GREEN INNOVATION IN CARBON BLACK CHECKING COMPOUND QUALITY IN-LINE MATERIAL FEEDING l MIXING TECHNOLOGY - NOVEMBER 2020 - YUDU
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NOVEMBER 2020 ISSN 2053-7174
GREEN INNOVATION IN CARBON BLACK
CHECKING COMPOUND QUALITY IN-LINE
MATERIAL FEEDING l MIXING TECHNOLOGY
Bringing the plastics industry together
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CONTENTS
5 News
PAGE 5
Adkenis and Chemson merge in PVC stabilisers, Delta Tecnic
invests to make masterbatch in Mexico, Röchling Automotive PAGE 17
launches biobased compound line, OCSiAl opens European
R&D centre, EU calls for new limits on BPA, Total Corbion to
build second world-scale PLA plant.
17 Green moves in carbon black
Environmental concerns continue to play a major part in
carbon black developments. We find out how suppliers are
responding to green pressure.
PAGE 29
29 Measuring up in real time
Data from measurements taken in-line with the compounding
process promise to allow users to monitor and make
PAGE 39
adjustments to improve quality.
39 Feeding with efficiency
PAGE 49
Feeding technology and equipment plays an important role in
efficient compounding. We review some of the latest
developments.
49 Mastering the mix
Batch and continuous mixers have an important role to play in
production of plastics blends, compounds, and masterbatches.
66 Diary
COMING NEXT ISSUE
� Flame retardants � Laboratory compounding � Anti-counterfeiting technology
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www.compoundingworld.com November 2020 | COMPOUNDING WORLD 3
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NEWS
Akdeniz/Chemson merger to
create $500m stabiliser giant
Turkish investment fund OYAK is to “We will increase our diversity in
Merger creates a
merge its Akdeniz Kimya and Chemson the industry and product groups as a
$500m giant in
businesses to create a global market result of the merger,” said Süleyman
PVC additives
leader in PVC stabilisers with annual Savaş Erdem, OYAK’s General
sales of around $500m. The new Manager.
company, which will have a sales Focus markets will include Europe,
presence in more than 100 countries, Russia, the Turkic republics of Central
is named Akdeniz Chemson. Asia, North Africa, Middle East, US,
OYAK, which is the largest occupa- China, Brazil and Australia. Akdeniz
tional pension fund in Turkey, said the Chemson will also continue to manu-
IMAGE: AKDENIZ CHEMSON
merged entity will remain active in facture many of the raw materials for
M&A and will develop new products its calcium, zinc and lead-based
for different industries and markets, in stabilisers in its six facilities.
addition to its existing range. It aims to OYAK acquired Austrian-headquar-
grow sales to $750m and capacity to tered Chemson in 2013.
250,000 tonnes/year. � www.akdenizchemson.com
Barentz to acquire Maroon SABIC’s
Netherlands-based Barentz
International, a global
US and Canada and turns
over around $500m
overlap between the two
companies in product and
specialty
distributor of life science
ingredients, is to buy
annually. It is active in the
life science sector as well as
markets and considerable
scope for synergies. It said
split is on
Maroon Group, one of the distributing a range of the acquisition was aligned SABIC said that its Special-
largest speciality chemical chemicals and additives for with its strategy “to become ties strategic business unit
distributors in North use in plastics. Barentz said a global leader in the life (SBU) becomes a separate,
America. The deal is the acquired business will science and broader stand-alone business from
expected to close within continue to be run by speciality chemical indus- 1 November.
2020. current CEO Terry Hill and tries”. The company said the
Ohio-headquartered his management team. � www.barentz.com new stand-alone model for
Maroon operates across the Barentz said there is little � www.maroongroupllc.com the Specialties SBU will
bring additional value to
customers for its Ultem
Milliken’s PP clarifier approved and Noryl resins and LNP
compounds and copoly-
Following testing by Europe’s RecyClass PP mers. “The task we have as
Technical Committee, Milliken’s Millad NX 8000 a business is to continue to
clarifying agent has been classified as fully strengthen our market
compatible with current European industrial position and bring added
recycling processes for PP containers. value to our customers,”
RecyClass certifies that Miliken Millad NX said Ernesto Occhiello,
8000 will not have a negative impact on Executive Vice President
IMAGE: MILLIKEN
European PP container recycling where the Specialties at the company.
container is made of clear PP, the density of the Anticipated capacity
final packaging is less than 1 g/cm3, and where expansions for Ultem and
the clarifying agent accounts for less than 0.4% Noryl resins are “progress-
of the total weight. Above: Tests show Milliken’s NX8000 ing”, the company said.
� www.recyclass.eu clarifier will not compromise PP recycling � www.sabic.com
www.compoundingworld.com November 2020 | COMPOUNDING WORLD 5
NEWS
Delta Tecnic moves ahead Piovan
Group buys
with Mexican production Doteco
Spanish masterbatch maker and 80% from outside of Piovan Group, a major
and distributor Delta Tecnic IMAGE: DELTA TECNIC Spain. player in process automa-
is moving ahead with its first The new plant will be tion systems for storage,
overseas production focused on the automotive preparation and transport
investment at Querétaro in cable sector, where Xirin- of plastic and powders,
Mexico, despite the global achs said Mexico is an has acquired Doteco, an
challenges imposed by the “industrial hub” for the Italian supplier of materials
Covid-19 pandemic. Americas. “We have been in handling technologies for
The company, which has Mexico as an importer for production of plastic films
two production locations many years and have an and synthetic fibres.
