Kisuma Chemicals enables fluorine-free alternatives for rubbers amid PFAS regulations

Kisuma Chemicals, a global manufacturer of magnesium-based additives, has presented new test data showing that its hydrotalcite-like DHT™-4 additive can significantly enhance the heat, fluid and ageing resistance of chloroprene (CR) and epichlorohydrin (ECO) rubbers.

In addition to acting as an efficient acid scavenger and improving both the mechanical and the chemical resistance of rubber compounds, this offers manufacturers a compelling alternative to partially replace fluorine rubbers (FKM) in light of upcoming regulations expected to ban the use of per- and polyfluoroalkyl substances (PFAS).

Target markets for PFAS-free rubber additives

DHT™-4 is especially targeted at European and North American rubber compounders, OEMs, tier suppliers, gasket, sealing and hose manufacturers in market sectors such as automotive, industry, fluid handling, who are impacted by REACH and other regulatory initiatives addressing particularly the production and use of PFAS.

 

As a tested and proven PFAS-free additive, it enables formulators and sustainability-driven material specifiers to reduce or eliminate the use of fluorinated elastomers like FKM, thus reducing the reliance on materials flagged as hazardous to human health and the environment.

 

With DHT™-4, Kisuma is positioning itself as a forerunner in supporting PFAS-free rubber formulations that also contribute to the United Nation’s Sustainability Development Goals 12 (Responsible Consumption) and 13 (Climate Action) by improving production safety, regulatory compliance and long-term material sustainability.

 

“With DHT™-4™, we are helping compounders and OEMs move towards high-performance, PFAS-free elastomer solutions without compromising quality,” adds Claudia Aguilar Carvalho, technical sales manager Europe for Kisuma. “The dual role of DHT™-4 as a protective and enhancing additive enables different rubber matrices to bridge the performance gap to FKM, providing an efficient future-ready solution for low-PFAS elastomer systems at low dosage levels.”

 

Kisuma’s market specialists will be available during K 2025 in Düsseldorf to discuss the strategic benefits of DHT™ 4 with visitors at the company’s booth H31 in Hall 8B.

 

Image Credits: Kisuma Chemicals/SpecialChem

Today's KNOWLEDGE Share : Project to recover PHAs from municipal wastewater

Today's KNOWLEDGE Share

Project to recover PHAs from municipal wastewater

Sewage treatment plants do more than just clean wastewater. They are also sources of raw materials. In the KoalAplan project, researchers from the Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB are working with partners to recover high-quality products from municipal wastewater. These include ammonium, hydrogen and polyhydroxyalkanoates (PHAs), which can be used to produce bio-based and biodegradable plastics.

Our wastewater carries more than just dirt and excretions. It also contains valuable raw materials, such as nitrogen and organic carbon compounds. Chemical, biological and physical methods can be used to recover hydrogen, ammonium and polyhydroxyalkanoates (PHAs) from it. The recovered ammonium can be used as a nitrogen fertilizer for farming, and PHAs are the raw material for bioplastics. These processes are the subject of inquiry for the researchers working on the KoalAplan project (see below). The project partners’ interdisciplinary research work is taking place at the wastewater treatment research facility operated by the University of Stuttgart in Büsnau. Working under real-world conditions, the partners are testing how raw materials can be reclaimed from sewage treatment plants. To this end, a biorefinery has been set up as a pilot plant. It operated for more than six months in 2024.

Getting around biological nitrogen removal:

One of the methods established in the project, the primary stream method, involves wastewater treatment following prior solid separation during primary clarification. In a traditional sewage treatment plant, the nitrogen in the wastewater is removed biologically. Microorganisms convert the nitrogen compounds into gaseous nitrogen (green house gases), which escapes unused into the atmosphere. In the KoalAplan project, by contrast, the nitrogen is not lost. Instead, it is recovered as a raw material by physically removing ammonium using a zeolite filter or ion exchange system. After that, the nitrogen is recovered by regenerating the zeolite filter, producing a concentrated ammonium solution that can be used in agriculture as a nitrogen fertilizer.

