Pacific Nano Products India, Pvt. Ltd. Innovative Synthesis of Synthetic Silicate Nano-Fibers and Super PCC

Transcription

1 Pacific Nano Products India, Pvt. Ltd. Innovative Synthesis of Synthetic Silicate Nano-Fibers and Super PCC March 23 rd, 2018 Dr. Vijay K. Mathur N.K. Agarwal Raghavendra Hebbar

2 Agenda 1. Technology, IP, and Products Super PCC Silicate Nano-Fibers 2. Applications Coatings Fine Paper 3. Summary 4. Conclusion

3 Technology & Products

4 To Reduce: Industry Needs ( US Agenda 2020) 1. Costs 2. Fiber Consumption 3. Water Usage 4. Power 5. Energy 6. Environmental Load

5 Process Innovation Patented Hydrothermal, High Pressure (HTHP) Process Synthesize Nano Materials

6 Products Innovation 1. Super Precipitated Calcium Carbonates 2. Silicate Nano-Fibers ( Fibrous Fillers )

7 Super PCC

8 Super PCC 1. Synthetic Super PCC Multiple Morphologies, Size, & Shapes 10 µm Aragonite Macro Rhombohedral Scalenohedral Nano Rhombohedral 100 nm

9 Advantages Super PCC 1. Higher Production Rate per Unit Volume 2. Lower % CO 2 Requirement 3. Controlled Crystal Growth / Crystal Geometry 4. Smaller Plant and Building Size

10 Silicate Nano-Fibers

11 Silicates 2. Synthetic Silicate Nano-Fibers Multiple Morphologies, Size, & Shapes Made of Calcium Silicate Hydrates Primary Secondary UHO Pulp Fiber

12 Advantages Silicates Lighter Low Bulk Density 12 lb/ft 3 Brighter Stronger 94 + ISO Brightness Silanol or OH-Si-HO Bonds Fiber Filler Bond Filler Filler Bond Low Abrasion < 1.0 mg/cm 2

13 Silanol Bonds Synthesis Silicates O H Si H Ca O H Silanol Bond Starting Ca O Si H O Silicate Nano-Fibers

14 Silanol Bonds Synthesis Silicates Cellulose C C C Water Out H C C O O O H Water Out H H Si Ca O H C C O O Cellulose C C H Silanol Bond Silicate Nano-Fibers Cellulose Cellulose Bond C Water Out

15 Mini Manufacturing Plant

16 Mini Manufacturing Plants Raw Materials Manufacturing Products SiO 2 Steam A: Silicate Production Slaked Lime Ca(OH) 2 Hydrothermal, High Pressure Vessel Silicate Nano-Fibers B: Super PCC Production Super PCC CO 2

17 Application of Silicates Nano-Fibers Coated Board Fine Paper US India Europe ( Fibrous Fillers ) and Super PCC

18 TiO 2 Control Unbleached Coated Board - Coating Blends Nano-Fibers TiO2, Calcined Clay, # 1 Clay # 2 Clay Top Coat Base Coat 65 % Super PCC 35 % Nano-TiSil 75 % Super PCC 25 % Nano-TiSil Base Sheet

19 IGT Pick Unbleached Coated Board - IGT Pick Higher Pick Strength Parts Nano-TiSIl 4 Parts TiO 2 Calcined Clay # 1 Clay Parts Nano-TiSIl 0 Part TiO 2 Aragonite Super PCC + 73%

20 ISO Brightness (%) Unbleached Coated Board - ISO Brightness Higher Brightness ± ± Parts Nano-TiSIl 4 Parts TiO 2 Calcined Clay # 1 Clay 4 Parts Nano-TiSIl 0 Part TiO 2 Aragonite Super PCC

21 Silicate Nano-Fibers for Fine Paper US Twin-Wire Integrated Trial Ash BW Control: PCC 17% 77 PCC & Silicate Nano-Fibers 17% / 5% 73 Goals Reduce Basis Weight Increase Filler Loading Reduce Cost

22 Xerocopy Paper Machine Trial - Bulk Higher Bulk Basis Weight (lb / 3000 ft 2 ) Control - 5.7% Bulk (cc/g) Control % % PCC 17.5 % PCC 17.5 % PCC 5 % Silicate 17.5 % PCC 5 % Silicate

23 RMS Stiffness (g*cm / 15 ) Xerocopy Paper Machine Trial - RMS Stiffness Higher Stiffness Basis Weight (lb / 3000 ft 2 ) Control - 5.7% Control % % PCC 17.5 % PCC 17.5 % PCC 17.5 % PCC 5 % Silicate 5 % Silicate

24 Silicate Nano-Fibers & Super PCC for Fine Paper Commercial Production Ash Control: GCC 17.5% Super PCC 19.5% Super PCC & Silicate Nano-Fibers 20% / 6% Goals Cost Reduction Increase Filler Loading Value Added Products

25 Ash Level (%) Bulk (cc/g) 70 gsm Commercial Production - Bulk Higher Bulk % % Control % % % Super PCC 17.5 % PCC 20.0 % Super PCC 6.0 % Silicate % PCC 19.5 % Super PCC 20.0 % Super PCC 6.0 % Silicate

26 Ash Level (%) MD Taber Stiffness (gcm/15 ) 70 gsm Commercial Production - MD Taber Stiffness Higher Stiffness % % % Control % % PCC 19.5 % Super PCC 20.0 % Super PCC 6.0 % Silicate % Super PCC 17.5 % PCC 20.0 % Super PCC 6.0 % Silicate

27 Ash Level (%) ISO Opacity (%) 70 gsm Commercial Production - Opacity Higher Opacity % Control % % PCC 19.5 % Super PCC 20.0 % Super PCC 6.0 % Silicate % Super PCC 17.5 % PCC 20.0 % Super PCC 6.0 % Silicate

28 Increase Filler Loading Silicate Nano-Fibers for Ultra High Ash Fine Paper Pilot Paper Trial Ash Control: GCC 15% Super PCC 25% Silicates Nano-Fibers 25% Super PCC & Silicate Nano-Fibers 22%/22% Goals Cost Reduction

29 Ash Level (%) Calendered Bulk (cc/g) Virgin Fiber Calendered Pilot Study - Bulk Higher Bulk % % Control Control % GCC 25 % Silicate 15 % PCC 25 % Silicate 0.8

30 Ash Level (%) Calendered L&W Stiffness (mn) Virgin Fiber Calendered Pilot Study - Stiffness Higher Stiffness % % Control Control % GCC 25 % Silicate % PCC 25 % Silicate

31 Summary

32 Silicate Nano-Fibers and Super PCC help meet Industry Needs to Reduce: 1. Costs 2. Fiber Consumption 3. Water Usage 4. Power 5. Energy 6. Environmental Load Summary

33 Innovation Conclusion Synthetic Silicate Nano-Fibers and Super PCC Increase Key Paper Properties Simultaneously while Increase Filler Loading and Reduce Cost

34 Conclusion Bulk Caliper L&W Stiffness ISO Opacity Bekk Smoothness ISO Brightness Porosity GCC Super Silicate Blend PCC GCC 15% -- Super PCC -- 22% 25% -- Nano-Fibers -- 22% 25% -- Total Filler Level 15% 44% 25%

35 Conclusion Industry Innovation Vision

36 Thanks for your time

37 Pacific Nano Products would like to acknowledge: Department of Energy USA DE-FC D14439 Department of Commerce WA State Our Industrial Partners JK Paper Weyerhaeuser Domtar Stora-Enso Grays Harbor Paper Georgia-Pacific Hercules