Pakkausalan peruskurssi 77, osa II Muovilaadut ja hyötykäyttö

Copyright © 2005 Borealis A/S

Auli Nummila-Pakarinen, Borealis Polymers Oy

Borealis at a Glance • Leading provider of chemical and innovative plastics solutions that create value for society

• More than 50 years of experience

• Unique Borstar® technology to develop polyolefin solutions that are tailored to customers’ needs

• 5,200 employees in over 20 countries • Ownership 64% IPIC / 36% OMV • Joint venture in Middle East and Asia: Borouge

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(Abu Dhabi)

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Borealis Finland Kilpilahti industrial area

Providing Solutions in Polyolefins

Infrastructure

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Mobility

Advanced Packaging

…and Base Chemicals

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phenol & acetone Phenol and Acetone

Feedstocks and Olefins

Melamine

Plant Nutrients

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Examples of polyethylene and polypropylene applications

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Examples of polyethylene and polypropylene applications

Plastics are used because of the properties they offer 1(2) • Easy mouldabitly, highly complicated shapes can be moulded very economically. • Plastics are light. The most important plastics having densities ranging form 900-1000 kg/m3. • Plastics are resistant to corrosion • Plastics are excellent electrical insulators. • Most plastics are also excellent heat insulators.

• Some plastics have excellent optical properties.

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• Many plastics are elastic

Plastics are used because of the properties they offer 2(2) • Easy pigmentation. • Excellent printability. • Heat sealable

• Good organoleptical properties and thus suitable for food stuff packaging. • Most thermoplastics are recyclable.

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• Many plastics are inexpensive.

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From oil to plastics

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Raw Oil Consumption

How are polymers built

Monomer

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Polymer

Groups of polymers and their properties

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Group of Polymer

Structure

Main Properties

Examples

Thermoplastics

Linear to branched molecule PE, PP, PVC, structure, no cross-links PS, PA, PMMA  melting / crystallisation reversible  low melt viscosity  at ambient temperatures soft to rigid, brittle

Elastomers

Slightly cross-linked  at ambient temperatures very elastic, soft

Silicones, PUR, Rubber

Duroplastics (Duromers, Thermosets)

Cross-linked  does not melt, thermal destroyed  at ambient temperatures very rigid

Polyesters, Melamines, Phenol resins

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Plastics vs. temperature

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PE processes

Basic structures of PE – branching (-> density)

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COPOs

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Viscosity

MFR - Melt Flow Rate (ISO 1133)

Thermometer

2.16 kg 5.0 kg 21.6 kg

Unit: [g/10 min] Load Piston Cylinder

PP: MFR

Heating

measured at 230 °C with 2.16 kg

Insulation

PE: MFR measured at 190 °C with different loads 2.16 kg / 5 kg / 21.6 kg e.g. MFR (190/2.16) = 4 g/10 min

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Die

2.09 - 2.10 mm

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Melt strength

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Density (ISO 1183) Unit Unit[g/cm³] [g/cm³]oror[kg/m³] [kg/m³] scale

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sample

_ _ _ _ _ _ _ _ _

Typical densities of various materials [g/cm³] liquid

Plastics reference samples

PE PP PC PA PVC Water Aluminium Steel

0.89 - 2.3 0.9 - 0.965 0.895 - 0.905 1.2 1.0 - 1.15 1.2 - 1.4 1 2.7 7.8

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Polyethylene properties vs. density

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PP processes Gas phase

Types of Polypropylenes

PP – Homopolymers

-P-P-P-P-P-P-P-P-P-P-

High stiffness & heat resistance

PP – Random Copolymers

-P-P-E-P-P-P-E-P-P-P-

Medium stiffness & good heat resistance

PP – Block Copolymers High stiffness & toughness & heat resistance

PP – Random Block Copolymers

-P-P-P-P- + -E-P-E-P-EMatrix

Rubber

-P-E-P-P- + -E-P-E-P-EMatrix

Rubber

High softness & toughness & good heat resistance

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P = Propylene E = Ethylene Comonomer

Comparison PP / PE – Temperature resistance LDPE (0.924)

PE

95°C

HDPE (0.945)

116°C

PP – Random/Impact

118°C

PP - Impact

PP 150°C

PP - Random

124°C

PP - Homo

152°C

PP – Homo nucl.

