Milestone for more cost-effective production of high-performance rotor blade

Covestro receives first DNV adjustment certification for partial reduction factor γm1 of wind turbine blades using aging-resistant PU.

Covestro has now received the first adjustment certification from DNV, the wind power industry’s certification organization, for the so-called partial reduction factor γm1 of wind turbine blades made of aging-resistant polyurethane (PU). This factor is an important indicator of the long-term aging resistance of rotor blades and is also used to measure the long-term service performance of the blades. It is also the first time that DNV has evaluated and adjusted this factor.

To do so, DNV evaluated complex and rigorous comparative tests as well as theoretical analysis by Covestro. Based on design standards for wind rotor blades (DNVGL-ST-0376:2015), DNV confirmed and adjusted the partial reduction factor γm1 of polyurethane resin processed using the vacuum infusion process. This certification applies to the Baydur 78BD085 PU resin and the Desmodur 44CP20 hardener from Covestro.

Longer and lighter rotor blade designs

Resin materials must prove their long-term aging resistance before they can be given lower safety margins that allow for broader rotor blade design and application. For the first time ever, DNV has lowered the γm1 factor of polyurethane resin, marking an important milestone for Covestro.

Compared to epoxy resin, which is often used to manufacture rotor blades, polyurethane resin shows better mechanical properties. With a lower γm1 value, rotor blade designers can take full advantage of polyurethane and also achieve greater design freedom. As the need for longer and larger rotor blades increases, so does the weight of the blades.

Therefore, weight reduction has become an important issue in the rotor blade industry. Polyurethane resin enables the production of lighter blades of the same length, which greatly improves the efficiency of blade production and its applications.

Dr. Irene Li, vice president of research and development for Covestro’s Tailored Urethanes business entity in the Asia Pacific, remarked, “We are pleased that the excellent performance of polyurethane has been recognized by a wind power industry’s certification authority.

As more and more polyurethane rotor blades are installed, we look forward to furthering innovations in polyurethane resin and the rapid development this will bring to the wind power industry.”

Innovative materials in focus

For a long time, epoxy resin was the main material used in the production of wind rotor blades. For years, Covestro has invested in research into polyurethane resins to improve rotor blade performance and reduce manufacturing costs. Today, polyurethane – new material in the field of wind rotor blade manufacturing – is rapidly gaining recognition in the market. With this innovative solution, Covestro aims to drive the use of renewable energy and, in the end, the shift to a circular economy.

Kim Sandgaard-Mørk, executive vice president of DNV’s Renewable Energy Certification Division, said, “Wind turbine blades are becoming lighter and larger, while favorable feed-in tariffs for wind energy are gradually being reduced. This poses a challenge for cost control in wind rotor blade production and development.

The wind power industry is therefore looking for new material applications while optimizing designs to reduce costs while ensuring optimal performance. By demonstrating the performance of polyurethane under the new blade standards and obtaining a new safety factor certification for its resin products, Covestro is blazing a new trail for blade design.”

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Way2K: Industry interviews in the lead-up to the K 2022 fair “We have the role of an ambassador”

Interview with Peter Steinbeck, CEO of Windmöller & Holscher KG

Mr. Steinbeck, what can a machine manufacturer like Windmoller & Holscher do to close plastic loops?

We can ensure that the machines are able to handle the recycled materials coming out of the loop and process them into new products in the best possible way. However, it’s also about designing products to make them recyclable in the first place. One example would be using mono materials that are easy to recycle, but have the same properties as multi-layer films. We can give customers machinery that can optimally handle the challenges of recyclate processing. But most importantly, we can also provide the right advice to help our customers deal with the requirements of the end customers in their countries in the best possible way. Sustainability is an important consulting topic in each of our discussions with customers. 

Some countries in Asia or Africa often don’t even have a garbage collection system, so where would you start?

Our possibilities with our own machines are limited, as waste systems and recycling plants are not part of our portfolio. However, we are making headway all over the world. We can help companies there to network and show them how to get the soiled material back, how to recycle it and where to get recycled goods. We see promising projects on our travels and can tell others in the regions about them. We have the role of an ambassador. In countries like Indonesia or Vietnam, where the circular economy is not yet considered, it’s
about generating lighthouse customers who are also motivated to tackle the issue of the circular economy, and subsequently offering them the right technology for their requirements.

Don’t we need to do more though if we want to reduce the amount of waste in the oceans?

