CARE National Conference: Market Development Update September 1, 2021
CARE National Conference held on September 1, 2021, showcased the progress in market development initiatives. The update included information on nonwoven projects by the Nonwovens Institute and Verdex Technologies, PET nonwoven initiatives funded by CARE grants, and project synopses evaluating various PET sample combinations. The development work for commercializing PCR PET nonwovens and challenges faced were also highlighted.
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Presentation Transcript
CARE Market Development Update CARE National Conference September 1, 2021
Number of Grid Items: 100 100 Number of Active Projects: 48 CARE National Grid By the numbers Number of California Projects: 15 15
PET - Nonwoven Initiatives Missionary Work in Development and research Funded via CARE grants and CARE funds Two primary projects 3 years of progress: Objectives Grant Testing funds for initial proof of concept Phase 1 Development: Complete NWI Nonwovens Institute PCR Carpet PET Nonwovens do not exist today Phase 1: Develop technologies for Carpet PCR nonwovens Verdex Technologies Phase 2: Commercialization beginning Development work to commercialize PCR PET for nonwovens General CARE development funds for research & Development Phase 2: Work with Companies Companies to Commercialize
Project Synopsis All nonwoven equipment types evaluated and trialed All Spunbonded equipment technologies All Melt Blown Equipment technologies Dozens of PET sample combinations Evaluated From: Purest - 0% PP & 1% Ash To: Most Contaminated: 15% PP & 5% Ash With and Without Compatibilizers Over 100 Combinations
Phase 1 Biax Meltblown Process Research & Development What worked Nonwoven web blown from orifices, directly onto a Web Carrier Requires some filtration Most Contaminated PCR PET 15% PP & 5% Ash Most widely available PET PCR Chemical Compatibilization 3% level to homogenize PP & PET
Phase 2 Commercialization Pursue Markets Using Biax Nonwovens Insulation Materials Oil Absorbent Products Filtration Media Geotextiles Pursue Companies Using Biax Process Companies Using biax Process Identified Biax process very Widely used.
Challenges: PCR PET Commercialization Established Competing Products. Acceptability of Recycled materials. Cost Incentives must be Attractive Develop Robust & Accurate Cost model Market Sustainability Story
Phase 2 Progress Primary Contact: Jeff Moore Large Assortment Automotive Products Initial Contact Initiated Discussions to follow GDC Inc. Companies Producing BIAX Products Primary Contact: Chris Miller Acoustical & Thermal Insulation Products Initial Contact Initiated Discussions to Follow Aim Fiber Products Meltblown/Spunbonded Equipment Produce products for all industries https://www.biax-fiberfilm.com/ Initial discussions Forthcoming Biax Fiberfilm Corporation https://www.biax-fiberfilm.com/
Phase 2 Additional Planned Activities Encourage Director of NWI for a more aggressive approach to introduce the results of CARE work to additional Companies. NWI has been very slow with these introductions. CARE will then make direct contact with additional companies to discuss potential options for utilizing PCR PET carpet fibers in nonwovens.
NWI Board recently Voted to make Sustainability a significant priority for their Activities NWI to form Focus Group with member Companies to discuss their interest and define a Road Map for Recycling and adding value to Recycled Materials. Signed a collaborative agreement with the first company to develop melt film fibrillation and will be setting up a small pilot line to test new materials. NWI: Other Activities Related to PCR Will focus significantly on compatibilizers and other polymer to polymer blend approaches. CARE will follow these efforts for any additional opportunities
Verdex proprietary Nozzle Technology makes Non- woven fibers into webs. Suited for Contaminated Polymers with since it does not depend on small orifice holes to make fibers. Verdex Process Suited for degraded Polymers such as PCR PET fibers with low fiber strength which ordinarily would not be able to be spun. Quick Overview Nozzle creates Aerodynamic Entanglement during web formation.
