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Omya AG
CaCO3 Particles
(oriention of lamellea)
Omya AG
Omya AG
Brittle Behavior
When ligament thickness is larger than 2 times the thickness of the oriented crystallization layer around the particles.
Bulk Matrix
Oriented Layer
Ductile Behavior
When ligament thickness is less than 2 times the thickness of the oriented crystallization layer around the particles and material with reduced plastic resistance percolates through the blend.
* Connecting lines show orientation of lamellae in inter-particle ligaments
Objective
To introduce CaCO3 in PE Blown Film in order to improve profitability by enhancement of productivity and mechanical properties.
Omya AG
Omya AG
KIEFEL EXTRUDER COMPEX 80 SA Screw Size : 80 mm X 25 D Die Diam : 200 mm X 1.4 IBC System with Aero-Cool Output without CaCO3 : 260 kg/hr. Specific Screw Output : 2,56 Kg/rpm/hr
65 % Omyafilm + LLDPE
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Omya AG
Process Conditions
Production Programme
Initial Thickness (without CaCO3) : 14 then downgauged Film to work at identical Weight by adding 10 %,17,5 % and 25 % of CaCO3
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Omya AG
Production Enhancement
Melt Pressure By introducing CaCO3 in the screw, melt pressure drops allowing an increase of screw speed. Lower manufacturing cost per unit (bag)
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Omya AG
0,0% -4,5%
-8,18% 505 bar -13,45%
20%
25%
CaCO3 Pigments
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Omya AG
Production Enhancement
Higher Spec. Output internal volume of the screw will be reduced viscosity of the blend will be reduced higher melt homogeneity Increase of the blend density higher efficiency of the grooved feed section of the extruder
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Omya AG
3,0
2,57
+19,5%
1,0
0,97 1,038
1,095
1,159
0,5 0,0 0%
5%
10 %
15 %
20 %
25 %
CaCO3 Pigments
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Omya AG
Production Enhancement
Bubble stability improved Faster cooling of blown bubble thanks to higher thermal conductivity of CaCO3 Neck Height could be increased from 8 X Die Diam to 13 X.
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Omya AG
Thermal Conductivity
[W/ MK]
3.00 2.50 2.00 1.50 1.00 0.50 -
PP
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LLDPE
HDPE
CaCO3
Omya AG
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Omya AG
17 g/ 16 g/ 15 g/
12,619 g/ 27,59% 16,100 g/ 0,00%
14 g/ 13 g/ 12 g/ 11 g/ 10 g/
0,0%
2,5%
5,0%
7,5%
10,0%
12,5%
15,0%
17,5%
20,0%
22,5%
25,0%
CaCO3 Pigments
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Omya AG
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Omya AG
Variation Elmendorf MD
12 mN/ 45,87% 11 mN/
11,254 mN/
39,73% 46,5%
37,2%
32,86%
7,715 mN/ 10,250 mN/
10,780 mN/
CaCO3 Pigments
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Omya AG
Variation Elmendorf TD
72,52%
130,116 mN/
69,71%
128,000 mN/
110 mN/
75,423 mN/
46,00%
0,00%
60 mN/ 0,0%
2,5%
5,0%
7,5%
10,0%
12,5%
15,0%
17,5%
20,0%
22,5%
78% 70% 61% 53% 45% 37% 29% 20% 12% 4% -4% -12% -20% 25,0%
CaCO3 Pigments
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Omya AG
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Omya AG
50 N/mm2
40 N/mm2
30 N/mm2
20 N/mm2
10 N/mm2
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Omya AG
50 N/mm2
40 N/mm2
30 N/mm2
20 N/mm2
10 N/mm2
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Omya AG
Elongation at Break MD
600 %
500 %
400 %
300 %
200 %
100 %
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Omya AG
Elongation at Break TD
600 %
500 %
400 %
300 %
200 %
100 %
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Omya AG
.
MD
Neck Height 8X Die
.
Neck Height 12X Die
MD
Without CaCO3
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With CaCO3
Omya AG
10% 25,433
17,50% 16,501
25% 13,672
Rate TD/MD
Aver. Decrease Rate
-20,15
-48,19 -57,07
Omya AG
Sealing
Sealing Strength with Omyalene 2021 P
12
10
15m monolayer
4
82% HDPE 13% LLDPE 5% White MB change HDPE for CaCO3 keep LLDPE const.
Sealing Strength 160 [N/15mm]] Sealing Strength 150 [N/15mm]] Sealing Strength 140 [N/15mm]] Sealing Strength 130 [N/15mm]] Sealing Strength 120 [N/15mm]]
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Omya AG
Omya AG
Dart drop increased by up to 45% Elmendorf MD tear increased by up to 150% Elmendorf TD tear increased by up to 140% Thinner film with equal mechanical properties OR Same thickness with much improved mechanical properties
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Omya AG
Lower melt pressures Higher specific screw output Better bubble stability Faster cooling due to higher thermal conductivity of CaCO3 Better melt homogeneity
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Omya AG
Potential raw material cost savings Potential to compete with higher performance resins Reduction of TiO2 Masterbatch Elimination of blocking problems Lower extrusion costs
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Omya AG
0 % CaCO3
10% CaCO3 2.926 236.875 234.147 2.246.466 2.717.488 0,93 -3,88% 0 - 91.472
17.5 % CaCO3 3.126 236.875 237.660 2.361.295 2.835.830 0,91 -5,71% - 165.130
Production (mT/Year) Total Fixed Costs Variable Costs Polymer Costs Total Costs Price/Kg of Good Film Total Saving Money
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Omya AG
Additional Benefits
CaCO3 cleans the die and extruder Shorter changeover times CaCO3 is an ecological product Replacing polymer Neutralising flue gases so preventing acid rain
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Omya AG
Additional Benefits
Incineration of bags containing CaCO3 decreases CO2 emission 1 Kg of PE gives 2.917 Kg CO2 1 Kg of bags containing 20 % CaCO3 gives 2,602 Kg CO2 - 17,2 % CO2
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Omya AG
Summary
Improve physical properties Competitive with higher performance resins Potential for down-gauging film Potential raw material cost savings Higher output rates Lower manufacturing costs
Contribute to a cleaner environment
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Omya AG