Hello all,
As cities in the U.S. battle back to normalcy in the aftermath of Superstorm Sandy, our hearts reach out to those affected………
TRENDING ENERGY
Designated by the United Nations as the “International Year for Sustainable Energy for All”; the World Energy Forum was held in Dubai in the Middle East in late October. Despite increasing levels of investment in alternate energy sources and a more diversified global energy mix, fossil fuels continue to account for most of the world’s energy production. Representatives of various nations deliberated on the development of oil, natural gas and coal in the global economy as well as the accompanying environmental obstacles and ways that governments and industries are working to reduce negative externalities [AME Info].
Increased political support and private investment have made natural gas a viable automotive fuel alternative with large growth potential. At an average price per gasoline gallon equivalent in the $1- $2 range, the fuel is plentiful and affordable in the U.S., thanks to the huge success of fracking technology. It burns more cleanly than gasoline, cuts greenhouse gas emissions by 30% and particulate matter by 95%. Currently, the fuel tank on a CNG vehicle is its most expensive single component. 3M‘s CNG tank solution reportedly combines its proprietary liner advancements, thermoplastic materials and damage resistant films to transform the pressure vessel industry. Using silica nanoparticle-enhanced epoxy resin technology, 3M plans to create CNG tanks that are 10-20% lighter with 10-20% greater capacity at lower cost compared to standard tanks while rendering them more safer and durable [Plastics Today].
The abundance of natural gas at low price has led to a manufacturing renaissance in the U.S. When energy costs are affordable, factories can once again hum with greater activity.
HEAT IS ON !
In the relentless pursuit of energy efficiency in automobiles, the goal for design engineers is metal replacement. Per industry estimates, a weight reduction as high as 50% can be achieved with plastic-for-metal substitution. Direct replacement of die-cast aluminum in mechanical water pump housings with polypthalamide (PPA), a semi-aromatic polyamide (nylon) is now possible [Design News]. Polyamide 66 reinforced with 50% glass fiber with higher stiffness and heat ageing resistance for continuous use over 3,000hours at 220C has been an effective substitute for metal in the engine compartment. Other advantages claimed are low system costs arising out of lower processing temperature, cycle time reduction, lower energy consumption and ease of welding.
This is just another example of plastics encroaching the domain of metals in “under the hood, close-to-engine components”.
Nanotechnology is progressing by leaps and bounds. Ever come across the application of polymer-based nanocomposites containing epoxy and carbon-based nanoparticles (carbon nanotubes and graphene) as a functional coating for glass fibers ? Recent tests have shown both mechanical and electrical properties of glass fibers are significantly enhanced after nanocomposites coating. Further, when graphene is used as nanoscale filler in nanocomposites, the coating functions as a barrier layer to prevent glass fibers from environmental attacks [Sciencia].
The word “nano” has not only revolutionized materials technology, but extended its usage to all walks of life. Even Apple could not resist tagging it as a subscript with the iPod !
SURFACE ELEGANCE
Beauty and brains are an ideal (and oft desired) combo! In composites parlance, this translates to high mechanical properties and aesthetics (surface finish) not only desirable, but essential in most molded products. Wavelet Texture Analysis (WTA) is a recent technique that has been used to automatically classify the surface finish properties of two FRP construction types (clear resin and gel coat) into three quality grades. Samples were imaged and wavelet multi-scale decomposition was used to create a visual texture representation of the sample, capturing image features at different scales and orientations. Principal component analysis was used to reduce the dimensionality of the texture featured vector, permitting successful classification of the samples using only the first principal component. Feasibility of this approach as the basis for automated non-contact classification of a composite surface finish using image analysis has been validated [Sciencia].
INTERFACIAL BOND
Fiber & resin producers and processors acknowledge the need for faster cycle times in automotive mass production. BASF and SGL are jointly working on a cost-effective Thermoplastic Resin Transfer Molding (T-RTM) process as well as Reactive Injection Molding (RIM) that permits shorter processing cycles than conventional thermosetting RTM. To achieve good wetting of the carbon fiber and shorter cycle times in T-RTM or RIM, low-viscosity highly reactive caprolactum ( precursor for polyamide) is contemplated in order to obtain optimal bonding of the polyamide to the fiber through suitable fiber surface treatment [Plastics Today].
