high performance, low cost polyurethane thermoset resin ......• leader in custom polyurethane...

22
High Performance, Low Cost Polyurethane Thermoset Resin Solutions for Filament Winding TSE INDUSTRIES, INC. A Passion for Polymers.ENVIRONMENTALLY PREFERABLE COMPOSITE SOLUTIONS

Upload: others

Post on 15-Jan-2020

1 views

Category:

Documents


0 download

TRANSCRIPT

Page 1: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

High Performance, Low Cost Polyurethane Thermoset Resin Solutions for Filament Winding

TSE INDUSTRIES, INC. A Passion for Polymers.™

ENVIRONMENTALLY PREFERABLE COMPOSITE SOLUTIONS

Page 2: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Thermoset polyester extensively uses both styrene monomer & MEKP, both volatile solvents, posing an increased risk of fire in processing and storage areas.!

•  Styrene monomer is classified as a suspected carcinogen. It can cause CNS issues & lead to fatal cardiac sensitization (IARC). Styrene is classified as a hazardous air pollutant. Emissions are strictly regulated as a VOC.!

•  Human lungs contain enzymes that convert styrene into styrene oxide, which has developed tumors in the lungs of mice.!

•  MEKP is a severe skin irritant, requiring careful treatment as a hazardous waste. It must be disposed of at an RCRA approved facility.!

•  Styrene monomer may be regulated even more tightly in the near future, making permits more difficult to obtain. This could limit production and force several large industries to scramble for alternatives (spa, tub, RV, boat, etc.).!

A New Strategic Approach is Needed Now!

Current Polyester Scenario

Page 3: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Potential for worker exposure lawsuits.!

•  Expensive ventilation and incineration equipment required.!

•  Hazardous waste handling adds expense.!

•  Yield losses are high due to styrene loss.!

The Use of Styrene is Vulnerable to Legislative Changes

Additional Impact of Styrene & MEKP Usage

Page 4: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Current Epoxy Resins use BPA (Bisphenol Epichlorohydrin) to achieve cross-linking and to raise Tg’s / HDT’s.

•  BPA can leach from epoxy resins, possibly causing severe adverse human health effects (based on more than 100 scientific papers): •  Endocrine disrupting chemical •  Liver enzyme damage •  Damage to brain and reproductive organs •  Damage to embryonic development •  Linked to breast cancer •  Low doses linked to increased risk of prostate cancer

•  A 2005 bio-monitoring study detected BPA in 95% of U.S. Citizens.

•  California bill introduced to ban BPA in certain toys and child care products.

•  EPA conducting search for an alternative to BPA for use in pipes and pipe linings.

A New Strategic Approach is Needed Now!

Current Epoxy / BPA Scenario

Page 5: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Polyurethane is an extremely versatile chemistry that allows creation of both thermoplastics & thermosetting plastics, ranging from very soft to hard and rigid.

•  As with polyesters, two liquid components are used, plus catalysts, fillers and reinforcements. The two basic components for most common polyurethanes are Isocyanates and Polyols.

•  No styrene monomer, MEKP or solvents are used. Some Isocyanates are regulated, but handling and disposal is much less hazardous and much less expensive than for styrene and MEKP.

•  Polyurethanes generally have higher tensile and impact strength vs. polyesters, but lower stiffness. Optimization of the fiberglass reinforcement can close the stiffness gap.

Polyurethane Background

Page 6: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  VOC-Free!!

•  BPA-Free!!

•  Styrene-Free! !

•  Ultra low emissions!!

•  100% Solids! !

•  Safer for your workers!!

Polyurethane Advantages: Environmentally Preferred

Page 7: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

• Polyesters & Vinyl Esters (anhydride epoxy resins) have an 8 hour cure time (3-4hrs with amine- cured epoxies).!

• Polyurethane takes just 1 hour to cure!!

• That’s up to an 800% increase in production with anhydride epoxy resins! Up to 400% with amine-cured epoxies! !

Think  about  what  you  gain  by  switching  to  TSE-­‐EcoWind      PU  composite  resin...    

• Increased  Produc-on  by  Up  To  800%!  -­‐  Make  up  to  8  +mes  the  product  in  the  same  amount  of  +me!  

• Reduced  Labor  Costs  -­‐  With  up  to  8  +mes  the  produc+on,  you  could  reduce  hours  and  lower  labor  costs!    