0

30

157°C

60

90

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Vicat A (°C)

120

150

180

Comparison PP / PE – Resistance to low temperature -40°C

LDPE (0.924)

-40°C

HDPE (0.945)

PE

PP

PP – Random/Impact

-25°C -20°C

PP - Impact -10°C

PP - Random PP - Homo +5°C PP – Homo nucl.

-40

-30

-20

-10

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Temperature of embrittlement (°C)

+7°C

0

10

Optics and Stiffness of PP for Film Applications

Borclear™

Brilliant

Optics / Haze

Transparent

Bormod™

Standard C2/C3Randomocoplymers

Translucent

Borsoft™

Standard Impact-Copolymers Soft

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Standard Homopolymer

Stiff

Softness / Stiffness

Exceptional balance of properties impact strength vs. stiffness for 40µm monofilm 500 g Borshape Dart drop [g/50]

C8-LLD 922mLL Borstar

FB2230

C6LLDPE

927mLL FB4230

FX1001 FB2310

934mLL

C4-LLD

FB4370 LDPE

100 g |

150 MPa Copyright © 2005 Borealis A/S

FX1002

|

| | | Tensile Modulus [MPa]

|

|

450 MPa

Property balance optics - mechanics of PO-blown films with air cooling Transparent

MC-LL

Borclear™

optical properties

Bormod™ Borpact™ LDPE + LLDPE

Borsoft™

PPHomo PPBlockcopo

HDPE

Matt

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Soft/Flexible

mechanical properties

Stiff

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Heat resistance and sterilisation/ pasteurisation capability of different polyolefins

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Extrusion techniques for PE and PP

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PE product map

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Moulding

Injection moulding

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Film

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Extrusion coating

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Multilayer materials

Multilayer structures combine best properties of individual products • Barrier properties (moisture and oxygen) • Stiffness & toughness • Sealing

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• -> Economy

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Borealis pursues the path of ‘Value Creation through Innovation’ ‘Commodity’ path

Feedstock

Olefins

Polyolefins Converters End users

Consumers

Reduce Recycle Recover

‘Value Creation’ path

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Feedstock

Olefins

Polyolefins Converters End users

Consumers

Reduce Recycle Recover

4Rs - Reduce, Reuse, Recover, Recycle Reduce • Overall carbon and water footprint reduction e.g. by material choice, product design and weight reduction

Reuse • Enhance durability and reusability of applications

• Support to reuse

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alternatives from pallet return to reusable bags

Recover • Solid Recovered Fuels • Ensure suitability postconsumer plastic waste in energy recovery options

Recycle • Design solutions allowing recycling and use of recycled material

• Alternative feedstock recycling options

 Addressing the most challenging sustainability targets downgauging.

Down gauging / Light weighting challenge

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Benefit

 Up to 30% downgauging potential.  In downgauging exercises toughness kept or even increased.

BorShapeTM

Composition of waste in Europe textile 2% plastics 8%

metal 4%

glass 7% paper 26%

organic waste 27% misc. waste 25%

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bulky waste 3% Source: Eurostat/OECD

Packaging & product Packaging can avoid product losses, which saves much more resources than the packaging contains.

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Energy to produce 700g of bread 97%

Source: Europen

Environ mental impact of packagi ng 11%

Environ mental impact of packagi ng 11%

Energy to produce plastic packagi ng 3%

Environ mental of 150g ham 89%

Environ mental of coffee 89%

Production of the product dominates the carbon footprint – not the package! Even one slice of ham wasted has bigger impact on CO2 emissions than whole production of the package.

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APET

PP

Source: FUTOPACK EKO2010

Carton

Benefits of recycling & recovery 3 MSWI with average energy efficiency Feedstock Energy recovery with high energy Material recycling recycling (e.g. blast furnace) efficiency (plastic to pl.)

20

0

-20

-40

-60

-80

• Impacts of collection, sorting and recycling processes as well as credits due to substituted primary production and substituted primary fuels are already summed up in the figures above

• Plastic waste is a valuable secondary resource Copyright © 2005 Borealis A/S

2 1 0

Landfilling

Net benefit of recovery

Energy [MJ/kg plastic waste]

40

-1 -2 -3 -4 -5 -6

GHG emissions [kg CO2-equiv. / kg plastic waste]

for Energy & GHG Emissions (example LDPE)

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4Rs - Reduce, Reuse, Recover, Recycle

Sustainable Development

“Humanity has the ability to make development sustainable to ensure that it meets the needs of the present without compromising the ability of future generations to meet their own needs.”

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(Source: Brundtland report)