Post on 15-Feb-2019
FIBRE ACRILICHE. DALLA CRISI DI MERCATO A NUOVI SVILUPPI
PRATO 10 MARZO 2009
Franco Francalanci - Montefibre S.p.A
0
5000
10000
15000
20000
25000
30000
35000
40000
1970
1975
1980
1985
1990
1995
2000
2005
1000
tons Synthetic
NaturalArtificial
• Steady growth• Natural fibers overtaken• Good forecast of further increase
SYNTHETIC FIBERS: A HEALTHY INDUSTRY
First impression:
• Steady growth• Natural fibers overtaken• Good forecast of further increase
SYNTHETIC FIBERS: A HEALTHY INDUSTRY
0
5000
10000
15000
20000
25000
30000
35000
40000
1970
1975
1980
1985
1990
1995
2000
2005
1000
tons Synthetic
NaturalArtificial
IN A DREAM WORLD
PRODUCTION OF SYNTHETIC FIBRES IN DIFFERENT REGIONS
0
5000
10000
15000
20000
25000
30000
1994
1996
1998
2000
2002
2004
1000
ton
AmericasEuropeAsia
PRODUCTION OF SYNTHETIC FIBRES IN DIFFERENT ASIAN COUNTRIES
0
2000
4000
6000
8000
10000
12000
14000
16000
1994
1996
1998
2000
2002
2004
1000
ton China
JapanSouth KoreaTaiwan
WORLD PRODUCTION BY TYPE OF FIBERsource CIRFS
0
5000
10000
15000
20000
25000
30000
1998
1999
2000
2001
2002
2003
2004
2005
AcrylicPolyamidePolyester
WORLD MILL CONSUMPTION source PCI
0
5000
10000
15000
20000
25000
30000
1996
1998
2000
2002
2004
2006
AcrylicPolyamidePolyester
PRODUCTION AND CONSUMPTION OF SYNTHETIC FIBRES IN CHINA
0
2000
4000
6000
8000
10000
12000
14000
16000
1996
1998
2000
2002
2004
2006
1000
ton
ProductionConsumption
MILL CONSUMPTION IN GREATER EUROPEsource CIRFS
0
500
1000
1500
2000
2500
1999 2000 2001 2002 2003 2004 2005
AcrylicPolyamidePolyester
MILL CONSUMPTION IN WESTERN EUROPEsource CIRFS
0
200
400
600
800
1000
1200
1400
1600
1997
1999
2001
2003
2005
2007
AcrylicPolyamidePolyester
80
85
90
95
100
105
110
115
'85 '86 '87 '88 '89 '90 '91 '92 '93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05
Seasonally adjusted index
European Textile Production Index((((sourcesourcesourcesource CIRFS)CIRFS)CIRFS)CIRFS)
PRODUCTION OF ACRYLIC FIBREsource CIRFS
0100200300400500600700800900
1000
1999
2000
2001
2002
2003
2004
2005
2006
2007
EuropeUSAJapanChina
0
100
200
300
400
500
600
700
2000
2002
2004
2006
2008
ProductionWEConsumptionWE
Acrylic production and consumption Western Europe
0
200
400
600
800
1000
1200
1400
2000
2002
2004
2006
2008
ProductionWEConsumptionWEProductionChinaConsumptionChina
Acrylic production and consumption Western Europe and China
• RAW MATERIALS• ENERGY• FINANCE
MAIN BURDENS ON INDUSTRY
On average:
Raw materials account for 65 – 75 % of production costEnergy accounts for 10 – 15 % of production costFinance accounts for ????
• Lower impact of raw material(less pure monomers, polymer blends, higher efficiency)
•Lower impact of energy(integrated processes, higher efficiency)
• Health care
• Protective materials
Cost Reduction Margin Increase
Process Innovation Product Innovation
Profit and Growhof Industry
Post production modificationsSide diversification (crutch)
POST PRODUCTION MODIFICATIONS
FEEDSTOCKS MONOMERS POLYMERS FIBRE
• Low impact on consolidated processes
• Different products from the same precursor
“ANTIPILLING” POLYESTER => weakness due to low molecular weight polymer
Alternative approach: getting a low viscosity polymer through controlled depolymerisation of melt
STARTING FROM A STANDARD POLYMER (INVENTA – FISCHER patent)
Classical approach: using a special crosslinked polymer of low polymer weight, but high melt viscosity. Melt Spinnable
Need to synthesize a special polymer and develop a “ad hoc” process
POST PRODUCTION MODIFICATIONSA few examples - 1
POST PRODUCTION MODIFICATIONSA few examples - 2
SUPERABSORBENT ACRYLIC FIBER => due to presence of – COOH groups
Classical :
Polymerisation in water ofacrylic acid and methyl acyilate
Dry spinning with Water evaporation
Stretching and drying Of resulting fibre
Crosslinking 250°C of –COOHGroups with functional groups
Introduced during polymerisation
Alternative :
Commercial Acrylic fiber
Crosslinking of 10-30 %of - CN groups
