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