no dust blends (ndb) - gsi · no dust blend (ndb) technology what is it ? • full stabiliser...

ONE PACK SYSTEM PERFORMANCE

No Dust Blends (NDB)

No Dust Blend (NDB) TechnologyNo Dust Blend (NDB) Technology

What is it ?

• Full Stabiliser Package In ONE Blend• Not Restricted to GSI/CHEMTURA Products Only• True Responsible Care Effort

Reduction of Worker ExposureReduction of Waste

• Many Technical and Commercial Benefits

Example Polyethylene FormulationExample Polyethylene Formulation

Additive Dosage %

Anox 20 0.02% 12.5

Anox PP18 0.02% 12.5

Alkanox 240 0.04% 25.0

Talc 0.08% 50.0

Formulation NDB Composition

NDB: ManufacturingNDB: Manufacturing

US PATENT 5,240,642

PelletsPellets

Compacted Granules: SmallCompacted Granules: Small

Compacted Granules: LargeCompacted Granules: Large

No Dust Blend (NDB)No Dust Blend (NDB)

NDB Homogeneity: SEMNDB Homogeneity: SEMCross Section View of Components in NDB

Scanning Electron Microscopy (SEM)

Phosphorus (blue) Zinc (green) Calcium (yellow)

All components

NDB:Anox 20Alkanox 240-3TZn StearateCa Stearate

High Abrasion ResistanceLow Dust Product

Good Flow PropertiesWide Range of FormulationsHomogeneous, Consistent Composition‘Difficult’ Additive IncorporationSingle Pellet Formulations

NDB: Technical FeaturesNDB: Technical Features

Low Dust Product

NDB: Technical FeaturesNDB: Technical Features

Reduced Explosion Risk Safety

Cleaner Working Environment Workforce Comfort

Cross Contamination Risks Lower Product Quality

Minimal Product Lost Into Extraction Cost Reduction

Faster Grade Changes / Clean down Productivity

Benefit Contribution

Reduced Waste Disposal Costs Cost Reduction

Benefits: Low Dust ProductBenefits: Low Dust Product

High Abrasion ResistanceLow Dust Product

NDB: Technical FeaturesNDB: Technical Features

Granules Flakes NDB

Anox PP 18 7 – 8 1 1

Anox 20 4 – 5 - 1

Binary Blend 12 – 16 - 5

NDB KS 10 - - 2

% of Product < 180 µm After 5 Minutes of Shaking with Glass Balls

NDB Hardness: Abrasion TestNDB Hardness: Abrasion Test

High Abrasion ResistanceLow Dust Product

Good Flow Properties

NDB: Technical FeaturesNDB: Technical Features

Powder NDB Granules

Anox 20 40° 37° 33°

Anox PP 18 48° 41° 36°

TBM6 52° 40° 35°

< 30° excellent, 31-35° very good, 36-40° good, 41-45° satisfactory, 46-55° poor, > 56° very poor

NDB NDB FlowabilityFlowability: Angle of Repose: Angle of Repose

Dosing Accuracy of Powder BlendsDosing Accuracy of Powder Blends

Primary AO

Secondary AO

DHT-4A

Over Dosing

‘Off-Spec’ Minimum Required

Set Point

Multiple Additive Addition

NDB Addition

Less Overdosing

No ‘Off Spec’ by NDB*

* Excluding Off spec due to outside effects (e.g. polymer quality…)

Dosing Accuracy of Powder BlendsDosing Accuracy of Powder Blends

3 Component Blend (1:2:1) of Anox 20 + Alkanox 240 + CaStTarget for Polymer Producer is 2000 ppm

DosingAccuracy

RequiredAdditivation

Cost($US / TPolymer)

20 % 2400 ppm $US 11.4015 % 2300 ppm $US 10.9310 % 2200 ppm $US 10.455 % 2100 ppm $US 9.972 % 2040 ppm $US 9.69

For a 250,000 TPA Plant Feeding at ±15% AccuracyUsing NDB Can Lead to > $US 300,000 Savings