Definitely. The great thing is that a lot is happening right now. I would also like to see the circular economy being promoted through city partnerships in developing and emerging countries. After all, every city in Germany has twin cities today; these are mostly cities in the West, however. Why not enter into a partnership with Surabaya in Indonesia with the aim of setting up a municipal waste disposal system there? Such a commitment would achieve much more than banning disposable drinking straws.

How is W&H represented with its own machines in these countries?

W&H machines are in use all over the world. Our customers appreciate the innovative strength of a German machine manufacturer and the partnership- based advice from W&H – especially on the subject of recycling management right now. In India, China and many other countries in particular, however, there are also companies that are not yet connecting to our high-tech machines. Nevertheless, our developments will also benefit them. This is comparable to cars, where technical innovations are initially implemented in the high-end segment. In time, however, they will also reach the mid-range, and finally every small car. So in the end, German technology can make a major contribution to the further development of the entire industry here as well.

One problem of the circular economy is the insufficient availability and even lower consumption of recyclates. What needs to be done here?

We in Germany, or even across Europe, need to set a good example. This also includes ensuring that the yellow bags that we all collect so diligently are no longer exported, but actually remain in the country. If it is cheaper to sell them to Malaysia, then this must be prevented, also at EU level. Politicians must put a stop to this. Incidentally, all the major film manufacturers – our customers – have been dealing with PCR, i.e. material obtained from plastic packaging waste, for some time now. They need machines that can be operated economically, even with lower quality materials.

Digitalisation is closely interwoven with the circular economy. How are you positioned in this regard?

With RUBY, we have developed an IoT platform that connects our customers’ machines within our process chain. It provides the data for our machines. Via apps, customers can make evaluations or also get help for the operators. This is becoming increasingly important because it is becoming more and more difficult to find highly trained skilled workers. We help the customer with internal networking and by evaluating their data via a cloud solution. The circular economy needs transparency, and digitalisation is the basis for more transparency – not just for the circular economy, but also for sustainability in general: for example, it helps to work more efficiently through automation, to use less material or less energy.

Is the willingness there to act across company boundaries?

The common goal of sustainability has given the industry a development boost, and there are now more collaborations emerging than ever before. We have existing long-term partnerships, for example with raw material manufacturers, in which we are now also quickly tackling these issues together. 

And we benefit from the fact that we have three processing steps in our own portfolio: extrusion, printing and processing. For example, we can directly test the effects of new, more sustainable formulations on printing. Sustainability is only possible together, along the value chain. This applies to digitalisation, efficiency and the circular economy.

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BOREALIS AND RECLAY GROUP ESTABLISH A UNIQUE STRATEGIC PARTNERSHIP TO TACKLE THE CHALLENGE OF PLASTIC PACKAGING WASTE AND ITS RECYCLING

• The strategic partnership will combine the complementary strengths and capabilities of both players in the plastics recycling value-chain, starting with Germany
• The agreement secures plastic waste from Reclay for Borealis to convert and revalorise in high-quality recyclate materials
• EverMinds  in Practice: providing circular solutions to meet customer expectations and market demand

Borealis, one of the world’s leading providers of advanced and circular polyolefin solutions and a European market leader in base chemicals and fertilizers, and the Reclay Group, international experts in environmental and material recovery management, announce that they have joined forces to satisfy increasing market demand for the supply of recyclate material for use in high-end plastic applications.

This unique partnership will optimise the recycling value chain starting with Germany, one of the largest European recycling markets. The partnership further accelerates the transition to plastics circularity by enabling customers and other value chain partners to meet their own sustainability targets.

New partnership capitalises on strengths of downstream and upstream recycling expertise
The new agreement provides Borealis with access to a secure and steady supply of feedstock in the form of lightweight packaging (LWP) waste collected by Reclay’s Extended Producer Responsibility (EPR) scheme in Germany.

The plastic packaging waste is then processed at Borealis’ own state-of-the-art recycling plants, thus extending the range of applications for which recycled plastics can be used. This in turn enables value chain partners, customers, and brand owners to meet recycling quotas and increase the volume of plastic recyclate used in products and applications.

“The reliable supply of high-quality recyclate is a prerequisite for a functioning circular economy,” explains Lucrèce Foufopoulos, Borealis Executive Vice President Polyolefins, Innovation & Technology and Circular Economy Solutions.

“Working together with the Reclay Group is a strategic step towards value chain integration in securing plastic waste feedstock and improving recyclability.  This will enable our customers and partners to achieve their circularity goals and reduce their overall carbon footprint, and at the same time underpins our Borealis journey towards more sustainable living.”