Hydrolysis of remaining-CN to -COOH
Drying of fibre
Open problem:Alternative to hydrazine
CNCN
+ NH2 – NH2 C==NHC==NH
NH --NHCN
CNCN
CN
POST PRODUCTION MODIFICATIONSA few examples - 3
LOTAN ®A SUPER FLAME RESISTANT FIBRE
CNCN
+ NH2 – NH2 C==NHC==NH
NH --NHCN
CNCN
CN LOTAN ®
0
10
20
30
40
50
60LOI %
PANOX
LOTAN
PBI
PPS
PHENOLIC
ARAMID
PES (FR)
MODACRYLIC
VISCOSE
PES
ACRYLIC
PP
Smokes: F1 (NF F 16-101)
(ISO 5659-2)(ISO 5659-2 + FTIR)
Fire: M1 (NF P 92-503/507)(UNI 9175)
(ISO 5660)
• Tenacity 13-18 cN/tex• Elongation 15-35 %• Density 1.5 g/cm3
• Autoignition Temperature (100% O2) 435°C • L.O. I. > 38% (typically 39-42)• Reaction to Fire Class M1 (NF P 92-503-507)• Smoke & Gas evolution CO2 - H2O with negligible amounts of HCN,HCl, SOx
• Toxicity and Opacity Smoke Class F0 – F1 (NF F 16-101)• Water Regain ~ 12 %• Water Imbibition ~ 45 %• Shrinkage in boiling water ~ 0%• Alkali & Acids resistance Good / Very Good• Common solvents resisistance Not soluble• U.V. Stability Good
General Properties
BY MONTEFIBRELOTAN ®
BY MONTEFIBRELOTAN ®
BeforeFlame Exposure
After Flame Exposure
Char BarrierNo Melting
No ShrinkingNo Flaming Drops
0
5
10
15
20
25
30
25 110 130 170 200
Temperature (°C)
Bre
akin
g T
enac
ity
(cN
/tex)
0
5
10
15
20
25
30
Bre
akin
g E
long
atio
n (%
)
Time Exposure : 24 h
Effect of Dry Heat
BY MONTEFIBRELOTAN ®
Effect of Acid Solution on tensile properties
BY MONTEFIBRELOTAN ®
0
5
10
15
20
25
30
35
40
45
50
Ten
acity
(cN
/tex)
0 120
Treatment Time (hours)
LOTAN
ARAMIDES
POLYACRYLONITRILE (100%)
Time Exposure: 120 hTemperature: 60 °CAcid Solution: HCl - 4%
BY MONTEFIBRELOTAN ®
POSSIBLE END USES ????:…………………….
No Limits to Product Design in the Firefighting Area
both in NONWOVEN
Andin
SPINNING SECTORS
Barrier
Fabr ic
s
Fireblan
kets
Hot ga
s Filtr
ation
Wall
Cover i
ngs
Liquid Filtration at
temperature
ExtremeSport
Clothing
ProtectiveClothings
Mattressesconstruction
For additional information, please visit: www.lotan.eu
SIDE DIVERSIFICATION (CRATCH FOR BUSINESS)
POLYESTER
POLYAMIDE
ACRYLIC
RESIN FOR BOTTLES
HIGH PERFORMANCE PLASTIC
CARBON FIBERS
ACRYLICCARBON FIBERS
ProcessoProcesso didi produzioneproduzione delladella fibrafibra didi carbonio da carbonio da PANPAN
PrecursorePAN
Ossidazione in aria
( 200÷÷÷÷300°°°°C30÷÷÷÷60 min.)
Carbonizzazione(Pirolisi in azoto 700 ÷÷÷÷ 1500 °C 2-10 min) - HS
Grafitizzazione(Pirolisi in azoto oltre 2000 °C 1-2 min) - HM
Trattamentosuperficiale
Sizing
bobinatura
PAN
C C CC C
C≡≡≡≡N C≡≡≡≡N C≡≡≡≡N
PAN
C C CC C
C≡≡≡≡N C≡≡≡≡N C≡≡≡≡N
Fibra ossidata
N N
C C C
N
C
C
C
C
C
C
O
Fibra ossidata
N N
C C C
N
C
C
C
C
C
C
O
C C C
N
C
C
C
C
C
C
O
Fibra di carbonio
NN
Fibra di carbonio
NN
Consumi mondiali di fibra di carbonio
9,7 10,812
13,515
16,6 17,119,1
20,923,1
26,5
31
34,4
0
5
10
15
20
25
30
35
40
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Anno
Mig
liaia
di t
on
- Forecast consumi mondiali di fibra di carbonio
26,531
34,438,8
41,9 44,448,4
0
10
20
30
40
50
60
2005 2006 2007 2008 2009 2010 2011
Anno
Mig
liaia
di t
on
Consumi fibra di carbonio per settore
3,3 4,8 5,9 6,1 735,2
7,6 8,315,4
3,5
6,5
12,916,6
25,9
0
10
20
30
40
50
60
1995 2000 2005 2006 2011
Anno
Mig
liaia
di t
on
Industrial
Aerospace
Sport
Ripartizione consumi industriali
Cuscinetti1,0%
Alberi trasmiss ione6,9%
Cilindri12,3%
Petro lio3,9%
Trasporti4,2%
Eolico9,2%
Nautica7,7%
Altro6,2%
Fuel cell2,3%
Edilizia11,6%
Medicale3,9%
Compositi12,3%
Recipienti pressione18,5%
2010 > 45.175 tons
Europa35%
USA31%
Altri5%
Giappone13%
/Taiwan /CoreaCina16%
2004 > 21.225 tons
USA30%
Europa27%
Altri14%
/Taiwan /CoreaCina14%
Giappone15%
2007 > 32.200 tons
Europa31%
USA29%
Altri12%
Giappone
13%
/Taiwan /CoreaCina15%
SVILUPPO FIBRE DI CARBONIO PER AREA GEOGRAFICA
CONCLUSIONS –
Synthetic Fibers Industry in big troubles (mainly in industrialized Countries)
Post modification and side productions (CRUTCH) may help
Main problem: Costs (raw materials),weak market
Solution will come from Innovation (both Process and Product)