Specialty Carbons for Polymer Compounds
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Polymers SPECIALTY CARBONS FOR POLYMER COMPOUNDS ENSACO® TIMCAL Carbon Black TIMREX® TIMCAL Graphite TIMREX® TIMCAL Coke TIMREX® TIMCAL Dispersion imerys-graphite-and-carbon.com Imerys Graphite & Carbon WHO ARE WE? IMERYS Graphite & Carbon has a strong tradition and history in carbon manufactur- ing. Its first manufacturing operation was founded in 1908. Today, IMERYS Graphite & Carbon facilities produce and market a large variety of synthetic and natural graphite powders, conductive carbon blacks and water-based dispersions of consistent high quality. Adhering to a philosophy of Total Quality Management and continuous process improve- ment, all Imerys Graphite & Carbon manufacturing plants comply with ISO 9001:2008. IMERYS Graphite & Carbon is committed to produce highly specialized graphite and carbon materials for today’s and tomorrow’s customers needs. IMERYS Graphite & Carbon belongs to IMERYS, the world leader in mineral-based specialties for industry. WHERE ARE With headquarters located in Switzerland, IMERYS Graphite & Carbon has an inter- WE LOCATED? national presence with production facilities and commercial offices located in key markets around the globe. The Group’s industrial and commercial activities are man- aged by an experienced multinational team of more than 430 employees from many countries on three continents. For the updated list of commercial offices and distributors please visit www.imerys-graphite-and-carbon.com Lac-des-Îles, Canada HQ Bodio, Switzerland Changzhou, China Mining, purification and sieving of Graphitization and processing of Manufacturing of descaling agents natural graphite flakes synthetic graphite, manufacturing of and processing of natural graphite water-based dispersions, processing of natural graphite and coke, and manufacturing and processing of silicon carbide Terrebonne, Canada Willebroek, Belgium Fuji, Japan Exfoliation of natural graphite, Manufacturing and processing of Manufacturing of water-based processing of natural and synthetic conductive carbon black dispersions graphite WHAT IS OUR MISSION? To promote our economic, social and cultural advance- ment with enthusiasm, efficiency and dynamism by of- fering value, reliability and quality to ensure the lasting success of our customers. WHAT IS OUR VISION? To be the worldwide leader and to be recognized as the reference for innovative capability in the field of carbon powder-based solutions. 2 Contents ENSACO® conductive carbon black TIMREX® graphite and coke Specialty carbons for polymer compounds THE PRODUCTS • Introduction to ENSACO® conductive carbon black p. 4 • Introduction to TIMREX® graphite and coke p. 5 • ENSACO® conductive carbon black for polymer compounds p. 6 • TIMREX® graphite and coke for polymer compounds p. 8 TYPICAL APPLICATIONS FOR ENSACO® CONDUCTIVE CARBON BLACK • Electrically conductive plastics p. 10 • Rubber p. 14 • Power cables and accessories p. 17 TYPICAL APPLICATIONS FOR TIMREX® GRAPHITE AND COKE • Self lubricating polymers p. 18 • Filled PTFE p. 20 • Thermally conductive polymers p. 22 3 Introduction to ENSACO® conductive carbon black Conductive carbon blacks are carbon blacks with high to very high stucture (or void volume) allowing the retention of a carbon network at low to very low filler content. The void volume can originate from the interstices between the carbon black particles, due to their complex arrangement, and from the porosity. THE PRODUCTS HOW ENSACO® The Imerys Graphite & Carbon carbon black process has been developed around 1980 CONDUCTIVE CARBON and is commercially exploited since 1982. The plant uses most modern technology. BLACKS ARE PRODUCED The process is based on partial oil oxidation of carbochemical and petrochemical origin. The major difference with other partial combustion carbon black technologies lies in the aerodynamic and thermodynamic conditions: • low velocity; • no quench; • no additives. This leads to a material with no or nearly no sieve residue on the 325 mesh sieve and allows the highest possible purity. The granulation process has been developed to achieve an homogeneously consist- ent product maintaining an outstanding dispersibility. It is in fact a free-flowing soft flake characterised by a homogeneous and very low crushing strength that guaran- tees the absence of bigger and harder agglomerates. The process enables the production of easily dispersible low surface area conductive carbon blacks as well as very high surface area conductive carbon blacks. The unique combination of high structure and low surface area also contributes to give outstand- ing dispersibility and smooth surface finish. The low surface area materials show a chain-like structure comparable to acetylene black. The very high surface area materi- als belong to the extra conductive (EC) family. Although ENSACO® carbon blacks are slightly more graphitic than furnace blacks, they are quite close to the latter ones as far as reinforcement is concerned. ENSACO® carbon blacks combine to a certain extent both the properties of furnace and acetylene black, reaching the optimal compromise. 