“We are proud to be working in partnership with an innovative and globally recognised company in the chemical industry moving into the future,” says Raffael A. Fruscio, Owner and Managing Director of the Reclay Group. “Borealis has state-of-the-art processes in the field of advanced recycling; we’ll jointly be setting a new standard in plastic recycling.”

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For more further details

Borealis and Reclay Group establish a unique strategic partnership  to tackle the challenge of plastic packaging waste and its recycling

• The strategic partnership will combine the complementary strengths and capabilities of
  both players in the plastics recycling value-chain, starting with Germany
• The agreement secures plastic waste from Reclay for Borealis to convert and revalorise
  in high-quality recyclate materials
• Everminds in  Practice: providing circular solutions to meet customer expectations and
  market demand

Borealis, one of the world’s leading providers of advanced and circular polyolefin solutions and a European market leader in base chemicals and fertilizers, and the Reclay Group, international experts in environmental and material recovery management, announce that they have joined forces to satisfy increasing market demand for the supply of recyclate material for use in high-end plastic applications. This unique partnership will optimise the recycling value chain starting with Germany, one of the largest European recycling markets. The partnership further accelerates the transition to plastics circularity by enabling customers and other value chain partners to meet their own sustainability targets. New partnership capitalises on strengths of downstream and upstream recycling expertise.

The new agreement provides Borealis with access to a secure and steady supply of feedstock in the form of lightweight packaging (LWP) waste collected by Reclay’s Extended Producer Responsibility (EPR) scheme in Germany. The plastic packaging waste is then processed at Borealis’ own state-of-theart recycling plants, thus extending the range of applications for which recycled plastics can be used. This in turn enables value chain partners, customers, and brand owners to meet recycling quotas and increase the volume of plastic recyclate used in products and applications.

“The reliable supply of high-quality recyclate is a prerequisite for a functioning circular economy,” explains Lucrèce Foufopoulos, Borealis Executive Vice President Polyolefins, Innovation & Technology and Circular Economy Solutions. “Working together with the Reclay Group is a strategic step towards value chain integration in securing plastic waste feedstock and improving recyclability. This will enable our customers and partners to achieve their circularity goals and reduce their overall carbon footprint, and at the same time underpins our Borealis journey towards more sustainable living.”

“We are proud to be working in partnership with an innovative and globally recognised company in the
chemical industry moving into the future,” says Raffael A. Fruscio, Owner and Managing Director of the
Reclay Group. “Borealis has state-of-the-art processes in the field of advanced recycling; we’ll jointly be
setting a new standard in plastic recycling.”

Further information:
www.borealisgroup.com
www.borealiseverminds.com
https://reclay-group.com

Tad McGwire Named Chairman of Plastics Industry Association

Washington, D.C.-The Plastics Industry Association (PLASTICS) has announced the election of Tad McGwire as Chairman of the Board. McGwire is CEO and owner of Industrial heater corp , a recognized leader in the process heating industry, and brings nearly four decades of manufacturing experience to his new role.

“As the only association that represents the entire plastics supply chain, we’re thrilled to have Tad as our Chairman,” said Tony Radoszewski, President and CEO of PLASTICS. “With thirty-plus years as an active member of PLASTICS and as past Chairman of our flagship event, NPE: The Plastics Show, Tad brings first-hand knowledge of the needs of our members and the opportunities and challenges of our vibrant industry.”

“I’m excited to take on the responsibilities as Chairman,” said McGwire, “and expect to work closely with Tony to rally our industry in these unprecedented times. As an industry, we don’t need to apologize for developing life-changing materials, but we do need to recognize the impact our materials have on the environment and take a leadership role in finding solutions.”

McGwire, who holds both a Bachelor of Science degree in Economics and an M.B.A. from University of Chicago, began his career as founder of Phoenix Lighting Products. In 1991, he moved into the President’s role at Industrial Heater Corp. He has served in various leadership positions within the Plastics Industry Association (PLASTICS) since 2005.

In addition to his role as Chairman, McGwire also serves on the association’s NPE2024 Executive Committee.

Jörg Krüger appointed CEO of Synova

  Synova, an advanced technology company focused on production of high value chemicals such as olefins and BTX from waste, announced today the appointment of Jörg Krüger as Chief Executive Officer.

Mr. Krüger brings with him substantial experience and a strong network in the chemical industry spanning over 30 years with Bayer, GE Bayer Silicones, Momentive Performance Materials, Orion Engineered Carbons and Compo Expert. He has a track record of building large chemical plants with EPC contractors and optimising chemical processes via developing operational excellence with global teams he led.

