” that contributes to more stable income for rubber tree growers by planting bamboo, fruit trees and other plants in natural rubber forests.

Source: Yokohama Rubber Co

 

Indorama Ventures and Loop Industries launch a JV to manufacture and commercialize sustainable Polyester Resin

Indorama Ventures Public Company Limited, one of the world’s leading petrochemical companies, and Loop Industries, Inc., a leading technology innovator in sustainable plastic resin and polyester has launched a 50/50 joint venture company to manufacture and commercialize sustainable polyester resin to meet the growing global demand from beverage and consumer packaged goods companies.
The world-class manufacturing footprint of Indorama and proprietary science and technology of Loop will form a world leader in the ‘circular’ economy for 100% sustainable and recycled PET resin and polyester fiber. The JV will use an exclusive worldwide license for Loop’s technology to produce 100% sustainably produced PET resin and polyester fiber.

Aloke Lohia, Group CEO of Indorama Ventures, said, “At Indorama Ventures, we continue to pursue the right opportunities to fill gaps that are intrinsic to our sustainable and profitable business by deploying resources in order to support the circular economy. This joint venture with Loop Industries emphasizes our belief in recycling and is aimed at investing in new technologies that can steer further our aspiration of being a world-class chemical company making great products for society.”

Daniel Solomita, Founder and CEO of Loop Industries, commented, “We are excited to launch this partnership with Indorama Ventures, who provide a global leadership platform in petrochemical manufacturing and a shared commitment to sustainability. This joint venture combines each of our companies’ area of expertise so that we may both play a leading role in the global shift by business and consumers to the circular economy. This is a first strategic step in our global commercialization plan and mission to accelerate the world’s shift toward sustainable plastic and away from the traditional, take, make and dispose economy.”

OCSiAl’s Graphene Nanotubes Replace Ammonium Salts & Carbon Black in PU System

Graphene nanotubes have demonstrated their ability to impart permanent and homogeneous anti-static properties to polyurethane (PU) materials, overcoming previous difficulties with nanotube dispersion in PU systems. The recently developed nanotube-based concentrate TUBALL MATRIX 202 has already built up a solid track record in applications such as industrial rollers and castors, PU shoes, printing rollers and cleaning pigs. 

TUBALL MATRIX 202 - Concentrate of High-quality TUBALL™ SW CNTs

OCSiAl’s TUBALL graphene nanotubes are rapidly gaining ground in customer-oriented applications with high-performance requirements. One remarkable example is PU discs in cleaning pigs for industrial pipelines. To avoid explosions and fires while also preventing static noise and improving diagnostic accuracy, manufacturers of cleaning pigs are replacing ammonium salts as an anti-static agent with TUBALL MATRIX 202. In addition to a permanent and stable resistivity level of 10^7–10^5 Ω·cm, the preliminary results have shown a 30% reduction in the rate of equipment failure. 

Applications of TUBALL MATRIX 202

• Another specific application of TUBALL MATRIX 202 is anti-static shoes, where the PU elastomer material used in the outsole and midsole allows the shoes to be used in various static-sensitive facilities in the chemistry, oil and gas, electronics and mining industries. 
• These nanotubes have also been well received by industrial roller manufacturers, as PU printing rollers can now be produced with a permanent volume resistivity level of 10^8–10^6 Ω·cm without dust formation at the facility and while preserving the essential mechanical performance characteristics such as abrasion resistance and hardness. 
• TUBALL MATRIX 202 is also gaining ground in rollers and castors used in the mining industry, where anti-static properties are critical for safety reasons. 

According to data supplied by one of OCSiAl’s customers, graphene nanotubes preserve or even improve mechanical properties of the system, whereas previously the 6.5 wt.% of carbon black that had been used for anti-static purposes led to a nearly two-fold reduction in tear strength. 

The TUBALL MATRIX 202 concentrate carrier is a plasticizer based on fatty carboxylic acid ester derivatives. 

To obtain a resistivity level of 10^9–10^5 Ω·cm, the working dosage range of graphene nanotubes is 100 times less than the working dosage of ammonium salts, 500 times less than that of carbon black, and 1000 times less than that of conductive mica.

In comparison with ammonium salts, graphene nanotubes enable a wider range of resistivity levels that are totally independent of humidity and temperature conditions, and these nanotubes’ superiority over carbon black is rooted in their easy dispersion and the preserved mechanical properties of the system. 

