pq corporation silica gels webinar - sam morell
TRANSCRIPT
© 2020PQ Corporation. 1
PQ Corporation
Silica Gels Webinar
PQ History
Our NA side, founded in 1831 as
“Joseph Elkinton’s Soap & Candle
Manufactory” and changed to
Philadelphia Quartz in
1864…now known as PQ
Corporation.
Our European side, founded in
1815 as Joseph Crosfield and
Sons Ltd. in Warrington, England
as a soap manufacturer. Changed
hands and names a few times and
most recently prior to merger, was
Ineos Silicas.
Joseph CrosfieldThomas Elkinton
PQ Today
• Headquarters in Malvern, Pennsylvania
• Annual sales revenue US over $1.6 billion
• About 3,000 employees
• Over 67 manufacturing sites in 19 countries on 5 continents
• Silicas and silicates used in many markets including coatings, construction, and oil field.
Wesley E. Robertson – Technical Manager
PQ Corporation
Silica-Gel Technology as Matting Agents in
Coatings
Types of Synthetic Silicas
Manufacturing Process/Locations
What is Silica-Gel?
Benefits and Limitations
Where is Silica Gel Used?
How is it used?
Product Selection
General Industrial Systems
Wood Systems
Matting Agents for Inks and OPV’s
Gasil Silica Gel Products
Silcron G-100
Advera Ti
Manufacturing Locations
Objectives
PQ’s Xerogel
Process
Joliet IL
Manufacturing Locations
Warrington, England
Synthetic amorphous silicon dioxide manufactured under tightly controlled
conditions to give the desired properties.
Sponge-like structure with a well defined porosity.
Low Pore Volume (LPV) Silica absorbs moisture vapor but have poor carrying
capacity for liquid systems. (Gasil GM2). Dense structure makes this type of product
suitable where particle strength is important.
Medium Pore Volume (MPV) Silica are used in High Solids Applications and Systems
where lower formula viscosity is needed.
Ultra High Pore Volume (UHPV) Silica are the most effective as matting agents
because they offer more SiO2 particles per unit weight. They possess a lower bulk
density which can create a thickening effect.
What is Silica-Gel
Silica Matting Agents
x5000
Low density
particulates with
controlled particle
size distribution
and high purity
Average Particle Size (APS) measured in microns @ Equal Pore Volume (PV)
Higher the micron size the more efficient for optical performance (Gloss)
Lower the Micron size the less efficient
Particle Size Distribution @ Equal Pore Volume (PV)
The narrower the distribution curve the more efficient the optical performance (Gloss).
The larger the distribution curve the less efficient
Particle Size and Distribution
Silica particles create a micro-roughness on coating surface.
Rough surfaces scatter light rays thus reducing gloss.
Matted Surface Viewed With SEM
Pore Volume
Low Pore Volume 0.4 ml/g Medium Pore Volume 1.2 ml/g Ultra High Pore Volume 1.8 ml/g
Matting Effectiveness 2.7 Matting Effectiveness 1.4 Matting Effectiveness 1.0
SiO2 Air
Pore Volume influence on Matting
Efficiency
MPV
UHPV
Polyester Coil Coating
0.5 mils DFT
8 µm APS of silica
2 3 4 5 60
10
20
30
40
50
60
70
% silica
Gloss@ 60
Degrees
1.2 PV
1.8 PV
Coatings Market Segment:Automotive (Interior)
General Industrial OEM
Architectural Coatings
CoilConstruction/Appliance/Transportation/HVAC/MOF
Furniture (Wood and UV Coatings)
Leather
Paper
Inks
Successful Markets
Coil Coatings
General Industrial (OEM)
Roof Coatings
Wood and UV Coatings
Decorative Coatings
Where is Silica-Gel Used
Advantages Disadvantages
Fumed Silica
Very Efficient
Minimal Effect on Clarity
Very Expensive
Builds Viscosity and Dusting
Precipitated
Silica
Easily Dispersed
Less Expensive
Only Neutral to Alkaline grades
Shear Sensitive/Friable
Builds Viscosity
Can give white/blue tones in
clear systems
Silica Gel Narrow Particle Distribution
Resistance to Over-grind
Efficient Matting
Acidic Grades for Acid Catalyzed
systems
Moderate Price
Benefits and Limitations of
Synthetic Silica
Coating Property Silica Property
Gloss Requirements Particle Size/Pore Volume
Dry Film Thickness Particle Size
% Solids (NVM) Particle Size Pore Volume
Viscosity Requirements Particle Size/Pore Volume/OA
Solvent or Waterborne pH
Acid Catalyzed pH
Pigmented or Non-pigmented Surface Treatment
Product Selection
Raw Material Selection
Resins, Additives, Pigments and Solvents
Order of Addition
Synergistic effects
$$ Cost
Millbase Optimization
Pigment to Binder Ratio (P:B)
Shear Rate
Dispersion
Stabilization
Letdown
Continual Mixing and Catalyzing phase
Formulation
Product Selection
High Batch Temperatures (> 140 deg. F.)
