Performance Comparison of Mineral Filled Olefins Imerys Performance Additives, North America Maz Bolourchi Senior Manager, Polymer Applications OutlineTable of contents IMERYS Talc Minerals in Plastics/Automotive Talc, Mica & Wollastonite Performances against Chopped Glass Fiber Mica Screening Approach & Objectives Findings Trends/Relationships Wollastonite Case Studies Performance Comparison Conclusions 2 2017 Polyolefin Conference North America IMERYS – Leading Global Supplier of Performance Minerals for Plastics 2015 Sales €€€4,087€4,087 million Energy Solutions & Filtration & High Resistance Ceramic Materials Specialties Performance Additives Minerals Talc, Mica & Wollastonite 3 2017 Polyolefin Conference North America Imerys, North America Leading supplier of mineral products Yellowstone, MT Argonaut, VT Penhorwood, ONT in North America: 3 Talc, 2 Wollastonite & 2 Mica mines 9 processing (milling, beneficiation, etc.) operations Large portfolio of: Mica Mines, Boucherville QC Kings Mountain, NC ‒ Purity, Particle Size & Morphology Laboratory in San Jose, CA. ‒Processing ‒Testing ‒Analytical Wollastonite Mine, Oakhill, NY ‒Product Stewardship 4 2017 Polyolefin Conference North America Talc Properties & Structure Hydrated magnesium silicate: Exterior Hydroxyl group Mg 3Si 4O10 (OH) 2 10 Å Naturally occurring Exterior SiO Layers Softest mineral; 1 on Mohs scale 2 Platy crystalline structure Hydrophobic exterior; relatively inert Delaminating Contains other minerals/impurities Macro-crystalline Micro-crystalline (Chlorite, Dolomite, Magnesite, etc.) Talc Parameters: Purity Morphology Particle Size 5 2017 Polyolefin Conference North America Mica Properties & Structure • Chemistry/Type • Phlogopite & Muscovite • Similar to Talc • Si substitution with Al • Interlayer ionic bond • Ionic interlayer interaction; more difficult to delaminate • Mohs hardness of 3 • Morphology - Platy • Delamination possible but more difficult than talc. • Surface modification possible 6 2017 Polyolefin Conference North America Wollastonite Properties & Structure Chemistry Calcium Silicate (CaSiO 3) Naturally occurring white mineral Morphology: Acicular Mohs hardness = 4.5 Surface modification possible Si – blue, O – red, Ca - yellow 7 2017 Polyolefin Conference North America Processing Optimization (Compounding) Critical processing parameters include – Extruder type & L/D – Screw design & RPM – Throughput; SME – Feed location; side or upstream – Processing temperature Aggressive Mild – Resin & rheology – Screen Pack Distributive Mixi ng Distributive & Dispersive Mixi ng Dispersive Mixing Processing parameters critical in achieving optimal end performance 8 2017 Polyolefin Conference North America Processing Optimization: Various Minerals Effect of Mineral & Process on Stiffness/Impact Balance Composition: 80% Hifax CA 387A (Reactor TPO), 20% Mineral by wt. 3500 Neat Resin 3000 CaCO3 - Supercoat 2500 Mica 150S 2000 Mica 325K 1500 HAR - H92 1000 FlexModulus, MPa Nyglos 4W 500 10992 Chopped Glass 0 Fiber 0.0 10.0 20.0 30.0 40.0 50.0 60.0 Notched Izod, kJ/m2 Melt compound on 25mm co-rotating/intermeshing TSE (46:1, L/D ) ISO test specimen prepared on Arburg 