and 20 production lines at important presence,” he “With this integration,
Barcelona in Spain and a said. “Our customers, we could combine
current capacity of around Above: Delta Tecnic CEO especially in automotive, Doteco’s film dosing
18,000 tonnes, specialises in Eric Xirinachs sees big wanted us to localise our technologies with Piovan’s
colour and additive prod- opportunities in Mexico production.” feeding and storage
ucts for the cable sector Xirinachs said the automations, becoming a
(including micro-master- delay. The plan was to start company, which has been leader in the supply of
batch), as well as colour this year…now aiming for majority-owned by PE firm complete plants in this
concentrates for PVC. It is Q1 2021. We are currently Aurica Capital since 2017, field and acquiring new
investing €4.5m in the installing the production currently generates sales of customers in a sector that,
Mexican operation, which lines.” around €3m in Mexico but also in light of the increas-
will cover 3,000m2 in its first He said the Mexican expects this to rise to €6m ingly necessary sanitary
phase and include two lines, investment marks an once local production and hygiene improve-
with plans to expand to five. important step for the begins. Part of this growth is ments, is becoming
Delta Tecnic CEO Eric company, which expects to expected to be due to its strategic in food packag-
Xirinachs said earlier this end this year with sales of micro-masterbatch technol- ing,” said Filippo Zup-
month that construction and around €40m (about 8% ogy, which is said to allow pichin, CEO of Piovan.
commissioning of the new down on pre-pandemic cable producers to reduce Doteco turned over
plant had inevitably been forecasts). Some 75% of this colorant cost and increase €19.7m last year and
impacted by the pandemic. is generated by its master- line speeds. posted an EBITDA of €3.4m.
“The plant has suffered a batch production activities � www.deltatecnic.com � www.piovangroup.com
Prototype recycled
Electrolux vacuum Electrolux joins Stena in
circular materials initiative
cleaner is part
of company’s
“Circular Initiative”
with Stena Electrolux and Stena Recycling have other than that they were sourced in
jointly developed a prototype vacuum the Nordic region.
cleaner made of 100% recycled and “We at Electrolux have a strong
reused materials sourced from con- commitment to reduce our climate
sumer electronic products such as impact by 2030 and circularity is a key
hairdryers, vacuum cleaners and dimension of this,” said Electrolux CEO,
computers. Jonas Samuelson, who said the com-
IMAGE: ELECTROLUX
It is the first result of Electrolux’s pany has pledged to use 50% recycled
‘Circular Initiative’ collaboration with materials in its products by then.
Stena. No details were given about the � www.electrolux.com
polymers involved in the joint project, � www.stenarecycling.com
6 COMPOUNDING WORLD | November 2020 www.compoundingworld.com
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NEWS
Röchling launches PLA-based
compounds for automotive
German automotive supplier Röchling “We want to support our customers specific composition of the BioBoom
has launched a family of PLA-based in the development of environmentally materials beyond its use of PLA as the
bioplastics that it intends to offer as an friendly vehicles and thus help shape main polymer component in combina-
alternative to PP, ABS, PA6, PET, PBT the transformation of the industry tion with fillers such as talc and glass
and PC for automotive parts. towards a sustainable one,” said Prof and natural fibre reinforcements.
Three standard grades of the Dr Hanns-Peter Knaebel, Chairman of The company was granted a
BioBoom compounds are currently the Board of Management and CEO of European patent in 2014, together
available, each of which contains a Röchling Automotive. with compounder Softer (acquired by
minimum of 90% sugar cane/beet- ‘We have set ourselves the goal of Celanese in 2016), covering formula-
based renewable materials and can be becoming the leading supplier of tions based on PLA and aromatic
further customised to specific applica- bioplastics and recycling materials in copolyesters that claimed high impact,
tions. The company said they are the automotive industry by 2035 at the scratch and UV resistance and HDT
suitable for interior, engine compart- latest,” he said. values of more than 140°C.
ment, and underbody applications. Roechling has not disclosed the � www.roechling.com
IMAGE: BENVIC
Rowa sets
sights on
pure black
Germany’s Rowa Master-
batch has added a “high-
purity” Rowalid PA-B044A
RHC Black to its range of Above: Benivc has acquired Italian medical component maker Luc & Bel
PA-based nigrosine
masterbatches for the
automotive industry.
Benvic buys into medical
RHC stands for ‘reduced PVC compounder Benvic cleanroom conditions. It is and we expect to further
halogen content’, which is has acquired a majority based near Modena, where develop Benvic’s medical
said to achieve a reduction stake in Italy-based injection Benvic last year acquired division, starting with Italy,”
in electrocorrosion and moulder Luc & Bel. It is Modenplast, which is active said CEO Luc Mertens.
reduced interaction with Benvic’s seventh European in the same sector through Luc & Bel founder and
other formulation compo- acquisition, including four in compounding of medical CEO Luca Ferrari will remain
nents — the company Italy, since it was acquired PVC formulations and at the helm of the company
claims some improvement by Investindustrial in 2018. extrusion of tubes and and will retain a minority
in mechanical properties Luc & Bel makes complex hoses. stake.
after thermal ageing. medical components and “PVC plays a fundamental � www.luc-bel.com
According to Rowa, assemblies under Class 8 role in all parts of this sector � www.benvic.com
because the new grade
prevents corrosion of
metals such as copper, it
may also find application in
Lactips to open new French plant
E&E applications, including Lactips, a specialist in production of soluble longer-term target of 10,000 tonnes/year.
heat exchangers, connector plastics, has announced plans to build a new The project includes a 2,500 m2 production
housings and terminal facility at Saint-Paul-en-Jarez in France. building and 1,000 m2 administrative and
blocks. The intention is to produce 3,000 tonnes/ sales building with a laboratory.