Recovery of organic carbon from solids found in wastewater:

In a traditional municipal sewage treatment plant, a large portion of the solids present in the wastewater is separated through sedimentation during the primary clarification. This “primary sludge” is fermented in a digestion tower, producing methane. In the biorefinery concept, it undergoes dark fermentation instead, with the degradation process being halted at the stage involving production of short-chain organic acids. After two-stage solid separation, a particle-free hydrolysate is produced. This hydrolysate is rich in short-chain organic acids and can be used for a variety of purposes. KoalAplan project explores these pontentials, for eg. microbial electrolysis for production of hydrogen and microbial production of PHAs. “Our job at Fraunhofer IGB was to use fermentation to convert the hydrolysate into PHA, a biodegradable, thermoplastic bacterial biopolymer,” explains Pravesh Tamang, senior scientist for PHAs and a researcher at Fraunhofer IGB.

Acidic hydrolysate converted to PHAs

The PHAs are generally produced using microorganisms, which can grow on a wide range of different substrates. The microorganisms use the hydrolysate, which is rich in organic acids such as acetic, propionic and butyric acid, as a source of carbon and energy. “The bacteria need the organic acids to grow and produce the PHAs,” Tamang explains. Where is the problem? If these organic acids are present in too high a concentration, they have toxic effects on the microorganisms. This meant that the first step for Tamang and his team was to identify suitable strains of bacteria that can use the acids both for their own growth and to produce PHAs. “Compared to the other bacteria we tested, Cupriavidus necator proved to be the more tolerant bacterium in contact with the organic acids,” Tamang says.

To prevent the acids from impeding the microorganisms’ growth, the researchers also developed a perfusion method with cell retention in the bioreactor. Cell retention takes place using a special filter that ensures that the cells or microorganisms remain in the reactor, enabling high cell density and a longer culture time. Tamang explains the process: “We pass the fermentation broth from the bioreactor through a cross-flow filter and then feed the cells with the PHA granules that are retained in the filter back into the reactor. This cell retention allowed us to feed in variable acid concentrations. The biopolymer is extracted from the bacterial cells at the end of the fermentation.

A sought-after PHA copolymer for a range of applications

The researchers at Fraunhofer IGB were able to use their perfusion method to prevent the bacterial growth from being inhibited. They showed that 97 percent of the carbon from the organic acids was utilized by the microorganisms and converted into biomass and PHAs. “Our PHA product is a specially adjusted poly(3-hydroxybutyrate-co-3-hydroxyvalerate), or PHBV, copolymer. Compared to a homopolymer, it has improved mechanical properties. This is because it contains about ten percent 3-hydroxyvalerate, which reduces crystallinity and makes the material more flexible, easier to shape and more versatile,” Tamang explains.

As their next step, Tamang and his team plan to optimize the fermentation process to produce PHBV with an even higher 3‑hydroxyvalerate concentration (40 to 70 percent). These specially adjusted PHBV copolymers can then be used by polymer chemists and application experts from industry as samples for testing the biopolymer’s material properties and discovering new potential fields of application. The ecofriendly raw material that is produced by this process can be used in a variety of ways — as single-use packaging, mulching film in agriculture, in the pharmaceutical industry, or even for medical implants or bio-based textile coatings.

Recovery of raw materials contributes to climate neutrality

Typically, carbon dioxide is produced when organic carbon is removed through a sewage treatment plant. The method developed as part of the project reduces emissions of this global warming gas. “At the same time, we also produce raw materials that help replacing petroleum-based products. In this way, the sewage treatment plants of the future can make an important contribution to climate neutrality,” Tamang explains.