100 nm TEM picture of ENSACO® 250G carbon black showing STM picture of the surface of ENSACO® 250G carbon the high level of aggregation. black 5x5 nm. By courtesy of University of Louvain (Louvain-La-Neuve) By courtesy Prof. Donnet - Mulhouse 100 nm SEM picture of ENSACO® 250G carbon black illustrating the high void volume. By courtesy of University of Louvain (Louvain-La-Neuve) 4 Introduction to TIMREX® graphite and coke Graphite finds wide application thanks to its favourable combination of properties such as: • low friction, chemical inertness and absence of inherent abrasiveness; • high thermal conductivity, thermal stability and electrical conductivity; • film forming ability on metal surfaces; THE PRODUCTS • relatively inoffensive nature of both powders and products of combustion. These properties are a consequence of the lamellar graphite structure and the ani- sotropic nature of chemical bonding between carbon atoms. In graphite, three sp2 hybrid orbitals (each containing one electron) are formed from the 2s and two of the 2p orbitals of each carbon atom and participate in covalent bonding with three sur- rounding carbon atoms in the graphite planes. The fourth electron is located in the remaining 2p orbital, which projects above and below the graphite plane, to form part of a polyaromatic π-system. Delocalisation of electrons in π-electron system is the reason of graphite’s high sta- bility and electrical conductivity. Interlamellar bonding was once thought to be weak and mainly the result of Van der Waals forces, however, it now appears that interla- mellar bonding is reinforced by π-electron interactions. Graphite is therefore not in- trinsically a solid lubricant and requires the presence of adsorbed vapours to maintain low friction and wear. HOW TIMREX® TIMREX® PRIMARY SYNTHETIC GRAPHITE GRAPHITE AND TIMREX® primary synthetic graphite is produced in a unique highly controlled graphiti- COKE POWDERS ARE zation process which assures narrow specifications and unequalled consistent quality PRODUCED thanks to: monitoring of all production and processing stages, strict final inspection, and clearly defined development processes. TIMREX® primary synthetic graphite shows unique properties thanks to the combi- nation of a consistent purity, perfect crystalline structure and well defined texture. TIMREX® NATURAL FLAKE GRAPHITE TIMREX® natural flake graphite is produced in a wide range of products distinguished by particle size distribution, chemistry and carbon content. Imerys Graphite & Carbon mines the graphite from its own source in Lac-des-Îles, Quebec, Canada. Further pro- cessing can be done either in Lac-des-Îles or in our processing plant in Terrebonne, Quebec, Canada. All TIMREX® “naturals” are thoroughly controlled in our laborato- ries to ensure quality, consistency and total customer satisfaction. TIMREX® COKE TIMREX® petroleum coke is calcined at appropriate temperature with low ash and sulphur content, well defined texture and consistent particle size distribution. Lc c c/2 SEM picture of TIMREX® Graphite showing the c/2 = Interlayer distance perfect crystalline structure. Lc = Crystallite height 5 ENSACO® conductive carbon black for polymer compounds TYPICAL VALUES THE PRODUCTS PROPERTY TEST METHOD UNIT ENSACO® 150G ENSACO® 210G ENSACO® 250G ENSACO® 260G ENSACO® 350G Form Granules (*) Granules Granules (*) Granules Granules BET nitrogen surface area m2/g 50 55 65 70 770 ASTM D3037 OAN absorption ml/100 g 165 155 190 190 320 ASTM D2414 (1) COAN crushed OAN ml/100 g 95 95 104 104 270 ASTM D2414 (1) Pour density kg/m3 190 210 170 170 135 ASTM D1513 Moisture (as packed) % 0.1 0.1 0.1 0.1 1 max ASTM D1509 Sieve residue 325 mesh (45 μm) ppm 2 2 2 2 10 ASTM D1514 Ash content % 0.1 0.1 0.01 0.01 0.03 ASTM D1506 Volatile content % 0.2 max 0.2 max 0.2 max 0.2 max 0.3 max TIMCAL Method 02 (2) Sulphur content % 0.5 max 0.5 max 0.02 0.02 0.02 ASTM D1619 Toluene extract % 0.1 max 0.1 max 0.1 max 0.1 max 0.1 max ASTM D4527 pH 8–11 8–11 8–11 8–11 8–11 ASTM D1512 Volume resistivity Ohm.cm 2000 max (3) 500 max (3) 10 max (3) 5 max (3) 20 max (4) TIMCAL Method 11 (3) (4) (1) Spring: 0.9 lbs/inch; 10 g of carbon black (2) Weight loss during heating between 105 and 950°C (3) 25% carbon black in HDPE Finathene 47100 (4) 15% carbon black in HDPE Finathene 47100 (*) ENSACO® 150 and ENSACO® 250 are also available in powder form. 6 TYPICAL EFFECTS ON POLYMER COMPOUNDS THE PRODUCTS PROPERTY ENSACO® 150G ENSACO® 210G ENSACO® 250G ENSACO® 260G ENSACO® 350G Form Granules (*) Granules Granules (*) Granules Granules BET nitrogen surface area 50 55 65 70 770 (m2/g) OAN oil absorption 165 155 190 190 320 (ml/100 g) Conductivity Dispersibility Purity Water absorption very low very low very low very low high Surface smoothness Electrical/mechanical properties balance Resistance to shear MRG Comments to Easy strippable (mechanical All polymers application domains insulation shields rubber goods) excellent very good good quite good difficult (*) ENSACO® 150 and ENSACO® 250 are also available in powder form.