� www.rowa-group.com yr of material on the 12,000m2 site, with a � www.lactips.com
8 COMPOUNDING WORLD | November 2020 www.compoundingworld.com
info@comacplast.it
NEWS
OCSiAl opens graphene Danimer
set to go
nanotube R&D centre public
Nanotechnology firm US biodegradable
OCSiAl has opened its latest polymers manufacturer
R&D and technical support Danimer has sealed an
centre for single wall carbon agreement with Live Oak,
nanotubes (SWCNTs) in a special purpose acquisi-
Luxembourg. tion company, that will
The facility covers 350m2 lead to a $210m invest-
and will be targeted at ment and see it list on the
development of elastomers New York Stock Exchange
and thermoplastic compos- as Danimer Scientific.
IMAGE: OCSIAL
ites enhanced with SWCNTs Danimer CEO Stephen E.
(which the company refers Croskrey will remain at the
to as graphene nanotubes). helm.
Key focus areas will include Danimer owns a
lightweight and smart car Above: OCSiAl’s Luxembourg centre will accelerate SWCNT portfolio of core patents it
bodies and energy efficient developments purchased from Procter &
tyres. Gamble in 2007. Its
Russia-headquartered Europe is at the forefront of SWCNT production capacity best-known product is
OCSiAl has existing R&D developments in material of around 75 tonnes/yr. It Nodax PHA, a fully
facilities in Asia and Eastern engineering solutions, plans to commission a 100 biodegradable and
Europe. It said the new including the ongoing auto tonnes/yr production unit in renewable plastic derived
Luxembourg location “is industry revolution.” Luxembourg in 2023. from canola oil that carries
related to the fact that OCSiAl currently has an � www.ocsial.com marine degradable
certification.
Nodax is currently made
Altair buys M-Base Engineering on an industrial scale at
Danimier’s facility at
Altair, a US-based company software supplier to CAM- customers to drive accurate Winchester, Kentucky, and
focused on data analytics PUS (Computer Aided simulation results. production there is said to
and computer-based Material Preselection by M-Base Engineering+ be fully sold out, based on
simulation technologies, has Uniform Standard), which is Software also develops its signed and pending
acquired Germany’s M-Base the world’s most successful own Material Data Centre contracts. The company
Engineering+Software, plastic material database. plastics information tool, said it will use the newly
which supplies material Altair said it will continue to which combines CAMPUS secured capital base to
database and information invest in the CAMPUS with other databases and increase production
systems, mainly for the database in order to ensure tools to support designers tenfold to about 90,000
plastics sector. consistent, high-quality and engineers. tonnes/year by 2025.
M-Base is the official material data is available to � www.altair.com � www.danimerscientific.com
Recycled PS suitable for food contact use
Styrenics Circular Solutions (SCS) says contact applications. It said it now simulated worst-case assumptions by
challenge testing carried out at plans to make a first application for an adding impurities to post-consumer PS
Fraunhofer Institute in Germany has opinion from the European Food before recycling it. The results, it said,
shown that polystyrene mechanically Safety Authority. showed that the high efficiency of the
recycled using “supercleaning” SCS, which is a value chain initiative mechanical recycling technology for
technology developed by Gneuss, also that aims to increase the circularity of removal of impurities.
of Germany, is suitable for food styrenic polymers, said the tests � www.styrenics-circular-solutions.com
10 COMPOUNDING WORLD | November 2020 www.compoundingworld.comCOMPLETE SYSTEM
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– the heart of customized systems.
Complete Compounding Solutions
BUSS is a worldwide leader in providing complete solutions for demanding compounding
applications. With a long history of meeting the needs of a diverse customer base, BUSS
offers expert consultation, planning, engineering, and innovative products. The COMPEO
as the heart of the compounding line ensures maximum performance and unrivaled flexibility
resulting in superior product quality.
www.busscorp.comNEWS
Mayzo
buys Bio
EU calls for more limits
Accutech on bisphenol-A content
Mayzo, a US-based The European Chemicals Proposal from
manufacturer and distribu- Agency (ECHA) has opened Germany
tor of polymer additives a call for evidence following would impose
and speciality chemicals, a proposal from Germany to a 0.02wt%
has acquired Bio Accutech, place a restriction on the limit on BPA
a distributor of chemicals presence of bisphenol-A
IMAGE: SHUTTERSTOCK
for the coatings, inks and (BPA) and alternatives as an
plastics markets also additive or unreacted
based in the US. monomer in articles and
Mayzo said the move mixtures at levels or more
extends its global supply than 0.02wt%.
chain and adds several BPA is used as a monomer
new optical brighteners, in production of polycarbon- sources of BPA emissions BPA content in PC is below
photoinitiators and PVC ate (PC) and epoxy resins. It into the environment, and the proposal’s 0.02wt% limit.
additives to its portfolio. is classified in the EU as toxic further clarifying research n A pilot project carried out
This includes antioxidants, to human reproduction and results being on the way.” by ECHA’s Enforcement
UV absorbers, optical restrictions already apply in The association said Forum has found more than
brighteners, release certain end use applications. studies shared with the 23% of products imported
coatings, polymer enhanc- Germany says it wants to German competent authori- into the EU non-compliant
ers, masterbatches and reduce environmental ties show PC articles with REACH and CLP
blends. emissions of BPA and is account for less than 1% of Regulations. Inspectors
Integration of the taking the restriction route, total BPA emissions to the across 16 member states
acquired business has rather than authorisation, as environment. It said that it checked around 1,400
already taken place and all the latter does not effectively would contribute to the products. 17% of the 1,225
activities are now man- address imported articles. process with “the expecta- checked for restricted
aged through Mayzo’s PlasticsEurope, which tion that a restriction substances had amounts
recently built 5,700 m2 represents PC producers at proposal shall be based on above the required limit. Of
operations centre at an EU level, said the German facts and the most recent the 167 products checked for
Walterboro in South move was unexpected scientific insights.” CLP compliance, 64% were
Carolina. “considering the data Previous published found to be non-compliant.