 

The KoalAplan project

Municipal wastewater as a source of ammoniacal nitrogen, hydrogen and bioplastic — the Büsnau biorefinery

Project partners:

• German Technical and Scientific Association for Gas and Water (Deutscher Verein des Gas- und Wasserfaches, DVGW) research center at the Engler-Bunte-Institut of the Karlsruhe Institute of Technology (KIT) (coordination, production of the acidic, particle-free hydrolysate, production of hydrogen by means of microbial electrolysis)

• Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB (PHA production)

• CUTEC Clausthal Research Center for Environmental Technologies at Clausthal University of Technology, Wastewater Process Engineering department (scientific support and carbon footprint)

• Hamburg University of Technology (TUHH), Institute of Technical Microbiology (production of hydrogen by means of microbial electrolysis)

• Umwelttechnik BW GmbH, state agency for environmental technology and resource efficiency in Baden-Württemberg (public relations and utilization of results)

• University of Stuttgart, Institute for Sanitary Engineering, Water Quality and Solid Waste Management — teaching and research sewage treatment plant (ammonium recovery)

Project funded by:

• Ministry for the Environment, Climate and Energy Sector of Baden-Württemberg

• Co-funded by the European Union

source : Fraunhofer Institute 

US Polycarbonate Manufacturing Gets Major Boost

In a boost for the North American plastics industry, AmeriLux International and Brett Martin have announced the formation of American Polycarbonate Co. (APC), a joint venture that will establish domestic manufacturing of polycarbonate sheets in Wisconsin.

The new operation will be housed within AmeriLux's recently constructed 500,000-square-foot manufacturing and distribution center in De Pere, WI, with production scheduled to begin in early 2026. The venture combines AmeriLux's distribution and fabrication capabilities with County Antrim, UK–based Brett Martin's six decades of thermoplastic sheet extrusion expertise.

Industry analysts note this partnership addresses growing market demand for reduced lead times and enhanced supply chain resilience for US customers, particularly following recent global logistics disruptions.

"This joint venture marks our commitment to long-term engagement in the US market and a recognition that dedicated local manufacturing and services provide the optimum package for American customers," said Paul Martin, group director of Brett Martin Ltd. "By uniting our technical extrusion expertise with AmeriLux's customer-centric distribution model, we're creating a platform that delivers innovative, high-quality products while upholding shared values.

Growth potential drives project:

Martin told the BBC the US factory had been in the works well before the latest round of tariffs announced by President Donald Trump.

"While tariffs are relevant for any exporter, our motivation was above all driven by long-term market growth potential, the strength of our partnership with Amerilux, and the opportunities we see in North America," he told the BBC.

The partnership brings together two family-founded businesses with complementary strengths. AmeriLux, established in 2004, has built its reputation as a value-adding distributor and fabricator of plastic sheets with logistics capabilities. Brett Martin, founded in 1958 in the UK, has grown into a global leader in thermoplastic manufacturing with particular expertise in polycarbonate extrusion technology.

Kurt Voss, CEO of the AmeriLux Family of Companies, emphasized the strategic importance of the venture.

"This joint venture enhances our ability to supply polycarbonate sheets produced in the United States while reinforcing our commitment to building lasting relationships with customers, employees, and the community.

Focus on polycarbonate sheets:

Initial production will focus on multiwall and corrugated polycarbonate sheets in various gauges and technical specifications. The companies plan to incorporate advanced features such as high-performance glazing for safety and energy efficiency, targeting applications in construction, data processing, agriculture, horticulture, and architecture.

The partners have indicated plans for future expansion beyond the initial product lineup, including R&D collaborations on new product lines to address evolving market needs.