The key to technological breakthroughs is to start from first principles. Right? History is replete with pathbreaking success stories of similar innovations that have revolutionized the industry.
Improvements in tensile strength by as much as 500% has been reportedly achieved by laterally cross-linking a polyurethane (PU) co-polymer with an extra MDI – a more rigid polycarbonate diol replacing conventional polytetramethylene glycol as the soft segment. The impact of possible molecular interaction between polycarbonate soft segment and lateral cross-linking results in a structural change. Shape recovery was over 90% [Sciencia].
LIGHT…..LIGHTER
Materials technology never ceases to amaze us.General Motors (GM) is using a blend of chopped carbon and glass fibers coupled with proprietary nanoclay technology in a SMC application for the 2013 Corvette. Two blends of 15% by volume of chopped CF with 30% GF as well as inverse ratio in a nano-based resin system were tested. There was a 36% mass savings over traditional SMC for the parts involved that included floor, rear surround and wheel housings. Total weight saving was 15 lbs before addition of any hardware to the components. The shape (more corkscrew than platelet) of the nano clay structures contributed significantly to the strength of the parts [Plastics Today].
While on the subject of the automotive sector, the American Chemistry Council (ACC) recently touted the results of a life-cycle analysis that shows lighter weight plastic auto parts not only save fuel, but the fuel savings outweigh any impact from producing those parts. The ACC’s Plastics Division used two parts already in production – a front support bolster on 2010 Ford‘s Taurus sedan (46% lighter than a plastics & steel bolster) and the running board (51% lighter than a steel counterpart) on GM’s 2008 Chevrolet Trailblazer. While considering the environmental impacts of the bolster and running board at each stage of the product’s life cycle; including energy used during their production, product manufacturing impacts, product use and end-of-life treatment of parts; the study showed that lightweighting the running board would reduce energy use by 2.7 million gallons of gasoline over the vehicle lifespan, while reducing the weight of an all-plastic bolster would reduce energy by 770,000 gallons [Plastics News].
This just goes to prove the multifarious spin-offs of weight reduction in automobiles.
TIDAL POWER – EMERGING FORCE
The United Kingdom & South Korea have teamed up on the U.K.-Korea Ocean Energy Technology Co-operation Project in the footsteps of another agreement signed earlier this year between Renewable UK and the Korean Wind Energy Association.While the U.K. is the acknowledged world leader in offshore wind energy capacity with 1,858 MW online (as of June 2012), it also has 2,359 MW under construction and more than 42,000 MW in the pipeline. South Korea has 2,500MW of offshore windpower under development with plans to build a 100 MW wind farm by 2014, a 400 MW project by 2014 and 2,000 MW development by 2019 [Renewable Energy World].
It is heartening to note that fostering of regional co-operation is enabling propagation of wind energy, with the U.K. sharing its expertise and knowledge for the benefit of the Asian giant.
RENEWABLES – ACING THE REST
Proponents of wind energy continue to tout its plus points to counter the perennial naysayers. Gas accounts for 48% of the U.K.’s electricity supply. Of the 372 TW hours of electricity it produces per year, 54% is lost as heat. Coal accounts for 28% producing 297 TWh and loses a higher proportion – 66%. Nuclear accounting for 16% of the energy supply with 162TWh, loses 65% and oil, with 3% of the supply, loses 77%. In contrast, renewable energy that accounts for 4% of the U.K.’s electricity supply producing 14TWh, loses less than 1% [Think Progress].
To industry observers, such debates on the pros and cons are obviously endless.
A German company [EPIC Polymers] is commissioning a new 4,000 Tons/year LFT production line in Q4, 2012 using an innovative impregnation technology with focus on high performance plastics such as polyamide (PA) and polythalamide (PPA). The fibers would include long-glass, carbon and aramid as well as tribologically modified grades and electrically & thermally conductive grades [Plastics Today].