� www.mayzo.com already available on the studies indicate residual � www.echa.europa.eu
Casio connects with Ultramid Advanced
Casio Computer Company is using resistance to heat distortion tempera-
IMAGE: BASF
BASF’s Ultramid Advanced N PPA in tures of up to 260°C during the
its newest digital watch and fitness production process. Casio and BASF
tracker, the G-Shock GBD-H1000. worked with Taiwanese connector
The material is used in the terminal maker Aces Electronics on the
header, which sits on the terminal development.
block and contributes to power Ultramid Advanced N is said to
charging and data synchronisation. combine high heat resistance, good
The terminal header is about mechanical and dimensional stability,
1.2cm wide with a wall thickness of low moisture uptake, high heat
0.2 mm and weighs less than 0.1 deflection temperature, exceptional
BASF Ultramid gram. Block and header are fixed to chemical resistance and good
PPA is used in Casio’s the motherboard using SMT (surface adhesion to the metal terminal block
latest G-Shock smart watch mount technology), which calls for � www.ultramid-advanced-n.basf.com
12 COMPOUNDING WORLD | November 2020 www.compoundingworld.comiNSPIRING XXTRUSION
THE NEW ZSE iMAXX SERIES
extruders.leistritz.comNEWS
IMAGE: TOTAL CORBION
IN BRIEF...
Nordmann is expanding
its distribution partnership
with Spain’s Repol to cover
the full European market.
The UBE Group company
Repol produces a range of
engineering compounds
Above: Total Corbion plans to build its second world-scale PLA facility at Grandpuits in France including Dinalon PA6 and
PA 66, Dinarex ABS,
Total Corbion to build Dinaxan PC, Dinadur PBT
and Dinatron PPS.
www.nordmann.global
PLA plant in France www.repol.com
Carbon black producer
Total Corbion PLA, the markets including packaging, multiple technology projects Birla Carbon has extend-
50/50 joint venture set up consumer goods, fibres and that will increase capacity at ed its joint development
by Total and Corbion to automotive. They are made its facility at Blair in Nebras- agreement with nanotech-
produce polylactic acid from renewable resources ka, US, by 10% be the end of nology firm Chasm
(PLA) bioplastic, is to build a and can be mechanically or 2021. These include Advanced Materials to
second industrial-scale plant chemically recycled, as well enhancements to its lactide include commercialisation
at an existing Total refining as being compostable and monomer purification of novel nanomaterials.
site at Grandpuits in France. degradable, according to the processes. www.birlacarbon.com
Due for completion in company. Natureworks CEO Rich www.chasmtek.com
2024, the project represents The investment is part of Altice said the PLA market
an investment of around a €500m ‘net zero’ strategy “continues to rapidly evolve LyondellBasell and Sasol
€200m and will take for the Grandpuits refinery due to the COVID-19 are to form a 50/50 joint
capacity for Total Corbion’s which also includes produc- pandemic” and that de- venture through which
Luminy brand of PLA resins tion of renewable diesel mand is still growing LyondellBasell will acquire
to 100,000 tonnes/year (the from used vegetable oils; a strongly in many end 50% of Sasol’s 1.5m tonne/
JV currently has a 75,000 chemical recycling plant markets. He said the yr ethane cracker and
tonnes/year facilty in joint venture with Plastic company continues to 900,000 tonne/yr polyeth-
Thailand, which started up Energy; and operation of pursue potential opportuni- ylene plants for a total
two years ago). It will be the two photovoltaic solar ties for a second manufac- consideration of $2bn. The
first large scale PLA produc- power plants. Total is ending turing site outside of the US JV will operate under the
tion operation in Europe. crude oil refining at the site. to serve growing interna- name Louisiana Integrated
Luminy resins include high n Meanwhile, NatureWorks tional markets. PolyEthylene JV.
heat and standard PLA — also a key player in PLA � www.total-corbion.com www.lyondellbasell.com
grades and are used in production — has announced � www.natureworksllc.com www.sasol.com
M Holland makes first moves in Europe
US-based resin distributor M Holland to Ireland and the UK. and the quality product offering will
has announced a partnership agree- “Our partnership with JL Goor strengthen our growth plans for the UK,
ment with JL Goor Materials, a polymer Materials provides a value-added complement business with our existing
distribution company headquartered logistical solution to support our polyolefin partners in Ireland, and
in Dublin, Ireland. clients who have international business enhance our supply options to existing
It is the US company’s first formal locations or expansion plans,” said and new customers. We will also be
venture in Europe and will allow it to Josh Blackmore, Global Healthcare working with M Holland to grow our
better support global clients and Manager at M Holland. medical polymer portfolio.”
expand the reach of its Mtegrity JL Goor Materials Managing Director � www.mholland.com
generic prime resins and compounds Gearoid Clarke said: “This partnership � www.jlgoor.ie
14 COMPOUNDING WORLD | November 2020 www.compoundingworld.comlenka.blazkova@unipetrol.cz vaclav.kubicek@polymer.cz helga.kirchner@unipetrol.de www.chezacarbcarbonblack.com
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E emily.nicholson@ami.internationalCARBON BLACK | ADDITIVES
Green moves
in carbon
black
IMAGE:
SH
Environmental concerns
UTTERSTOCK
continue to play a major
part in carbon black
developments. Peter
Mapleston finds out how
suppliers are responding to
green pressures
Environmental issues continue to dominate covering rCB, but there is as yet no universally- Main image:
discussion and developments in carbon black for agreed definition. Specifications will be required, Whether its
plastics. Whether producing new blacks from old however, as rCB quality consistency is important sustainable
tyres or reducing levels of polycyclic aromatic and can be a challenge to maintain when tyre sourcing,
hydrocarbon (PAH), major and minor carbon black feedstocks are not controlled. process
producers are working hard to grow opportunities Von Wolfersdorff says markets are exerting a improvement,
for this workhorse product, and in doing so strong pull, particularly at tyre producers, which or emission
providing masterbatchers and compounders with interface directly with consumers. Several have set reduction, both
wider choice in terms of “green” solutions. themselves targets for incorporation of rCB into new and
Demand for carbon black recovered from old new tyres and/or have invested in tyre recycling established
tyres (rCB) in the plastics compound supply chain is companies. Bridgestone, for example, has invested players in
certainly growing, says Martin von Wolfersdorff at in Delta Energy and is already using rCB in some carbon black
Wolfersdorff Consulting in Berlin in Germany, tyres. Pirelli says it aims for its tyres to have on are seeking
who closely monitors this market. But supply is still average 3% rCB content by 2025. And Continental “greener”
limited. Few companies are currently in commercial is already at 4% rCB content and wants to be at solutions
production with the types of rCB suitable for 10% by 2026.