This development represents one of the most significant investments in domestic polycarbonate manufacturing capacity in recent years, potentially reshaping supply dynamics in the North American market. By localizing production, APC aims to offer expedited material delivery, customized solutions, and responsive service backed by the partners' combined eight decades of plastics industry experience.

source : Plastics Today

The Wind2Water catamaran, upcycled from end-of-life wind blades

Akvotransiro Tech, an Indian startup based in Guwahati, has manufactured and tested a four-person catamaran built from discarded wind turbine blades using a technology named “Wind2Water”, for which a patent is being considered. Extensively tested on Deepor Beel, near Guwahati, the prototype has proven stable, maneuverable and robust. Akvotransiro says that these types of vessels, which will be safe and affordable, are intended for developing countries as well as for environmentally conscious buyers.

With over 43 million metric tonnes of blade waste expected globally by 2050, and India alone projected to generate 25,000–30,000 tonnes annually by 2030, the company’s Wind2Water technology re-employs end-of-life blades into modular hulls, pontoons and docks. The approach has several advantages: it enables to manufacture affordable, low-maintenance vessels for inland and coastal transport, but also reduces landfill disposal costs for wind firms and minimises waste, therefore positioning India as a leader in blade up-cycling.

We all know that managing wind turbine blade waste is a challenge to the renewable energy sector. More than 341,000 operational turbines worldwide will eventually contribute to an estimated 43 million metric tonnes of composite blade waste by 2050, according to research from Cambridge University. India, which has installed 43.7 GW of wind capacity and is targeting 170 GW by 2025, is projected to generate 25,000– 30,000 metric tonnes of discarded blades annually by 2030. To be noted that the blades are built from non-recyclable fibreglass and carbon fibre and each one weighs 10–25 tonnes.

The hulls of Akvotransiro’s vessel are repurposed from the tip section of a wind blade, while the frames and the deck are from Bamboo composites. “Every wind turbine blade is an environmental disposal headache in the waiting,” said Ravi Jyoti Deka, founder of Akvotransiro. “We have shown they can be re-engineered into reliable working boats that not only address waste but also provide the water transport solutions that developing countries urgently need. This is not a concept note, it’s a working vessel ready to scale.

Founded in 2020 and supported by the Technology Innovation Hub at IIT Guwahati, Akvotransiro is India’s first startup dedicated to green, affordable water transport solutions. The company pioneered BamBateau bamboo-composite boats, creating unsinkable flood-rescue craft, lightweight fishing canoes and an 18-passenger river trimaran. Its bamboo-composite process remains one of the world’s only proven, production-ready sustainable boatbuilding technologies. Wind2Water extends this legacy, demonstrating how end-of-life blades can be transformed into modular hulls, floating docks and pontoons. The Wind2Water proposal was a finalist in the EU’s Horizon 2020 EIC programme, but could not advance due to country restrictions. Now, with full-scale trials in India, the concept has moved decisively from theory to practice.

The working life of discarded blades extended by 10–15 years:

Akvotransiro is developing 24–36m multipurpose catamarans (up to 25 tons displacement) for inland and coastal transport, but also 10–12m catamarans, pontoon boats and trimarans built from blade sections, as well as low-carbon floating docks and jetties derived from turbine blade stems. The customers expected are wind energy companies, currently paying up to €18,000 per 10MT blade for co-processing in cement plants, or €5,000 for landfill disposal, but also inland water transport operators in developing nations, where blade-derived hulls can be built at one-third to one-quarter the cost of conventional vessels and shipped worldwide for on-site assembly.

The Wind2Water project extends the working life of discarded blades by 10–15 years, without energy-intensive recycling. With this milestone, Akvotransiro is seeking global partners across the wind energy sector to advance to the next stage: building a full-scale 12-38 meter multi-purpose catamarans and scaling the Wind2Water technology internationally.

source: Akvotransiro/ JEC Composites

Today's KNOWLEDGE Share : Scientists Develop Plant-Based Plastic That Is Self-Repairing and Antimicrobial

Today's KNOWLEDGE Share

Researchers develop self-repairing and anti-microbial plant-based polymer

From medicine to electronics and optics, new materials developed by scientists at Kaunas University of Technology (KTU) can be applied in various fields where cleanliness, precision, and durability are essential. They stand out not only for their functionality but also for their sustainability: they are made from renewable raw materials, and no solvents are used during production.

