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Description
As a result of the project, BIOLARS plans to develop innovative alkyd eco-emulsions and on the basis of them create a ready-made eco-varnish and paint material with significantly reduced CO2 emissions.
Alkyd resins are polyesters (condensation products of polyols and polyfunctional acids) modified from vegetable oils or free fatty acids. Thus, BIOLARS intends to synthesize this type of binder, which is based on renewable natural resources, which allows to create paints with reduced carbon dioxide emissions.
By emulsifying such polymers in water, a wide range of environmentally friendly materials can be formed in the presence of suitable surfactants. The economic potential is not only for finished paints and varnishes, but also for alkyd emulsions themselves as semi-finished products, offering them to paint and varnish manufacturers in the EU market.
Summary of project results
The project conducted by the project promoter is a significant step towards the production of more environmentally friendly and sustainable coating products.
The main goal of project was development of innovative biobased polymer emulsions that could be used for a production of environmentally friendly paint products. Historically, the company has significant experience in synthesising and applying alkyd polymers. Biolar specialists focused on developing, researching, and implementing waterborne alkyd emulsions to develop ready-made varnish and paint materials for various market segments. The main priority is universal paints, anticorrosive protective paints, and road marking materials. Furthermore, vegetable oils and fatty acids are used to obtain alkyd polymers, with a material content exceeding 60%. These bioproducts are formed in plants by consuming atmospheric carbon dioxide during the process of photosynthesis. Thus, the use of water-based alkyd emulsions not only reduces emissions of petroleum products into the air but also in a way reduces the entry of CO2 into the atmosphere. Consequently, such materials are more sustainable compared to, for example, water acrylic paints, where the polymer component is produced from petroleum-derived chemicals.
A tailored emulsion production process that allows us to use existing intermedia product AM60 as raw material as well as use existing production line was developed. It means that no investment for new production lines is needed in order to start industrial scale production. As a result, we produced a full industrial-scale batch - more than 600 kg- of biobased polymer emulsion without any change in the production line. Is also has more than 50% lower carbon footprint in comparison to conventional alkyd resin. Thanks to the implemented project, special alkyd resins AT80 were synthesized, on the basis of which two modified alkyd emulsions were developed – ATU56w45 and ATU52w45. ATU56w45 is an emulsion suitable for the production of universal paints. It is currently in the active pilot batch testing phase. ATU52w45 is a modified alkyd emulsion with increased hardness and abrasion resistance, which could be used in the production of road marking materials. Two new products have been created – universal water-based alkyd paint "Aqualux" and water-based anticorrosive paint "Laraprim Aqua." Both products have already been registered as trademarks in Latvia. Project has created a strong base of knowledge and practical experience in biobased polymer emulsion manufacturing. Fully developed alkyd emulsification technology allows Biolar to ensure the local market with environmentally friendly coatings in the near future. Developed modified alkyd emulsions open the possibility of transferring most conventional Biolar solvent-based products to water-based variations.