plastics (the property requirements for plastics are Michelin is taking a very pro-active approach,
quite different from those used in rubber com- having acquired the tyre granulate company
pounding). “Inspired by recent announcements by Lehigh Technologies and invested in Swedish rCB
Michelin and BASF, many tyre pyrolysis ventures producer Scandinavian Enviro Systems (the tyre
are aiming to go into business all around the world, maker is now the principal shareholder).
but the timeline to market is two years or longer,” Michelin is also involved in the three-year
says von Wolfersdorff. EU-sponsored BlackCycle project, which
Recovered carbon black differs from regular commenced in May and aims to develop an
carbon black in being a composite of carbon integrated approach to producing and using rCB
blacks used in the tyre feedstock, inorganic (“ash”) and pyrolysis oil from old tyres. According to its
content, and organic content from rubber prospectus, the BlackCycle project “has an
polymers. The ASTM workgroup D36 is currently upcycling ambition, targeting to create a circular
working on test methods and specifications economy of the end-of-life tyre (ELT) into technical
www.compoundingworld.com November 2020 | COMPOUNDING WORLD 17ADDITIVES | CARBON BLACK
IMAGE:
SCANDINAVIAN
ENVIRO SYSTEMS
Above: applications…by producing high technical second announced it was aiming to develop its next tyre
Scandinavian raw materials (SRMs) from ELTs. The BlackCycle carbonisation plant at the Port of Rotterdam.
Enviro Systems project aims at creating, developing, and Construction is set to begin next year on the facility,
and Michelin optimising a full value chain, from ELT feedstock to which will decompose granulate from end-of life
hope to build a SRMs, with no waste of resources in any part of the tires into carbon black, pyrolysis oil and gas.
pyrolysis plant chain and a specific attention for the environmental
to produce rCB impact.” Pandemic effects
from tyres The project’s ambition is that by 2029 close to Germany-headquartered Pyrolyx was one of the
one out of every two end-of-life tyres will go earliest players in the rCB sector and had been
through its new recovery process, “which will be making progress until the arrival of the Covid
the only virtuous cycle of this magnitude amongst pandemic. The company has one plant at Stegelitz
all industrial sectors in the recovery of end-of-life in Germany, which has been operating for several
products.” years, and another at Terre Haute in Indiana in the
R STO C K
US, which began operation in January. However, it
U TTE
AG
E : SH Investing upstream said in March that both would be idled and has
IM
In July, Scandinavian Enviro Systems and given no indication yet as to when they will restart.
Michelin prolonged their letter of intent Despite the pandemic challenges, US-based
regarding a strategic partnership until Bolder Industries, another company converting
the end of October (after this article end-of-life tyres into carbon black and
was written). Initially, the parties petrochemicals, says 2020 has been a year of
expected a final agreement would growth due to increasing demand for sustainably
have been reached by mid-year, produced products. Its flagship product,
but negotiations have been BolderBlack, is aimed squarely as an alternative to
delayed, in part due to the petroleum-derived carbon black pigments in
ongoing Covid pandemic. The two plastics and offers the typical virgin carbon
companies have agreed, however, attributes critical for thermoplastics products such
that the partnership will include a as UV protection, conductivity, and anti-static
development agreement to deploy properties, according to the company.
Enviro’s pyrolysis technology on a larger BolderBlack is made from 100% post-consumer
scale and a shared project to build a or post-industrial tyres and scrap rubber. Its
factory to industrialise the technology. lifecycle impact versus virgin carbon black is
Above: Projects Enviro Sales Manager Fredrik Olofsson says that massive, according to the company, which claims
such as the the company does intend to work on plastics 90% less water consumption, 61% less electricity
EU-funded applications for rCB and is carrying out some trials, input, and 97% lower CO2 emissions. “We recover
BlackCycle aim but for the moment its emphasis is on tyres and 98% of the materials from each discarded tyre,”
to developed other rubber products. “The problem with plastics says CEO Tony Wibbeler.
integrated applications is the high ash content in rCB,” he Bolder Industries broke ground on a plant
systems to says. Without special processing steps, ash expansion earlier this year that will increase
recover carbon contents in rCB are substantially above what is capacity by nearly 200%. It will add around
black from normally required to produce plastic compounds 1,580m2 to the company’s existing footprint at its
scrap car tyres with good levels of blackness. site at Maryville in the US state of Missouri.
Other leading rCB producers include Black Bear Completion is scheduled for Q1 2021.