• Reduced  U-li-es  -­‐  With  a  cure  +me  of  just  1  hour,  you're  saving  7  hours  of  electricity  or  gas  each  cycle!  

This Means More Profit for You!

®

Polyurethane Advantages: Drastically Shorter Cure Times = More Profit!

Page 8: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

®

Our patented, dripless applicator virtually eliminates resin waste and saves you money! •  On average, current systems waste approximately 5% of the material being applied.

Our patented, near dripless applicator virtually eliminates waste, slashing it to about 0.25%!

•  Do the math: •  Multiply the number of pounds of resin you use each month by 4.75%. •  Now, multiply that number by your cost per pound of resin.

•  That’s about how much you’ll save each month on resin using our applicator! •  Now, add those savings to your additional income from increasing production by up to

800%, plus your savings from lower labor costs, plus your savings from a lower utility bill!

Are you getting an idea of the impact that TSE-EcoWind can have on your bottom line?

Polyurethane Advantages: TSE’s Applicator Reduces Waste & Saves Money!

Page 9: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Polyurethanes are less brittle and have better impact and fatigue resistance. •  Similar tensile and flexural strengths. •  Superior abrasion resistance.

•  Improved burst strength before and after fatigue testing: •  Pressure Vessels in Epoxy and Polyurethane

•  Water Heaters in Polyester and Polyurethane

Test  Condi-on   Epoxy   Polyurethane  Ambient  Burst  Test   880  PSI   1250  PSI  Burst  test  aDer  250,000  Pressuriza-on  cycles.  

800  PSI   1240  PSI  

Hot  Water  Burst    Test   725  PSI   1237  PSI  

Test  Condi-on   Polyester   Polyurethane  Average  Burst   465  PSI   550  PSI  Low  Burst   425  PSI   520  PSI  Max  cycles  -ll  failure   250,000   +2  Million  

Polyurethane Advantages vs. Polyesters & Vinyl Esters

Page 10: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Polyurethane Resins Offer Step Change Process & Product Improvements

• Improved mean burst strength of 18%-40% while decreasing resin usage.

• Improved burst strength consistency

• Improved structural and burst performance allows redesign of thicknesses of the laminate to further reduce glass and resin consumption.

• Temperature resiliency: lower limit is -40 to -50F; Upper limit is approximately 205F (Tg of 300F /150C).

Polyurethane Performance Improvements: The Numbers

Page 11: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

•  Improved impact resistance due to improved elongation and tensile strengths.

•  PU resins provide significant improvement in adhesion to fiberglass roving.

•  40% improvement in POST-hot cycle (250,000 cycles) strengths.

•  No reduction in burst strength after POST-hot cycle.

•  UV protection improved. (Based on 1 year side-by-side test in water/UV environment).

Polyurethane Resins Offer a ‘Groundbreaking Change’ Towards Improved Products & Enhanced Processes

Polyurethane Performance Improvements: The Numbers

Page 12: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Isocyanates Are Classified (N120) by the EPA as Reportable Only On An Annual Basis

•  Flash points of Isocyanate and Polyol are close to 400 ºF. •  Volatility is extremely low, i.e., only 1 / 1,800,000 of the vapor pressure of water. •  Reacted waste is non-hazardous. •  Health & Safety information on MSDS:

•  Polymeric Isocyanate – The ingredients of this product are not classified as carcinogenic by ACGIH or IARC, not regulated as carcinogens by OSHA, and not listed as carcinogens by NTP

•  Polymeric Isocyanate - This material is not a hazardous waste under RCRA 40 CFR 261. Small quantities should be treated with a decontaminant solution. The treated waste is not a hazardous material under RCRA 40 CFR 261

Polyurethane Health & Safety

Page 13: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

TSE is the Best Choice for a Strategic Polyurethane Partner!

•  Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance requirements.

•  TSE not only provides Resin Technology solutions, but groundbreaking Process Technology to ensure a seamless fit for Polyurethane-based resin systems into your existing processes.

•  On-site training for the Process Technology and in proper handling of chemicals.

•  TSE R&D has proven experience converting both styrene ester and epoxy resins systems to polyurethane systems.

•  TSE provides its patent pending, dripless impregnator roller applicators for glass wet out and higher application speeds, ensuring additional savings through waste reduction.