66T Injection molding 2017 Polyolefin Conference North America Processing Optimization: Various Minerals Effect of Process on Morphology and Stiffness 1742 MPa 2790 MPa 2977 MPa Chopped Glass Fiber Neat 1400 MPa 2050 MPa Nyglos 4W 1450 MPa 1800 MPa Mica 150S 10 2017 Polyolefin Conference North America Results: Performance Comparison 4000 3000 2977 1989 1766 2000 1743 1621 1488 936 1000 788 0 Flex Modulus, Modulus, Flex MPa Base Resin HAR H92 HAR Coat GCC Mica,150S Nyglos 4W Nyglos Neat Resin Neat Glass Fiber Glass Jetfine 3CW Jetfine Mica, 325HK Mica, CaCO3, Super CaCO3, Mica 80 Talc 60 54 57 55.1 49 Wollastonite 45 Chopped GF 40 25 20 20 11 0 Notched Izod, kJ/m2 Izod, Notched HAR H92 Coat Mica,150S Nyglos 4W Neat Resin Glass Fiber Jetfine 3CW Mica, 325HK CaCO3,Super Composition: 80% Hifax CA 387A (Reactor TPO), 20% Mineral by wt. 11 2017 Polyolefin Conference North America Results: Performance Comparison Melt Flow, 230C/2.16kg 18.0 17.7 Base Resin 20.0 15.4 13.3 12.9 11.8 12.7 GCC 10.0 5.3 Mica g/10min Talc 0.0 Wollastonite Chopped GF HAR H92 Coat Mica,150S Nyglos 4W Nyglos Neat Neat Resin Glass Glass Fiber Jetfine Jetfine 3CW Mica, 325HK CaCO3, CaCO3, Super Composition: 80% Hifax CA 387A (Reactor TPO), 20% Mineral by wt. Findings Superior attributes with Chopped GF in Modulus (Strength, HDT and Shrinkage) but inferior in other properties: Impact retention (both Notched Izod & Multiaxial Impact) Flow Anisotropic Warpage Surface finish/aesthetic Equipment wear Balance of Properties often Critical 12 2017 Polyolefin Conference North America Screening Objectives/Approach Objectives Evaluate commercial Talc, Mica & Wollastonite grades in PP Copolymer at 20% by wt. loading Identify performance space, trends/relationships Approach Melt compound via 25mm co-rotating/intermeshing TSE (46:1, L/D) Screw Design Profile at 15kg/hr & 200/450 screw RPM, Atmospheric Vent Materials Resin: Braskem PP Copolymer # T16200Q4 Minerals: Talc (15 grades), Mica (10 grades) and Wollastonite (4 grades - neat & surface treated) 13 2017 Polyolefin Conference North America 14 2 Baseline BraskemBaseline FexCopolymer PP modulus: Composition:Braskem 20% Mineral & w Copolymer by PP Notched Izod, kJ/m Flex Modulus, MPa Test Results -Test Talc 1200 1600 2000 2400 25 50 0 33.0 2191 HAR T84 2 µm HAR T84 2 µm 27.2 2119 HAR H92 2 µm HAR H92 2 µm 1984 49.9 Jetfine 3CC 0.8 µm Jetfine 3CC 0.8 µm Macro-Crystalline Talc Macro-Crystalline 1931 39.4 JetFil 700C 1.5 µm JetFil 700C 1.5 µm 1884 31.7 JetFil 625C 2.2 µm JetFil 625C 2.2 µm 850 850 Mpa, 1628 16.6 JetFil T590 4.5 µm JetFil T590 4.5 µm 1590 11.6 JetFil T290 8.5 µm JetFil T290 8.5 µm Notched – Notched Izod t. 2017 Polyolefin Conference Polyolefin 2017 1957 38.2 Jetfine 3CW 1.1 µm Jetfine 3CW 1.1 µm 1938 No Break Break No 32.4 JetWhite 7C 2 µm JetWhite 7C 2 µm 1927 28.1 JetWhite 6C 2.5 µm JetWhite 6C 2.5 µm 1774 21.0 North America North JetWhite 5C 3.9 µm JetWhite 5C 3.9 µm Micro-Crystalline Talc Micro-Crystalline 1797 39.1 N 674-DT2 1.9 µm N 674-DT2 1.9 µm 1721 24.6 Nicron 554 3.3 µm Nicron 554 3.3 µm 1642 19.9 Nicron 403 4.8 µm Nicron 403 4.8 µm Silverline 1581 17.0 12 µm Silverline 002 12 µm 002 Test Results - Talc