Source: OCSiAl

OCSiAl’s Graphene Nanotubes Enhance Polymers at Very Low Dosages

TUBALL graphene nanotubes, also known as single wall carbon nanotubes, are extremely thin single-layer rolled-up sheets of graphene more than 5 µm in length and with a diameter of 1.6 nm. They have a number of exceptional characteristics, such as superior electrical conductivity and strength, high temperature resistance and flexibility, and they translate these properties by enhancing the characteristics of polymers at very low working dosages.

With its unique facility for industrial-scale production of low-cost graphene nanotubes, OCSiAl has transformed these nanotubes from being an interesting laboratory material into a highly competitive industrial technology. Together with its partners, the company has achieved a number of exciting results in applying graphene nanotubes in key thermoplastic compounds, such as polyethylene, ABS plastics, PVC plastisols, polyamide and polycarbonate.

Among the products containing TUBALL nanotubes that have already been successfully launched on the market, there are semiconductive compounds destined for medium- and high-voltage power cables with a volume resistivity below 20 Ω·cm at 23°C and below 100 Ω·cm at 90°C. Graphene nanotubes are also being applied in ABS plastics produced by injection molding, resulting in a surface resistivity below 10^8 Ω/sq while maintaining high impact resistance.

Source: OCSiAl

Korea sets out to seize lead in hydrogen energy

After a decade of dragging its feet, the South Korean government has come up with a set of measures to nurture an ecosystem for hydrogen vehicles, seeking a transition from fossil fuels to zero emission energy.For more than a decade, the state drive for a hydrogen economy has been sidelined, due to policy inconsistencies through different administrations and a global preference for batteries over fuel cells.

Amid problems of energy intermittency being addressed over renewables, however, interest in the potential role of hydrogen in South Korea’s de-carbonization has grown. 

In June, the Ministry of Industry, Trade and Energy announced a 2.6 trillion won plan to supply 16,000 hydrogen-powered vehicles and build 310 hydrogen refilling stations across the country. Under the five-year plan, businesses are expected to get state support for the development of fuel cell stacks and fuel cell storage containers, as well as tax breaks for hydrogen vehicle drivers. 

The announcement is a follow-up to a pan-industrial alliance launched in April. The ministry signed a memorandum of understanding with local automakers, state-run utilities companies and related organizations to establish a special purpose company to build hydrogen fueling stations in major cities and on highways.

Park Jong-won, of the automobiles and aviation department of the Ministry of Industry, sees hydrogen and battery-powered vehicles (EVs) as complementary, not rivals.

Although there are only 170 hydrogen powered vehicles currently registered here, he expects that to reach 15,000 by 2022 –the same order of magnitude as the current number of EVs.For EVs, which now have a head-start on hydrogen, the ministry also expects the number registered in South Korea to grow, from 25,500 to 350,000 over the same period. 

“The technology of electric vehicles has become widely available now, but that of hydrogen cars are still in an infant stage and there should be more basic infrastructure like refilling stations (to buttress its growth),” he said. 

Both hydrogen and battery-powered vehicles are electrically driven and have no carbon emissions -- qualities sought after by most advanced economies to minimize the use of gas or diesel in order to curb pollutants. Hybrids and plug in hybrids are also considered eco-friendly, using electric power to reduce the emissions from their regular diesel or gasoline engines.

The difference between hydrogen cars and EVs is that the latter are charged with electricity externally, while hydrogen powered cars generate energy by converting the chemical energy of hydrogen by reacting hydrogen with oxygen in a fuel cell. Aside from the difference in where the electricity comes from, the charging time for hydrogen vehicles is shorter than that of EVs, while a single charge gives a longer driving distance.

There are only a handful of commercial hydrogen vehicles in the market that include the world’s first Hyundai Tucson ix35 FCEV along with the Toyota Mirai and the Honda Clarity. Hyundai has also recently unveiled the newest flagship Nexo this year.

“Currently, South Korea is one of the leading countries in fuel cell electric vehicle (FCEV) technology which is yet taking a small portion both in domestic and global market,” said Ryan Lee, principal analyst at IHS Markit. 

“However, the investment will accelerate popularizing FCEVs with more realistic numbers of charging infrastructure (only 11 FC charging stations in Korea currently) and sufficient subsidy support,” he said.

But the South Korean government’s focus appears to be limited to auto industry and is far from comprehensive, experts say

In a hydrogen economy, vehicles would play a crucial part. But more comprehensive work has to be carried out -- such as building nationwide networks of energy supply and storage system, which cost a lot of money and require a high level of technology.

Japan has also been active in hydrogen. 

By 2020, the year the country hosts the Tokyo Olympics, Japan plans to increase the number of hydrogen-powered vehicles by 40,000 units and 800,000 units by 2030. Under its 2014 road map toward a hydrogen economy, not only carmakers that have already succeeded in commercial production of fuel-cell electric vehicles, but also other traditional industrial players -- energy firms, steelmakers and shipbuilders -- have formed an alliance to switch to hydrogen energy.