Carbon in The Netherlands. However, its attempts International market interest in Bolder Industries’
to bring rCB to market suffered a major
set-back in early 2019 when its already-
limited production facility was taken out Left: Black Bear Carbon’s rCB ambitions were
of production by a fire. In Novem- hit by a fire at its Netherlands facility.
ber last year, the company Plans for a new facility are underway
18 COMPOUNDING WORLD | November 2020 www.compoundingworld.com
IMAGE: BACK BEAR CARBONinfo@mixaco.de info@mixaco.com
ADDITIVES | CARBON BLACK
Masterbatch interest
IMAGE: BOLDER INDUSTRIES
Some leading supplies of black masterbatch for
plastics have already dipped their toes into the rCB
waters. Avient (formerly PolyOne) has been taking
material from Bolder Industries for several months
and Ampacet and Modern Dispersions are also
among the early adopters: Ampacet introduced its
Rec-O-Black 216 masterbatch — which uses not only
carbon black from recycled rubber products at a level
of 40% but also recycled polyethylene for the carrier
resin — in 2016; Modern Dispersions launched its
EcoBlack product the same year. Last year, Cabot
launched its TechBlak 85 masterbatches, which are
made from post-industrial carbon black and recycled
polymers. And Brazilian company Cromex said it is
Above: Bolder products is said to stretch well beyond its planned using rCB from tyre recycler Polimix Ambiental to
industries capacity, with interest from as far as Latin America, produce masterbatches in a range of carriers.
plans to the Middle East and Europe. The company says its Commenting on its introduction of the Rec-O-
expand rCB product can be found in more 300 plastic and Black product line, Ampacet Strategic Business
capacity at its rubber products, with use split roughly 50/50. It Manager François Thibeau says: “The market is very
facility at cites existing applications in wearables, indoor and curious about this kind of development as it
Maryville in the outdoor gear, accessories, instruments, and responds to needs of the circular economy: re-use,
US by 200% furniture and says it has more than 100 additional repair and recycling…Rec-O-Black provides very
product evaluations underway. good opacity in finished articles. Opacity data may
slightly vary upon the nature and quality of the
M&A activity feedstock used to generate the recycled black
Also looking to be making progress in rCB is pigment but overall there is no compromise in
Canadian company Klean Industries. In 2018, it terms of quality.”
acquired a shuttered pyrolysis facility at Boardman, Bolder Industries has also integrated into
in Oregon in the US, that was previously owned by masterbatch production, according to Wolfersdorff
ReKlaim (a joint venture partner of Pyrolyx). It plans Consulting. “Kylos is a new brand we are working
to use the facility to prove its own technology on an with that was created by a customer. It is a brand
industrial scale. dedicated to sustainability and all of its products
Last November, Klean Industries acquired contain BolderBlack and use recycled resin. Kylos
Carbon Resources Recovery (CRR), which is based also allows us to provide sustainable masterbatch
in Berlin in Germany. According to Wolfersdorff solutions to plastic compounders and other plastic
Consulting, CRR operates a series of rotary kilns at manufacturers who reach out,” says Bolder CEO
Bukowno in Poland, supplying local masterbatch Tony Wibbeler.
companies with rCB. The company says these are Wibbeler says the Kylos brand has not yet been
running in 24 hour operation 365 days a year.
Right: The Klean says the combination of the two compa-
market is nies makes it a world leading tyre pyrolysis technol-
“curious” to ogy company with a combined IP portfolio that is
explore “second to none in the tire pyrolysis recycling
opportunities sector.” It says that CRR already had the largest fully
for circular continuous, commercial scale facility operating in
recycled Europe. Now branded as part of Klean’s technol-
carbon black ogy portfolio, it says that means the company now
products, says has plants in operation in Asia, South America and
Ampacet Europe. Klean says it also plans to start up a
number of additional facilities in the US.
IMAGE: AMPACET
Traditional carbon black suppliers are also
taking a close look at what can be done in the rCB
sector. Orion Engineered Carbons, for example, is
involved in the EU BlackCycle project.
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meeting for senior managers and
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[The Masterbatch
CONTACT US conference] is a very good
Camille Lemercier platform to see what is happening
Conference Organiser in the world of masterbatch. From
T +44 (0) 117 314 8111 machines to raw materials to
E camille.lemercier@ami.international
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Director Marketing,
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ALOK MASTERBATCHESADDITIVES | CARBON BLACK
alternatives to demanding them,” he says. This
IMAGE: MONOLITH MATERIALS
demand has accelerated Monolith’s expansion
plans. It recently announced plans to construct a
second facility, OC2, which will have a capacity of
180,000 tonnes/yr. The sum of the two capacities
will make Olive Creek the largest single carbon
black manufacturing facility in the US, according to
the company. Construction on OC2, which is in the
early design phase at present, is set to begin in Q2
of 2021, with completion expected in 2024.
Traditional gains
Traditional carbon black manufacturers are, of
course, working on more sustainable solutions for
their current product lines. Cabot cites the example
Above: formally released. “But I’m happy to hear that word of its new Black Pearls 1180HD specialty carbon
Monolith is getting out that a fully sustainable masterbatch is black which addresses calls for reduced CO2
Materials available for sale in North America,” he says. “Kylos emission from markets such as automotive.
claims its has two manufacturing partners, one in New York “Vehicle lightweighting and metal replacement is
facility at State and the other in the Chicago areas and creating a market demand for stronger, more
Hallam in the product is shipping. Kylos is fairly focused on a durable plastic materials with deep, dark colour,”
US produces niche so we can still work with other [masterbatch the company says.
zero emission producers].” “Due to the difficulty of dispersing traditional
carbon black high colour carbon blacks, until now it has been
Carbon from gas difficult for automotive plastic compound
US-based Monolith Materials is taking another manufacturers to deliver high black colour and
novel approach to improving the sustainability of mechanical strength simultaneously. Black Pearls
carbon black production. The company says it 1180HD breaks this trade-off, promoting high
achieved mechanical completion of its Olive Creek jetness at low loadings, good dispersibility and
1 (OC1) facility near Hallam in Nebraska in the US mechanical strength preservation. Ultimately, this
earlier this year. This is claimed to be the first creates more opportunities for metal replacement
commercial-scale carbon black manufacturing and further reduction in wall thickness of existing
plant to combines natural gas feedstock and plastic parts which help to reduce a vehicle’s
electricity through the methane pyrolysis process weight,” the company says.
to manufacture carbon black with zero emissions. Cabot says carbon black users in the electrical
Methane pyrolysis-produced carbon black is and electronic and consumer markets can also
said to be “nearly identical” in performance benefit from this new grade’s combination of
properties to carbon black made from petroleum favourable product characteristics. “Black Pearls
feedstock. “In some formulations, it will be an easy 1180HD is an ideal choice for any application
drop-in. In others we will formulate the carbon requiring deep, dark colour in combination with
black to match the properties,” says Monolith CTO mechanical performance,” it says.