Multiaxial Impact at 0 ºC, 4.4 m/s (ISO 6603) 24.0 Impact Rating Total Energy 20.2 18.2 18.0 15.8 16.4 14.5 15.2 14.9 14.1 13.3 13.7 12.6 11.8 12.0 10.4 9.9 7.3 6.0 2.8 2.8 2.7 2.0 2.0 1.7 1.6 1.6 1.5 1.5 1.3 1.3 1.2 1.2 0.6 0.0 Impact Rating & Total Energy (J) (J) Energy Total & Rating Impact HAR T84 HAR HAR H92 HAR N674DT2 Jetfil 625C Jetfil JetFil T590 JetFil T290 JetFil JetFil 700C JetFil Nicron 403 Nicron Jetfine 3CC Jetfine Nicron 554 Nicron JetWhite 7C JetWhite 6C JetWhite 5C JetWhite JetFine 3CW JetFine Silverline 002 Silverline Impact Rating 3 – Extended Ductile 2 – Ductile Finer d50 psd = Superior Impact Retension 1 – Semi - Ductile 0 – Brittle Composition: Braskem PP Copolymer & 20% Mineral by wt. 15 2017 Polyolefin Conference North America Test Results - Talc Heat Deflection Temperature at 0.45 psi 130 124 124 121 120 118 120 118 116 114 113 113 113 112 112 112 110 107 Temeprature (C) Temeprature 100 90 002 HAR T84 HAR HAR H92 HAR Silverline N 674-DT2 N JetFil T590 JetFil T290 JetFil JetFil 700C JetFil 625C JetFil Nicron 403 Nicron Jetfine 3CC Jetfine Nicron 554 Nicron JetWhite 7C JetWhite 6C JetWhite 5C JetWhite Jetfine 3CW Jetfine Composition: Braskem PP Copolymer & 20% Mineral by wt. 16 2017 Polyolefin Conference North America Test Results - Talc Brightness 100 79.2 76.6 74.9 76.3 74.3 80 67.8 63.6 65.1 67.0 66.6 65.2 66.5 66.4 61.4 58.0 60 CIE, L* CIE, 40 20 HAR T84 HAR H92 N 674-DT2 JetFil JetFil T590 JetFil T290 JetFil JetFil 700C JetFil 625C Nicron Nicron 403 Jetfine Jetfine 3CC Nicron Nicron 554 JetWhite 7C JetWhite 6C JetWhite 5C Jetfine 3CW Silverline 002 Silverline Composition: Braskem PP Copolymer & 20% Mineral High Brightness Grades Talc Findings HAR – Best reinforcing talc Particle size: ↓ Particle size results in ↑ Modulus & ↑ Impact retention; finer particles are generally better Purity influences Brightness (↑ Purity ↑ Brightness) Macro-crystalline generally superior in mechanicals vs. Micro-crystalline 17 2017 Polyolefin Conference North America 18 Baseline BraskemBaseline FexCopolymer PP modulus: Composition:Braskem 20% Mineral & Copolymer PP Test Results -Test Mica Notched Izod, kJ/m2 Flex Modulus, MPa 1200 1600 2000 2400 25.0 50.0 0.0 1665 10.4 C-3000 25 µm C-3000 25 µm Muscovite 1711 9.8 9.8 WG 325 35 µm WG 325 35 µm 1777 4K 45 µm 4K 45 µm 850 850 Mpa, High Brightness Brightness High Muscovite 1807 10.4 Notched – Notched Izod 325-G 26 µm 325-G 26 µm 1855 11.5 2017 Polyolefin Conference Polyolefin 2017 500-C 32 µm 500-C 32 µm No Break Break No 1991 10.1 250-L 48 µm 250-L 48 µm North America North 1748 12.8 325- HK 25 µm 325- HK 25 µm 1882 12.5 Phlogopite 80-SF 45 µm 80-SF 45 µm 1935 11.5 200-S 55 µm 200-S 55 µm 2176 12.0 150-S 150 µm 150-S 150 µm Test Results - Mica Multiaxial Impact at 0 ºC , 4.4 m/s (ISO 6603) 8.0 7.0 Impact Rating Total Energy 6.3 6.0 5.7 5.3 4.8 5.0 4.7 4.2 4.2 4.0 3.5 3.1 3.0 2.2 2.3 2.0 1.0 0.7 0.3 0.0 0.0 0.0 0.0 0.0 0.1 0.2 0.2 0.2 Impact Rating & Total Energy (J) Energy & Total Rating Impact 0.0 4K 250-L 500-C 325-G C-3000 WG 325 WG Impact Rating Suzorite 150-S Suzorite Suzorite 80-SF Suzorite 80-SF Suzorite 3 – Extended Ductile 200-S Suzorite 2 – Ductile HK 325- Suzorite