Japan has currently 97 hydrogen filling stations across the country. The number is set to grow to 160 by 2020 and 900 by 2030. Under its grand plan, Japan will build massive electrolysis plants in Australia and the Middle East, and transport them back to Japan on vessels designed to store and carry hydrogen.

Germany has also set a long-term project in 2007 to take the lead in fuel cell technology, while participating in a joint project by EU-member countries aimed at testing efficiencies of hydrogen-powered vehicles and pushing for the commercialization of the green cars. By 2023, Germany plans to operate 650,000 fuel cell electric vehicles and 1.8 million by 2030.

South Korea had also set a master plan in 2005 aimed at increasing the portion of hydrogen-based energy to 15 percent.

Since the late 90s, the government has supported R&D projects initiated by the local carmaker Hyundai to develop hydrogen-powered cars. President Roh Moo-hyun was an ardent hydrogen supporter, according to sources, citing an exchange between him and Hyundai Motor Chairman Chung Mong-koo when the former was in power. Roh reportedly had told the corporate mogul that he would “fully support” the carmaker’s hydrogen project, after taking a ride on a fuel cell vehicle prototype back then.

The power transfer from the liberal to the conservative government led by former President Lee Myung-bak in 2007, however, brought a dark age for hydrogen projects, an industry insider who declined to be named. Instead, Lee promoted the nation’s strength in nuclear energy, curbing the state drive toward hydrogen. Lee himself played a crucial part in signing $40 billion nuclear deal with UAE.

Also, the political shift in US from the Bush administration to Obama was a setback for Korea’s hydrogen drive, said Cho Sang-min, head of new energy development team at Korea Energy Economics Institute.

“President Bush paid keen interest in hydrogen energy, but Obama didn’t. After he took office, the market interest in hydrogen also simmered down, deeply affecting policymakers in South Korea,” he said.

As the government turned a cold shoulder to hydrogen power, projects at small and medium-sized companies died, but some projects pushed by wealthy conglomerates survived. 

To take a lead in the uncharted market of hydrogen vehicles, Hyundai spent more than 20 years and succeeded in developing the world’s first fuel cell electric car, the Tucson ix35. Posco and Doosan both invested in fuel-cell production, but reports say that Posco's energy arm is considering shutting down its fuel-cell business. 

Along with inconsistent government policies, the absence of hydrogen-related law, safety concerns and lack of public awareness add to uncertainty over whether the hydrogen business can turn profitable, experts noted.

And there is another fundamental issue that needs addressing: Where will the hydrogen come from?

Even though local petrochemical plants produce a considerable amount of hydrogen, it is mostly used as a desulfurizing agent to generate high-value added petroleum products, and none of them has plans to supply them as a new energy source. Gas companies are reportedly reviewing the economic feasibility of investing in hydrogen production, but they are still reluctant.“It is difficult for Korean companies to invest in a sector that has no infrastructure to begin with. The government needs to ensure them that it is a new market to be created,” an industry insider declined to be named.

Despite the 2.6 trillion won plan, the government feels pressure to go on with hydrogen due to its complexity.

“Energy transition from fossil fuels to hydrogen is more complex, more than many would think,” Ahn Kook-young, chairman of the Korean Hydrogen and New Energy Society, stressing that the transition is equivalent of the introduction of the internal combustion engine in the 19th century’s.

“Building hydrogen infrastructure will take years of effort, money and political consideration,” he said. It cost around 3 billion won to build a hydrogen refilling station, compared to 200 million won for a gasoline station, he added.

Still, South Korea keeping its hydrogen dream has a point.

“The world of hydrogen is still unknown, but we are standing on the path toward the hydrogen economy,” said Shin Jae-haeng, the head of H2Korea, a think tank under the Ministry of Energy.“The government is determined to complete its goal on climate change to comply with the global consensus on reducing emission.”

The Moon Jae-in administration’s nuclear phase-out policy in October was widely expected to include some support for hydrogen power. But last year, hydrogen was not mentioned when President Moon vowed to slowly end nuclear power.For businesses, particularly conventional ones facing pressures to cut down CO2 emissions, a transition to a hydrogen economy could secure their survival.

“To keep its hegemony in the market, carmakers will continue to develop (hydrogen technology). So too, the government, (will push the drive) to keep jobs (in the traditional industries),” said Im Eun-young, an analyst at Samsung Securities and Investment.

Source:Korean Herald