Tom Maier.
Right: Cabot The OC1 facility is projected to produce
says demand approximately 14,000 tonnes/yr and Monolith
for deep black expects to start delivering carbon black to
plastics is customers in Q4 of this year. Chris Cornille, Chief
growing in Commercial and Supply Chain Officer, says: “No
automotive as a matter who we talk to in the marketplace, ‘sustain-
consequence of ability’ drives every conversation.” He says the OC1
lightweighting plant will only supply a small percentage of the
IMAGE: SHUTTERSTOCK
more than 14m tonne global market demand for
carbon black but considers it a glimpse into the
future of global carbon black manufacturing.
“Over the last year, we’ve seen a shift in
customers asking for clean carbon black
22 COMPOUNDING WORLD | November 2020 www.compoundingworld.comCARBON BLACK | ADDITIVES
At Russia’s Omsk Carbon Group, Ivan
IMAGE: OMSK CARBON GROUP
Maslenikov, Head of Product Development,
Marketing and Strategic Development, says that
with global trends towards sustainability and health
putting more attention on chemical purity of
products intended for contact with people, food
and water, the company has been working on
innovations to deliver carbon black with
significantly reduced PAH (polycyclic aromatic
hydrocarbon) content. Two new grades, Omcarb
S500FA and Omcarb S600FA, are intended for a
broad range of applications, including toys, home said to have very low levels of PAH. Above: Omsk
appliances and domestic tools, sport equipment, Deep blacks are proving increasingly popular in Carbon has
clothing and materials, which may come into direct plastics applications due to the association between extended its
contact with potable water. black depth and quality, according to Birla Carbon. line of low-PAH
“Producers of pressure pipes for potable water “Plastic formulators are looking for ever-increasing carbon blacks
and gas, thin and multilayer films, and fibres jetness in their finished product,” says Fabrizio with two new
demand enhanced dispersibility, good production Rossin, Plastic Sector Head at Birla Carbon Italy. grades
efficiency and long product service life,” “Deep black is becoming more prominent in the
Maslenikov says. “For those applications, Omsk automotive industry. Car interiors are showing more
Carbon Group specially developed P-type grades jet black components. In consumer electronics,
Omcarb P72 and Omcarb P108 with outstanding brands are using deep black exteriors to add value
physical and chemical cleanliness, good filter to their offerings. Home appliances are also turning
pressure values, low moisture absorption and a deeper shade of black. Deep black plastics, with a
improved pellet properties.” These grades too are smooth surface finish, are also being used to
Imerys Graphite & Carbon
The Experts in Electrical and
Thermal Conductivity for your Polymers
ENSACO®
Conductive Carbon Blacks Ideal solutions for
TIMREX® C-THERM™
electromagnetic
High Aspect Ratio Graphite shielding compounds
Imerys Group is proud to announce we have been
awarded the highest rating from Ecovadis putting
us in the top 1% of all companies assessed.ADDITIVES | CARBON BLACK
across multiple markets. “One of the fast growing
applications for electrically conductive compounds
is EMI shielding, linked mainly to the deployment
of 5G technology and vehicle electrification with
the adoption of EV and hybrid vehicles, the
increased number of sensors and electronic parts
on-board vehicles,” the company says.
“Thanks to their high conductivity and ease of
processing, Ensaco conductive carbon blacks and
high aspect ratio Timrex C-Therm are ideal
solutions to confer EMI shielding properties to
polymers and to achieve high levels of attenuation
in combination with other conductive additives
Table 1: Chart showing volume resistivity and through-plane thermal such as metal fibres,” it says. “Ensaco is a cutting-
conductivity (Laser Flash on injection moulded samples) of Ensaco 250G edge conductive carbon black, with a winning
and C-Therm carbon blacks as a function of additive loading in HDPE combination of high purity, high structure and low
Source: Imerys Graphite and Carbon surface area, which guarantees low moisture
pick-up as well as easy dispersion. This unique set
displace black surface coatings.” of properties enables reaching high levels of
Rossin points to Birla Carbon’s high-colour conductivity at low loadings and is a key benefit for
Raven blacks, which he says are designed for compound mechanical and flow properties. The
exceptional colour and physical properties. He says high level of graphiticity of Ensaco also makes it a
they offer high jetness, UV protection and viscosity suitable additive to bring thermal conductivity to
control. “Raven 2800 Ultra , Raven 2900 Ultra and polymers, especially in applications where high
Raven 3000 Ultra blacks are particularly designed through-plane thermal conductivity is required.”
keeping both colour and processability in mind,” Advances in hybrid (HV) and fully electric vehicle
he says. “Because of their unique combination of (EV) technology have increased demand for
surface area and structure, they are easy to thermoplastic conductive compounds for shielding
disperse and hence provide excellent jetness. Birla against electrostatic discharge and
Carbon aims to set the bar even higher by electromagnetic interference (RFI/EMI). Both
launching a new ultra-high (piano) black product functions are enabled by conductive fillers. Orion
for plastics in 2021.” Engineered Carbons says it has been focusing on
the nature of carbon black conductivity, conductive
Conductive solutions black application in these applications, and in
Imerys Graphite & Carbon says its Ensaco and applications development.
specialty Timrex C-Therm carbon solutions are “Consumers and our customers require us to
formulated to confer electrical (and thermal) move forward with sustainability initiatives,” says
conductivity to polymers. It also points to the Greg Zartman, Orion Marketing Manager,
impact of megatrends such as metal replacement Polymers, Americas. “This work in conductive
and light-weighting, which are causing a steady plastics, on-going efforts to reduce tyre roll
increase in demand for conductive carbon black resistance, and participation in the BlackCycle
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project are important components of Orion’s
sustainability efforts.” He says that while most all
carbon blacks impart conductivity in plastics, a key
requirement for HV and EV applications is to
enable conductivity while retaining good
compound mechanical properties. “Meeting this
requires sound carbon black selection and
application development.”
