1 Product sustainability in the water based polymers industry The VINAVIL case Marco Cerra Vinavil S.p.A. R&S
2 ITALIAN SITUATION : IMAGE OF CHEMISTRY Chemistry is not perceived today as sustainable for three reasons: It is pervasive, which is considered difficult to controll and viewed as a threat People does not use it directly, he does not see the benefits, but he is easily reached by negative news. Poor communication to the public that tends to display behaviours that are inconsistent highlighted by some newspapers at the expense of positive messages. We must take the road of innovation for improving sustainability of products, processes and technologies. In this sense REACh Regulation must be seen as an opportunity.
3 CHEMICAL INDUSTRY SUSTAINABILITY We have to work on the three pilars of economic development, environmental protection and social development: PLANET PEOPLE PROFIT
4 PLANET EMISSION REDUCTION WASTE MANAGEMENT ENERGY EFFICIENCY
6 EMISSION REDUCTIONS novembre 2013 Reduction of gaseous emission through elimination of free monomers and VOC s in the polymers 1) Increasing reaction yield, with ultracatalysts 2) Vacuum stripping and biological treatment of stripping waters 3) Producing high performances polymers film forming at low temperatures without use of VOC s containing coalescents. 4) Elimination of formaldehyde using alternative catalysts and crosslinking systems
7 EMISSION REDUCTIONS Elimination of polluted water : novembre ) Through chemical-physical and biological treatment. 2) Limiting cleaning water by using ultra high pressure pump to wash off reactors. 3) Recovering end cycle cleaning waters in the same product.
8 EMISSION REDUCTIONS novembre 2013 LIMITING THE USE OF RAW MATERIALS ROAD TRANSPORT IN FAVOUR OF RAIL CONVEYANCE:
9 % WASTE MANAGEMENT novembre 2013 Optimized processes designed to reduce environmental impact of all wastes : liquid, solid and gaseous 3 2,5 2 1,5 % tons wastes on tons produced 1 0,
10 WASTE MANAGEMENT novembre 2013 Packaging : preference of bulk shipment and reusable containers over disposable packaging
11 ENERGY EFFICIENCY novembre 2013 Cogenerator plant in Villadossola site REDUCTION OF: 1120 tons/year of fuel 2700 tons/year of CO 2 emission
12 ENERGY EFFICIENCY novembre 2013 Replacing cooling units containing substances that deplete Ozone
13 ENERGY EFFICIENCY novembre 2013 Reduction of energy consumption through use of alternative lighting at higher yield REDUCTION OF : 180 tons/year of fuel 400 tons/year of CO 2 emission
14 PEOPLE SAFETY TRAINING RELATIONSHIP
15 SAFETY Accident prevention of employees and workers inside Villadossola plant Number of accidents for million hours worked
16 SAFETY Prevention for health and safety protection of the people living around the plant.
17 Customer health vision by complying REACH Directive Intensive research program to eliminate SVHC substances APEO Phtalates Heavy Metals(Co) Boron derivatives SAFETY
18 hours Number of employees novembre 2013 TRAINING Internal and external training on company objectives and results obtained Training Villadossola site FORMAZIONE PERSONALE
19 TRAINING Increasing attention to human capital and internal careers Education situation in Vinavil. Technical degree 72% University degree 11% Others 17%
20 RELATIONSHIP Clear and collaborative relationship with Unions to increase confidence and awareness in the common goal to obtain the highest production output in the safer way.
21 RELATIONSHIP Strong link with the people living around the plant and commitment to show what happens within the Company.
22 PROFIT Transparent dialogue with selected suppliers on the basis of competitiveness of price and service. More raw material qualified for the same application
23 PROFIT Knowledge of customer needs and cooperation to meet their expectations through sales offices and a strong Technical Assistance, before and after sale.
24 A FEW EXAMPLES OF INNOVATION STRATEGY AND TRENDS TOWARD SUSTAINABLE CHEMISTRY Raw materials from naturale resources (Bioethanol) Alternative feedstock Recovery of used tyres Natural rubber from alternative crops
25 BIOETHANOL Bioethanol from lignocellulosic biomass that does not compete with the food chain to reduce CO2 emissions to comply with the EU Fuel Directive (6% reduction of greenhouse gases from 2010 to 2020) Positive energy balance: energy yield up up to 10 times that consumed. Possibility to produce alcohol-based chemicals diversifying stages downstream.
26 Renewable resources (Celluolosic material ) ETHYLENE VAE PolymersVVA EAE VINAVIL ADHESIVE RANGE ETHANOL VINYL ACETATE PVA Polym ers PVOHc
27 RECOVERY OF USED TYRES In order to decrease the dependance from natural rubber Design a methodology of depolymerization that allows to obtain a polymer similar to the original (by the use of microwaves, ultrasounds, electron beam or sulfurextractor microorganisms) Functionalize the polymer obtained in high percentage to make it compatible with the natural product. Make compatibility studies for mixing it with natural rubber.
28 ALTERNATIVE FEEDSTOCKS Hydrogen as an energy carrier from renewable resources. Excess glycerol from biodiesel can be converted into HCOOH to be fed directly or indirectly (after decomposition to H2 and CO2) to fuel cells to produce energy. Studies are still needed to optimize the reforming of glycerol in the gas or liquid phase to maximise the yield in HCOOH and to promote the decomposition to CO2 + H2 and minimize the deydration reaction to CO +H2O.
29 NATURAL RUBBER FROM ALTERNATIVE CROPS Half of the rubber production (about 23 million tons) is of natural origin, it comes from a tree called: Hevea Brasiliens. The main production comes from areas of South Asia where political risks and infections are present. With the actual output the expected deficit for 2014 is 1,5/3 million tons. Alternative cultures are going to be studied : Guayule (that can grow in semi arid hot clymate, it was already cultivated in the 30 s). Dandelion (tarasacco) that can grow in cold weather areas. Studies on agronomic and genetic enhancement are in progress to maximize yield, analytical studies to isolate and recover by-products like Inuline are going to be completed.
30 THE CHALLENGE OF SUSTAINABILITY Can Sustainability be a factor of competitiveness? YES, provided that the characteristics of sustainability are: Acknowledged by the market as a real value Made aware to consumers and industrial users through information and education strategies. Supported by specific legislation programs Considered as custom barriers against the entry of products with substainability characteristics not complying with the new European Standards, like the REACh directive
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