Wind energy blade manufacturers go through a LOT of resin. Large volumes of epoxy resins and hardeners typically require numerous containers, substantial handling, and significant residual waste. Hexion Hexi-Bag™ aims to help blade manufacturers address these challenges through the use of a large-volume packaging system.

Thanks to a 900-1,000 liter capacity in a single Hexi-bag (that’s five times the volume of a standard barrel), Hexi-bag can result in residual resin of less than 1%, versus 5-10% in traditional packaging. Larger Hexi-bag packaging can also reduce handling, damaged drums, and storage requirements. This total logistics reduction can result in a savings of up to 80%.

Increasingly stringent VOC regulations driven by air quality concerns demand creative measures. That’s why Hexion scientists developed the NextGen Epoxy™ Waterborne System – capable of less than 100 g/L VOC content in concrete and metal applications.

The key to the new system is a novel, water-soluble amine curing agent called EPIKURE™ Curing Agent 8530-W- 75. This solvent-free curing agent has a lower equivalent weight which means that formulators can use less curing agent to cure the same amount of epoxy resin. When combined with EPI-REZ™ Resin 7520-WD- 52, the curing agent can deliver lower VOC, a faster drying time, and superior corrosion resistance.

Hexion’s resin-coated proppants—proven in all major basins across North America—optimize well productivity to make the most of every well.

OilPlus™ proppants are field-proven in over 1,000 wells with one billion pounds pumped so far. Case studies of the Permian Basin and the Eagle Ford show Hexion’s advanced proppants have outperformed alternative products with a 49% increase in production over uncoated frac sand and a 28% increase in production over traditional resin-coated sand.

AquaBond™ proppants utilize a unique resin system that can reduce the production of formation water. In a recent Granite Wash case study, they were shown to reduced formation water production by 89% while increasing hydrocarbon production compared to traditional proppants.

Traditional epoxy products for composite interiors of aircraft, marine, rail and architectural applications require special additives to achieve the acceptable fire, smoke and toxicity (FST) properties needed to keep passengers safe in the event of a fire. The use of additives can add an element of uncertainty to the product performance, as they are not inherent in the chemistry.

Hexion has invented a new epoxy solution with FST properties built right into the molecular structure of the resin, without the need for additives. This is a true breakthrough in epoxy technology.

This new epoxy resin system—EPON™ FlameX Resin 9600 / EPIKURE™ FlameX Curing Agent 9700—enables manufacturers of aircraft components like interior panels, cargo holds, and seats to make fire-safe parts faster, thus reducing cost. Furthermore, the system is free of dangerous halogens, such as chloride, fluoride and bromide, that can form toxic and corrosive gases if caught on fire.

Building a lab that simulates an auto factory is a big investment. To do it, we partnered with the French Technological Research Institute of Materials, Metallurgy, and Processes (Institut de Recherche Technologique —Matériaux, Métallurgie et Procédés or IRT M2P). On the Fast Resin Transfer Molding (RTM) production platform in Porcelette France, we run trials generating net shape, glass fiber reinforced plastic (GFRP) structural parts of 1m². “Net shape” refers to parts that are completely finished after the molding process with no need for further machining.

Our successful, fully industrialized, automated production of around 100 large, structural parts in two minutes, part to part, proves the robustness of this process and of our EPIKOTE™ Resin System TRAC 06170. This cooperative demonstration should put to rest any doubts automotive OEMs have about adopting composites for mass-produced vehicles.

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At our newly expanded technology center in Edmonton, Alberta, Canada we have invested in a large project with Canadian government agency Alberta Innovates to accelerate the development of next-generation resin chemistries and engineered panel products—in which lignin and other bio-based raw materials replace phenol.

Plant-based lignins are some of the most abundant natural polymers on earth. They help form and support plant cell walls creating the strong cellular structure in wood.

The new technology center will accelerate Hexion’s ongoing focus on developing novel resin formulations designed specifically for the oriented strand board (OSB) market. The expanded center, which has broad technical capabilities, is designed to improve velocity in commercializing new adhesive solutions.

Our commitment to innovation and limitless imagination comes alive in the work our commercial and R&D teams are doing every day. For example, we recently partnered with John Warner to hold a bio- based summit where 50 Hexion chemists, engineers and innovators met in Rotterdam, Netherlands to explore how bio-based chemistry is changing the way we develop product solutions for our clients’ evolving needs – many times in an accelerated, cost-efficient manner – while reducing waste and operating in a sustainable manner.

The people at Hexion are enthusiastic supporters of the Responsible Care® initiative and are committed to best practices related to the sustainability and safety of our facilities around the globe. Our hard work paid off and in 2019 Hexion was recognized by the American Chemistry Council with the Waste Minimization, Energy Efficiency and Employee Health and Safety Awards.

The council recognized 19 U.S.-based Hexion facilities and three programs. Their achievements included major reductions in water and energy use and significant achievements in employee health and safety performance. In addition, many sites within Hexion’s global manufacturing network have achieved additional certifications including ISO 9001 (Quality Management) and 14001 (Environmental Management System).

Composites UK has recognized Hexion with a 2017 Health & Safety Award. The award is open to all UK composite industry suppliers, manufacturers, processors and OEMs. The industry association’s judges look for H&S programs and initiatives that produce quantifiable improvements and go beyond legal requirements.

Hexion received the award for developing a series of ULEF (ultra-low emitting formaldehyde, less than 0.1%) phenolic resins for the composite industry. Because these Cellobond™ brand resins contain one-tenth the free formaldehyde of previous systems, they can reduce emissions during composite manufacturing. Even better, these Cellobond™ brand resins also pass the EN45545-2 rail standard for FST (flame, smoke toxicity).

At Hexion we believe in the education and advocacy of a responsible chemistry. That’s why we have made product stewardship summaries available on our website, including the health and environmental considerations related to formaldehyde.

Facts we bring to the fore include how widespread formaldehyde is in nature as a byproduct of plant and animal metabolism as well as combustion; and how the average human actually generates about 1.5 ounces of formaldehyde each day.

We believe a well-informed public will result in sensible legislation and regulation.