BIO- (R)EVOLUTION
In mid-October, European Bioplastics released its annual market forecast. Worldwide production capacity for bio-plastics is forecast to increase more than five-fold from 1.2 million tonnes in 2011 to 5.8 million tonnes by 2016. Chemically identical bio-based versions of conventional materials derived from renewable building blocks instead of from petrochemical sources, are stated to be enjoying robust growth. Leading the field is partially bio-based PET which already accounts for approximately 40% of global bio-plastics production capacity. Second in place is bio-based PE constituting more than 4% production capacity. The preferred locations for new production sites are South America and Asia with Europe and North America serving as R&D hubs [Plastics Today].
Shale-gas boom in the U.S. (due mainly to the success of fracking) is expected to add enough ethane/propane to expand light olefin derivative production between 2014-16 to the tune of 6-10 billion pounds. This could result in the U.S. being a key supplier of polyethylene (PE) to the rest of the world. Industries in Mexico and Latin America are expected to benefit to a great extent through the availability of plastics for different market segments [Plastics News].
As stated in my June post, PE (at the expense of PP) could be a game changer in the coming years – both in terms of increased applications and, possibly price.
GFRP REBAR – CONFIDENCE BOOST
The changes that can occur in GFRP composites with ageing can affect its application, performance and lifetime. Hygrothermal ageing (accelerated ageing by moisture absorption and temperature change) is a very useful technique to evaluate durability of GFRP in a reasonable time frame. Dynamic mechanical thermal analysis (DMTA) is able to detect all changes in the state of molecular motion in polymeric composites, as temperature is scanned. In one such study, pultruded GFRP rebars were subject to accelerated ageing in an alkaline aqueous environment at 6C for 1, 2, 3, 4, 6 months to evaluate the changes in glass transition temperature. Five different glass transitions at an average temperature range from 11 to 165C were observed at storage modulus, loss modulus and damping factor traces of DMTA. It was observed that the glass transition temperature changed up to a maximum of 6C compared with that of the control sample and believed to be due to moisture absorption by the rebars. No evidence of degradation of GFRP was observed after 6 months of hygrothermal ageing [Sciencia].
BEST OF THE BRAINS
What happens when leading like-minded majors like Coca-Cola, Ford, Heinz, Nike and Procter & Gamble, all with strong R&D resources; join forces to accelerate the development of and use of 100% plant-based PET materials in their products. These five brands have formed the Plant PET Technology Collaborative (PTC) to support new technologies to evolve today’s material that is partially made from plants to a solution made entirely from plants. Currently Heinz licenses the technology from Coca-Cola (PET beverage bottles made partially from plants) to select ketchup bottles in the U.S. and Canada [Plastics Today].
The resulting synergistic R&D of the five multinational companies spells success from the word go !
WATER…THE NEW GOLD ?
Climate and weather patterns are changing natural water patterns. Industrial pollution is making water a scarce commodity. It is therefore not surprising that water has been rightly dubbed the gold for investors in the 21st century. In terms of consumption, according to Fortune; globally, agriculture accounts for 71%, industry 16% for a total of 87% of all water used. Thanks to innovative superfine filters, 20 % of Singapore’s drinking water comes from processed sewage. While desalination plants are common in the Middle East, one in America is underway [Yahoo Finance]. It is common knowledge that plastics & GFRP are used to a large extent in transportation and treatment of water. Little wonder that the number of pipe manufacturers (be it PVC, HDPE, GFRP) is always on the rise and this trend, obviously, will continue for several decades.
Water…the elixir of life ?
AAH! RECORD OF SORTS
The Dubai Mall is the largest retail destination in the world and boasts of numerous applications of GFRP running into several hundred meters of skylighting and tonnes of composites. Dubai is now home to the world’s largest department store dedicated exclusively to shoes ! The new 96,000 square feet store contains 15,000 pairs of shoes (for men and women) across around 250 different brands. The previous record holder was Macy’s 39,000 square feet shoe store in Manhattan, U.S.[Arabian Business].
So much for the luxury market and the fiscal might of petrodollars !
We shall be back with the next post in early January 2013 !
Till then,
Happy holidays !
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com
Sundaram
ESSJAY Composites 
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