Carlos Pereira & Jan-Luiken Hemmes & Elisabeth Lackinger- Csarmann Application Specialist Sr Manager, Business Development Technology Manager, Paper Strength·Pulp & Paper Process & Functional Chemicals

Kemira Chemicals, Brazil Kemira Chemicals, Germany Kemira Chemie, Austria

New Vegetable Oil based ASA Sizing Chemistry

REGULATION

CONSUMERS BOARD & PAPER PRODUCERS

PACKAGING SOLUTION PROVIDES,

CONVERTERS

BRAND OWNERS

RETAIL CHEMICALS RAW MATERIALS

DRIVE FOR SUSTAINABILITY

Packaging value chain Push from consumers and regulations

Summary and outlook

• Around 60% of the globally used Paper Sizing Chemicals are already today made from bio-based non fossil raw materials (Fatty acids and Fatty acid derivatives).

• In Asia are the biggest users and producers of sizing chemistries.

• New bio-based ASA has been developed by Kemira based on Sunflower Oil.

• Due to different product characteristics some adaptations are necessary at the customer site. • ca. 60 °C for 100% Bio-ASA (MSOHO)

• Adjustment of Equipment (Pumps, Emulsifier)

Bio-based Raw materials for Paper and Board are in price competition for other industries and Energy use (Biodiesel)

Due to the impact of the Corona Crisis the cost structure for our main raw material is changing in an unpredictable manner. Thus economics might look unfavorable in the short run.

300 M€

300 M€

600 M€

Global annual growth of 2 % stimulated by the packaging market development Asia Pacific is the Growth leader.

AMERICAS

AKD

ASA

Rosin

Surface

ASIA & PACIFIC

AKD

ASA

Rosin

Surface

EUROPE & ME

AKD

ASA

Rosin

Surface60%

52%

65 %

Global Market for Sizing Chemicals (in Million EURO)

The increasing need for hydrophobation

LIQUID PACKAGING BOARD

Liquid repellency

CONTAINERBOARD

Strength

Dimensional stability

FOOD SERVICE BOARD

Improve moisture tolerance

Grease resistance

CARTON BOARD

Modify surface Converting properties

PRINTING & WRITING

Print quality

Decrease linting and dusting

Kemira Sizing Production Footprint

Washougal St. Caths Marietta Telêmaco Estella Helsingborg Tarragona Krems Joutseno Pasuruan Nanjing Yanzhou Suzhou Gunsan Wellgrow Hallam

ASA

AKD-E

AKD-W

Rosin Size

Surface Size

Raw material sources for sizing additives

Palm Trees

Pine Trees

Fossil Oil / Gas

Palm-oil

Gum / Tall Rosin

Olefins

AKD Wax

Fortified Rosin

Alkenyl Succinic

Anhydride 100%

AKD Emulsions 15-22%

Rosin Emulsions

11-52%

on-site Emulsification

AKD

Rosin

ASA

Styrene + Acrylates

Polymerisation SAE

Emulsions 15-37%

SAE

Targets of Product Development

• Development of a highly sustainable internal sizing chemical

• That is as efficient as ASA

• Applicable like ASA

• Using renewable & locally available raw materials

• Different vegetable oils were tested

• Most suitable one: Sunflower oil

• Replacement of fossil-based Olefins

• Scale-up production from Lab (200ml) to 20 tons – including needed registrations (REACH)

• Register the new substance for use in food packaging grades (BfR, FDA, GB 9685)

Finding the right raw material

Renewable and locally available raw material

Different vegetable oils were tested (linseed, soybean, rapeseed…)

High oleic sunflower oil had the most appropriate characteristics (residual oil, viscosity)

Focus on fatty acid composition

Patented Kemira technology – MSOHO New molecule for internal sizing

O

O

O

H

O

O

O ene - reaction

ASA

MSOHO = Maleated sunflower oil, high oleic

Product characteristics

Use of renewable and locally available raw materials

Independent from fossil-based raw materials

Better stability against hydrolysis

Higher resistance against peroxide

Low volatility ( steam distillation )

As efficient, applicable, and cost-effective as standard ASA

Can be combined with other sizing chemicals

Higher viscosity than standard ASA

Product Characteristics MSOHO = 100% maleated oil FennoSize MO 30 = 30% MSOHO + 70% ASA FennoSize AS = Standard ASA

Viscosity Residual Starting Material

Density

25°C 20°C

[mPas] [%] [g/L]

MSOHO 3500 (+/- 1000) 6 (+/- 3) 970 - 1030

FennoSize MO 30 410 (+/- 30) 3,2 968

FennoSize AS 180 (+/- 20) 2 (+/- 1) 955

• Kraft process

• 100% fresh fibers

Sack paper CASE STUDY 1

MORE SUSTAINABLE SOLUTION

SIZING PERFORMANCE CONSISTENT WITH

STANDARD ASA

Multi-layer board

• 100% recycled fibers

• Low ash retention

• High water hardness

MORE SUSTAINABLE SOLUTION

CONSTANT SIZING PERFORMANCE

SMALLER EMULSION PARTICLES

BETTER EMULSION STABILITY

CASE STUDY 2

CASE STUDY 3

Multi-layer solid board, 500 g/m2

• Packaging material from 100% recycled fibers

• High sizing requirements

• 24h water absorption < 85%

MORE SUSTAINABLE SOLUTION

SIZING PERFORMANCE AND WATER ABSORPTION ON THE SAME LEVEL AS

WITH STANDARD ASA

Application Know How – Further Steps

• Increase of maleated oil content in sizing blends (final target 100%)

• Currently maximum maleated oil ratio is 40%

• Proof positive effect on steam distillation

• With higher maleated oil ratios adjustments at customer sites would be necessary

• Storage / Transportation heated, insulated

• Online heating (heat exchanger)

• Equipment modifications

Application Know How – Scale Up

• Production facilities were adapted

Double tank each 50m3 for raw material & product

Adaptation of pumps & distillation receiving vessels

• >200 tons pure MSOHO were produced up to date = 30 Batches

• Approved two different suppliers for high oleic sunflower oil

• Production was developed further

Viscosity was reduced (~6000mPas 3500mPas)

Product fine-tuned regarding side products (Residual oil + Oligomers)

Compliance for use in food packaging

• Reach registration Completed

• FDA Compliant

• BfR XXXVI Accepted

• GB 9685 Not applied yet

• EC 1935/2004 Compliant

• CAS Number 2205860-51-9

Executive Summary

• FennoSize MO Series launch in EMEA 2020

• This will be first new molecule introduced in 40 years for internal sizing

• Allow our customers to increase the shares of renewable & sustainable products in use

CARLOS PEREIRA

THANK YOU

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