The TSE Advantage

Page 14: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Pipes & Piping Systems Tanks & Pressure Vessels Elastomeric Lined FW Pipes

Filament Wound Products TSE 1 Specialty Chemicals & Resin Manufacturing Facility in Clearwater, FL

® TSE-EcoWind Complete Polyurethane Solution

Page 15: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Products ! Process !

Pipes  and  Piping  Systems! • TSE-­‐EcoWind®  P200G  –  High  Performance    Filament  Winding  resins  for  General  pipe  and  piping  system  applicaKons  

• TSE-­‐EcoWind®  P200HE  –  High  ElongaKon,  High  Performance  Filament  Winding  Resin  for  pipes  and  products  requiring  a  higher  degree  of  flexibility  and  elongaKon!

• Patented  TSE  Applicator  technology  for  high  speed  filament  winding    processes  incorporaKng  opKmal  applicaKon  of  polyurethane  onto  the  glass/carbon  fiber  reinforcement)  

• Turnkey  Filament  winding  Process  SoluKons  and  process  consultancy  for  Polyurethane  soluKons  in  Pipes,  Piping  Systems,  Tanks,  Pressure  vessels,  Water  Heaters  etc.  

• Well  equipped  Research  &  Development  Lab  to  develop  custom  applicaKon  soluKons. !

Tanks  and  Pressure  Vessels  (with  internal  liners,  i.e.  water  so_eners) !

• TSE-­‐EcoWind®  T210  

Miscellaneous  Filament  wound  products  (i.e.  water  heaters!

• TSE-­‐EcoWind®    M100!

Elastomeric  Liners  (internal  or  external)  for  Pipes,  Rollers!

• TSE-­‐EcoWind®    L85  

® TSE-EcoWind Complete Polyurethane Solution

Page 16: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

ACE Award Presentation, October 2014, CAMX Orlando!

TM

® Winner: ACE Award, CAMX Orlando 2014

Page 17: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

The TSE EcoWinder Resin Applicator TM

Page 18: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Pipes wound using TSE-EcoWind Polyurethane Thermoset Resin systems

displayed at the 2013 JEC Americas Innovation Showcase held in Boston.!

JEC Americas 2013 – Innovation Award Ceremony! ®

Winner: JEC Americas 2013 Innovation Award

Page 19: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

TSE-EcoWind PU Filament Winding system was a Finalist at the 2013 Polyurethanes Technical Conference conducted by the American Chemistry Council in September.!

TSE’s presentation of its innovation in polyurethanes for filament winding applications at the Polyurethane Technical Conference 2013 held Sept. 23-25 in Phoenix, AZ.!

®

Finalist: 2013 Innovation Award American Chemistry Council

Polyurethanes Technical Conference

Page 20: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

TSE-EcoWind® Polyurethane Filament Wound pipes was a finalist at the 2013 JEC Europe Innovation Showcase held at Paris.!

JEC Europe 2013 – Innovation Showcase!

Winner: JEC Europe 2013 Innovation Award Paris, March 2013

Page 21: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

®

®

TSE-EcoWind Polyurethane Resin System: •  Reduces Cure Time from 8Hrs to Just 1Hr Meaning Up to an 800% Increase in Production, Increasing Profits While Reducing Labor and Utilities!

•  High-Speed, Patented Applicator Virtually Eliminates Resin Waste, slashing it from 5% down to About 0.25%, Saving You BIG Money!

•  Environmentally Preferable Solution - VOC, BPA & Styrene-Free! 100% Solids.

•  Produces Products as Strong as Steel, but Lighter with Better Burst Strength.

•  Seamless Conversion and On-Site Training from TSE Professionals.

•  TSE-EcoWind Resins. Great for the environment, your workers, & your bottom line!

Conclusion

Page 22: High Performance, Low Cost Polyurethane Thermoset Resin ......• Leader in custom polyurethane compounding and development of resin formulations to meet and exceed your product performance

TSE INDUSTRIES, INC. A Passion for Polymers.™

®

Thank you! For more information, contact!Mark D’Souza!

Composite Research & Development Manager!727-540-1306!

[email protected]!

5260 113th Avenue North, Clearwater, Florida 33760!TEL: 1-800-237-7634 | FAX 727-230-8090!

www.TSE-Industries.com | www.TSE-EcoWind.com!