As CEO of Synova Jörg Krüger will play a key role in Synova’s transition from demonstrating the technology at industrial scale to commercial roll out of the technology, an area where he brings extensive expertise. Jörg will be based in Maassluis where he will lead the planning, execution and evaluation of the Synova strategy.

Jörg Krüger said: “I am passionate about the need to transform the industry from linear to circular and thrilled to join the Synova team on their journey to Plastic Circularity 2.0. I am looking forward to work with our partners in the value chain to make a large contribution to the sustainability of the industries we serve. I am convinced Synova’s technology will prove to be a differentiator in terms of much needed feedstock flexibility and significantly reduced CO 2 -emissions.”

Ibrahim Al Husseini, Chairman of the Synova Board of Directors said: “We are thrilled to have Jörg join our Synova team as the new CEO. He brings a wealth of industry experience both in the chemical as well as the private equity space. The timing is perfect with Synova gearing up its efforts to demonstrate and commercialize its advantaged process technology, now widely recognized by the industry.”

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Borealis appoints Dirk Langhammer as Vice President Strategy & Group Development

Borealis announces the appointment of Dirk Langhammer (42) as Vice President Strategy & Group
Development effective 1 January 2022. Dirk succeeds Tom Asselman, who will move to OMV in the role
of Vice President Strategic Planning & Projects.

Dirk Langhammer joins Borealis from OMV where he has held various positions since 2013, including Head of In-house Consulting and Head of Business Development Middle East & Asia in Abu Dhabi. Prior to joining OMV, Dirk worked at McKinsey & Company in Germany and Australia. Most recently, he has held the position of OMV Vice President Business Transformation, shaping the OMV Refining transformation in the areas of Hydrogen, e-Fuels and Advanced Biofuels.

Dirk Langhammer holds a PhD in natural sciences from the University of Augsburg in Germany and a Master’s degree in Mechanical Engineering and Business Administration from the Technical University of Braunschweig, Germany. He is a German national, married and the father of three children.

“We are very pleased to welcome Dirk to Borealis,” comments Borealis CEO Thomas Gangl. “Dirk brings a lot of experience in business development and transformation. With his leadership, he will further drive our Strategy & Group Development, addressing the transition of our industry towards sustainable solutions.”

“At the same time, I would like to thank Tom Asselman for his outstanding contribution in various
positions during his long career at Borealis.”

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Moorfields patient receives world’s first 3D printed eye

STACKTECK INVESTS IN CAPACITY– REACHING A MILESTONE OF 8000 MACHINING HOURS PER WEEK

Solvay to Collaborate with Trillium on Bio- Based Acrylonitrile for Carbon Fiber Applications

New agreement with Trillium Renewable Chemicals will enable Solvay’s development of sustainable, bio-carbon fiber for use in various applications.

Solvay and Trillium Renewable Chemicals have signed a letter of intent to develop the supply chain for bio-
based acrylonitrile (bio-ACN). Trillium will supply Solvay with bio-ACN from Trillium’s planned commercial asset, and Solvay will evaluate bio-ACN for carbon fiber manufacturing as part of its long-term commitment to developing sustainable solutions from bio-based or recylcled sources.The aim of this partnership is to produce
carbon fiber for use in various applications such as aerospace, automotive, energy, and consumer goods.

Acrylonitrile is a chemical intermediate typically made from petroleum-based feedstocks like propylene and is
the primary raw material used in the production of carbon fiber. Trillium’s Bio-ACNTM process delivers
acrylonitrile from plant-based feedstocks like glycerol with a lower carbon footprint.

“We are thrilled to be partnering with Trillium which aligns well with our Solvay One Planet commitment to more than double our revenue based on renewable or recycled materials by 2030,” comments Stephen Heinz,head of composite research & innovation, Solvay.

Innovation partnerships such as this are driven by a desire to make a real-world sustainability impact. Bio-based feedstocks are a key part of Solvay’s sustainability strategy, and we look forward to being a consumer of bio-ACN from Trillium’s first bio-based acrylonitrile plant.”

“Trillium’s bio-ACN process technology enables bio-carbon fiber,” explains Corey Tyree, CEO of Trillium. “We are excited to continue our partnership with Solvay, who have supported the bio-ACN process technology development since 2014. Solvay is a leader in the most rapidly-growing acrylonitrile segment (carbon fiber)
and are market leaders in bio-carbon fiber and sustainable development.”

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