Covid 19 delayed project 9 months & Atl anta joint Venture disbanded. Moved Operations to Richmond Va. Building lease Obtained, New Funding Obtained Pilot Plant Equipment ordered. 90 days for delivery. Ability to make 25" rolls and webs. Verdex Development Timeline Produce 2 types of webs: Axi-Symmetric & Functionalized webs using Verdex Nozzle Technology Quick Overview Plan to make final wide webs with CARE NWI type material. Verdex doing their own marketing to push CARE products to market from their own member companies
Operational In Minnesota Plant. Processing Post Consumer PET Continuing to Expand California Carpet fiber Supply Rise Composite Technologies Active in Promoting EPR Legislation in several States Expansion of PCR fibers is likely in future
ACR1 in Arizona Continures to be operational ACR2 (woodlands Ca.) partially operational Aquafil California Adequate Nylon supply is Challenge Received CARE Grant for PCR Expansion: Baler and Opening system for Dry processing additional PCR capacity
One of Californias PC4 Success Stories. Unique Oil absorbent Product Called Absorbs Well PC4 Oil Absorbent product (Absorbs Well) Safe Path Products California Moved into new Building Process appears to be running relatively well 30 Ace Hardware Stores, Several True Value Locations. New potential with California DOT and Cal Trans.
Key Partner and Supplier to Eastman PET Carbon Renewal Process. New CARE Processing Grant Received for new Tile Processing technology Circular Polymers California Tile processing in Pilot plant stage Validation phases. Working primarily with PU (Polyurethane) backing systems. Goal to recover face fiber and Some backing components Goal to recover face fiber and backing components
One of the Original PET Depoly. Systems Trialed by CARE. Held promise for PCR PET Company accused of Fraud by Short Seller Hindengurg Group. Company reputation took hit Loop Industries Disappointing. No Carpet Activity at this point South Carolina Depoly. Plant Cancelled and is not forecasted to be built in the future
New Recent Addition. Initial production phases Using Sellers Shearing Machine popular in the active shearing days. Apex New Addition How does Shearing Make sense Economically? Not economically viable in the past. 80% carpet loss in Carcass Depending on fiber, may make Economic sense with California Carpet and California Subsidies and low landfill costs.
Chemical Recycling Technology Carbon Renewal and Methanolysis. Update from Jaclyn Shuman of Eastman Chemicals Eastman Chemical Key CARE PCR End Use partner Volume expected to increase as technologies are deployed
Potential Additional Testing on PC4 Areas of Investigation Include: Cleaning, Temperature treatments, Etc. to expand safe use of PC4 UC Davis California Discussions pending for potential new work
Mohawk & Shaw Regional Distribution Centers Pilot System in Fontana for Mohawk. Shaw program began in July 2021. RDC Take Back Program California Servicing as drop off site for old carpet for people picking up new carpet.
Contiunes to offer high potential for PET conversion to Polyols Currently Processing PI PET. Actively looking for High Purity PCR PET as raw material feed Arropol High Purity PCR PET & Low costs are extremely incompatible. PI PET extremely inexpensive. Odds not good for success
Prof. Kunigal shivakumar. Director of Center. North Carolina A&T. Product research for PET Outlets. Center of Composite Materials Research New Addition Asked for funding. Program & Details are being Vetted. Samples being sent
Located in Netherlands. Josse Kunst: Founder & Owner. Formerly of DSM/Niaga development partner for 100% PET carpet with Mohawk Molecular Recycling of PET, Nylon 6, and PLA Molecular Recycling. Kiduara Version of Depolymerization. Kiduara New Addition Pilot plant in Operation. Scaling up to 2.5 kiloton capacity (5,625,000 lbs.) per Annum. Following Progress Closely as one new Chemical recycling systems for PCR Plant scale expected completion at end of 2023.
Aim Fiber Products: Nonwoven Market Target: NWI Project GCC Corporation: Nonwoven Market Target: NWI Project Nonwoven Commercial Development New Additions Biax Fiberfilm Corporation: Nonwoven Target: NWI Project Other Nonwoven Commerical Targets: Verdex Confidential.
Intensity Increasing weekly. Sustainability, Closed Loop, Circularity, Ocean plastics, Brand Pressures: All play some role in pressure to close the loop. List of Entrants getting longer: Eastman, Shell, Pure Cycle, Loop, Kiduara, AmberCycle, Lyondell Basel Chemical Recycling Established Players such as Aquafil for Nylon 6. Other Chemical Recycling initiatives forming rapidly. Many systems in Pilot Plant Stages
Business has accelerated. Moved to another facility. Morphed into different company. No ties with Brazil Miura Board Well Funded by new Owner. Engineering 2 new full Scale lines utilizing new Proces technology Concentrating on Heavy Industrial Applications. Some boards are 6 inches thick PCC Carpet is still part of the Recipe.