Dosing Accuracy Affects Set PointDosing Accuracy Affects Set Point

Less Feeding Problems Productivity

Accurate Dosing (Less Additive Used) Cost Reduction

Packing / Unloading / Handling Productivity

Benefit Contribution

Benefits: Good Flow PropertiesBenefits: Good Flow Properties

High Abrasion ResistanceLow Dust Product

Good Flow Properties

NDB: Technical FeaturesNDB: Technical Features

Wide Range of Formulations

Formulation Optimisation Reduced Cost

Lower Additive Levels Possible Reduced Cost

Benefit Contribution

Benefits: Wide Formulation RangeBenefits: Wide Formulation Range

High Abrasion ResistanceLow Dust Product

Good Flow PropertiesWide Range of FormulationsHomogeneous, Consistent Composition

NDB: Technical FeaturesNDB: Technical Features

Anox NDB xxxxx #980003/L - cp #16

15.0

19.0

23.0

27.0

31.0

35.0

1 6 11 16 21 26

%

Anox 20 Alkanox 240 Component 1 Component 2

Composition AccuracyComposition Accuracy

Less Off Spec Product Increased Profits

Reduced Additive Overdosing Cost Reduction

Consistent Polymer Properties Product Quality

Significantly Lower QC Costs Increased Profits

Lower Human Error Potential Productivity, Profits

Benefit Contribution

Decreased Homogenisation Time Productivity

Benefits: Consistent CompositionBenefits: Consistent Composition

High Abrasion ResistanceLow Dust Product

Good Flow Properties

Wide Range of FormulationsHomogeneous, Consistent Composition‘Difficult’ Additive Incorporation

NDB: Technical FeaturesNDB: Technical Features

Less Sticking / Clumping (Low Melters) Productivity

Liquids Can Be Included Cost Reduction

Dispersion, Dust (Non-Melters) Performance, H&S

Benefit Contribution

Benefits: Benefits: ‘‘DifficultDifficult’’ Additive UseAdditive Use

High Abrasion ResistanceLow Dust Product

Good Flow Properties

Wide Range of FormulationsHomogeneous, Consistent Composition‘Difficult’ Additive IncorporationSingle Pellet Formulations

NDB: Technical FeaturesNDB: Technical Features

to Pelletizing (5)

PP Processing Technology 2PP Processing Technology 2

from Storage (1)Balance (2)

Balance (3)

Balance (4)

Mixer (5)

Feeding (6)

Extruder (7)

Polymerization Process

PP “Powder”(main stream)

PP “Powder”(side stream)

Single Additives

Master Fluff

to Pelletizing (5)

PP “Powder”

Polymerization Process

NDB

Extruder (4)

from Storage (1)

Balance (2)

Feeding (3)NDB

Alternative Concept Alternative Concept -- Technology 2Technology 2

Less Storage Volume Operation Costs

One Products vs Several Admin Costs

Lower Human Error Potential Productivity, Profits

Less Capital Investment Capital, Op Costs

Process Simplification Productivity, Costs

Benefit Contribution

Reduced Maintenance Required Operating Costs

Benefits: Single Pellet FormulationsBenefits: Single Pellet Formulations

• Good Flow Properties• High Abrasion Resistance• Improved Industrial Hygiene • Accurate Composition of NDB• Reduced Errors due to Feeding• Reduced Risk of Human Error• Homogeneous Additive Distribution in Polymer• Potential Concentration (Set Point) Reduction• Reduction in Homogenisation Time

NDB: Summary of AdvantagesNDB: Summary of Advantages

NDB: Summary of AdvantagesNDB: Summary of AdvantagesBy Key AreasBy Key Areas

Safety Quality Productivity & Cost Savings

• Good Flow Properties• High Abrasion

Resistance• Accurate Composition

of NDB• Homogeneous

Additive Distribution in Polymer

• Improved Industrial Hygiene• Eliminate Dust Explosion

• Reduced Errors due to Feeding• Reduced Risk of Human Error• Potential Concentration (Set

Point) Reduction• Reduction in Homogenisation

Time• Reduced Material Losses from

Spillage or Dust• Less Material Inventory• Reduce Number of Sampling of

Individual Components• Less Capital Investment on &

Maintenance of Laboratory Equipment

SummarySummary

Consistent Quality, Value, Cost Benefits, H&S

• NDB’s offer New Solutions and Services• Features and Benefits • Many Technical and Commercial Benefits