The new invention – polymers developed by KTU researchers – belongs to the class of vitrimers, a relatively new type of polymer discovered only about three decades ago and named vitrimers just 15 years ago. This makes it a rapidly growing research field that is attracting increasing attention from scientists worldwide.

Eliminates use of additives making it more environmentally friendly

According to Ostrauskaitė, until now most vitrimers were derived from petroleum resources and required catalysts for processing.

 

“Advanced materials can be not only functional, but also friendly to people and the environment. Such work paves the way for technologies that contribute to a safer and more sustainable everyday life,” says professor Jolita Ostrauskaitė at the KTU Department of Polymer Chemistry and Technology.

 

“The polymers we have developed are unique because they are made from plant-based compounds, cured under UV or visible light, and do not require catalysts for processing. This happens naturally due to the chemical structure of the material itself,” emphasizes the scientist.

 

This is important not only because it simplifies the technological process but also for sustainability – catalysts are often expensive, derived from non-renewable resources, or even toxic. By eliminating them, material consumption is reduced, no additional additives are needed, and the technology becomes simpler, safer, and more environmentally friendly.

 

“Vitrimers are thermosetting polymers that, thanks to dynamic covalent bonds, can be thermally reprocessed or reshaped, similar to thermoplastics. At certain temperatures, they can self-heal after damage and also retain a temporary shape that can later be restored – this is known as thermally responsive shape memory,” explains prof. Ostrauskaitė.

 

These materials were developed and studied by researchers from the Department of Polymer Chemistry and Technology at KTU: KTU PhD student Viltė Šereikaitė, Dr. Aukse Navaruckienė, and Dr. Sigita Grauželienė.

 

Polymers with such properties are considered smart materials, opening new possibilities for advanced high-tech applications.

 

KTU scientist notes that the most significant scientific achievement was combining, in a single material, plant-based origin, radiation-induced polymerization, self-repairing ability, shape memory, antimicrobial effect, and suitability for optical 3D printing.

 

“Such multifunctional and sustainable solutions are still very rare, making this an important step forward both scientifically and industrially,” says KTU researcher.

Suitable for optical 3D printing

One of the most notable achievements by KTU researchers is the polymers’ suitability for optical 3D printing, which can be performed at room temperature, consumes less energy, and generates less waste. When exposed to UV or visible light, these polymers can be printed in complex shapes, such as medical device connectors.

 

“We successfully printed a Y-shaped connector – a typical medical component used to join tubes in infusion or respiratory equipment. This part requires high precision, making it an excellent test of the material we developed,” the professor explains.

 

Optical 3D printing technology also allows the production of other complex components, such as optical lenses or electronics parts, which demand extremely precise dimensions and geometry. Additionally, the material can be shaped into temporary structures that can later be transformed or repaired – invaluable for prototyping and quickly responding to industrial needs.

 

Another important innovation is the polymers’ antimicrobial properties, arising from structural fragments in their composition.

 

“The starting compounds used in the study were obtained from plant oils and by-products of biodiesel production, and certain fragments interfere with bacteria and other microorganisms, disrupting their vital functions. This is why such materials can be used to create surfaces or products that must remain clean and hygienic, for example, in medical devices, electronics, sensors, or other items where microbial control is critical,” explains the KTU scientist.

 

Test results showed that the materials effectively inhibited standard and other common microorganisms.

 

The study was conducted as part of a Lithuanian Research Council-funded project No. S-MIP-23-52, Antimicrobial Shape-Memory Photopolymers from Plant-Based Materials, in collaboration with scientists from the State Scientific Research Institute Nature Research Center, JSC 3D Creative, and partners from the University of Upper Alsace in France and Centria University of Applied Sciences in Finland.

 

source : KTU/Specialchem