Beyond percolation
Higher black dosage enables lower resistivity, but
adversely affects compound mechanical
properties. In addition, formulators have to deal
with the issue of percolation. The graph shows how
conductivity in a compound can change with
carbon black loading. The percolation curve shown
in Figure 1 is typical for conductive carbon blacks.
It shows that to achieve stable compound resistivity
Figure 1: Chart showing how resistivity of a
it is prudent to dose the conductive carbon black
conductive polymer compound drops rapidly around
to the flat part of the curve beyond the critical area
the percolation point, demonstrating the need for
where small changes in loading can have accurate dosing control
disproportionate effects on conductivity. Source: Orion Engineered Carbons
Although other properties affect compound
resistivity, carbon black surface area, structure, and Narayan says. “EMI/RFI applications require much
porosity drive resistivity at the target carbon black lower resistivity, so Printex XE2 is more preferred, at
dosage (see Table 1). 8-10% in the polymer.”
“Many conductive black compounders prefer
super-conductive blacks, such as Printex XE2, CLICK ON THE LINKS FOR MORE INFORMATION:
because of the low resistivity it imparts at low � www.wolfersdorff.com
dosage,” says Vasanthakumar Narayanan, Orion � www.deltaenergy.com
Technical Market Manager, Polymers, Americas. � www.lehightechnologies.com
“We work with customers to ensure conductivity � www.envirosystems.se
and mechanical properties are in balance.” � www.blackbearcarbon.com
Within the HV and EV applications (and in future � www.pyrolyx.com
autonomous vehicles), the density of electronic � www.bolderindustries.com
components and potential EMI and RFI � www.kleanindustries.com
interference has created strong demand for � www.avient.com
conductive thermoplastics. To give some idea of � www.ampacet.com
the scale of this issue, he says humans can perceive � www.moderndispersions.com
a 3000V static discharge while electronic vehicle � www.cabotcorp.com
components can be damaged by a 100V � www.cromex.com.br
discharge. “For these electrostatic discharge � www.monolithmaterials.com
applications, Orion’s Printex Kappa 70, � www.omskcarbongroup.com
compounded at 15-20% by weight in � www.birlacarbon.com
polypropylene, will provide desirable balance of � www.imerys-graphite-and-carbon.com
low resistivity and mechanical property retention,” � www.orioncarbons.com
Table 2: Carbon black surface area and Oil Absorption Number (OAN) versus MFR and resistivity for various carbon black grades
Sample – 14% Printex Kappa 70 Y200 acetylene black HiBlack 40B2 Printex XE2 (at 10%)
Resistivity (ohm-cm) 990 2.16x10 6
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Measuring
up in real
time
Data from measurements taken in-line with
the compounding process allow users to
monitor and make adjustments to improve
quality. Jennifer Markarian reports
IMAGE: SHUTTERSTOCK
The traditional approach to process control relies reflected to the spectrophotometer, where it is Main image:
on monitoring of equipment parameters — such as measured and output as colour values (L*, a*,b*, in-line
temperature, pressure, or feeder rate — to ensure C*, h). The probes allow measurement in measurement
that production is running as expected. Off-line reflectance mode for opaque materials and technology
laboratory testing is then used to ensure transmission mode for transparent materials. The promises to
compound and masterbatch product quality has company says that measurement intervals as short help plastics
been met. By the time that quality determination as one to two seconds are possible, but adds that compounders
has been made a lot of product may have been 10 to 60 second intervals are recommended for improve
produced. In-line analysis during processing continuous process monitoring. product quality
provides an alternative that allows “real time” Gómez says the L* measurement feedback can and reduce
process adjustments to be made to improve be used to provide immediate adjustment of the material
product quality and reduce or eliminate out-of- colorant feeder to maintain the final product in wastage
specification product. specification throughout the product run. “With a
“The ongoing automation of traditional more sophisticated pigment library, closed loop on
manufacturing requires the use of smart a* and b* can also be achieved,” he says.
technology that can measure, analyse and He explains that laboratory and in-line colour
diagnose issues without the need for human instruments will produce numerically different
intervention,” says Jaime A Gómez, President and results because of differences in the instruments
CEO of US-based Equitech, which offers in-line and in the measurement environment. He says that
colour measurement solutions. He says that the a best practice for harmonising these numbers is
pandemic has driven an increase in automation this straight-forward. “We use the offline (laboratory)
year as many companies have had to restrict access measurement values to adjust our in-line
to their facilities and looked for ways to reduce measurements by making an offset that matches
employee interaction. the laboratory. In this way, when the offline
Equitech’s colour measurement solution uses measurement is done (every two or three hours) we
optical fibre probes connected to a use it to adjust our in-line measurement and
spectrophotometer. A sapphire-tipped probe is eliminate any drift in in-line data.”
inserted into the melt through a die adapter, Equitech reports a growing trend to use real-
allowing the melt to be illuminated and the light time data for more comprehensive analysis of the
www.compoundingworld.com November 2020 | COMPOUNDING WORLD 29You can also read