Millbase not balanced.
Solvent Shock
Acid Shock
Formulation Pitfalls
Raw material selection
Synergies
Order of addition
Rate of addition
Keys to Successful
Formulation
Break-up of particle agglomerates
Wetting
Stabilization
Letdown
Keys to Successful Silica
Formulation
High Speed Disperser
Cowles type stirrer
Milling Equipment
High Speed Disperser
Cowles type stirrer
General Industrial Systems
0
20
40
60
80
100
1% 2% 3% 4%
Silica Gel
Precipitated Silica
60o Gloss Comparison of Silica-Gel versus
Precipitated Silica in a White GI Formulation
0
400
800
1200
1600
2000
2400
2800
3200
cps
1% 2% 3% 4%
Silica Gel
Precipitated Silica
Viscosity Comparison of Silica-Gel versus
Precipitated Silica in a White GI Formulation
Solvent Borne Clear Systems
Treated Silicas are best suited for clear systems.
Untreated Silicas are best suited for pigments systems.
Acidic silica's are best suited for Solvent based systems.
Neutral silica's are best suited for water based systems.
Pigmented vs Clear Systems
0
10
20
30
40
50
60
70
80
90
100
2% 4% 6% 8%
Loading
Gloss
HP240J HP210 HP220
Optical Characteristics of
Gasil Silica in a Polyurethane
Wood Coating
0
50
100
150
200
250
300
350
0% 2% 4% 6% 8%
Loading
Viscosity(cps)
HP240J HP210 HP220
Physical Characteristics of
Gasil Silica in a Polyurethane
Wood Coating
Synthetic Silica-Gel (New Development)
Manufactured in the UK
Comparable properties to TS100Viscosity
Clarity
Potential Cost Savings
ApplicationUltra High Efficient Silica Matting Agent. Suitable for Wood,
Coil and General Industrial Coatings. It performs well in
Water-Based Formulations.
PV – 1.8 mL/g
APS (D50) - 9.5 μm
pH (5% acq.suspension) - 4.5
Loss at 1000C 8% Max
Oil Adsorption (Linseed) 390g/100g
Surface Treatment - None
Gasil XE3100
Properties Gasil HP335 Gasil UV70C Gasil HP380 Gasil HP710
APS (Malvern 100 mm lens) microns 4 7.5 7.7 10.0
Pore Volume (mL/g) 1.8 1.8 1.8 1.8
pH (5% aqueous suspension) N A N N
Loss @105 deg. C (%) 2 2 2 2
Loss @1000 deg. C (%) 12 14 12 12
Oil Absorption, Linseed (g/100g) 250 250 250 250
Surface Treatment PE* PE PE* PE*
* High MW PE Wax
Silicas for UV Curable Coatings
Properties Gasil IJ35 Gasil IJ37 Gasil 23D Gasil HP230 Gasil HP33C
APS (Malvern 100 mm lens) microns 5.2 6.3 4.4 3.6 3.3
Pore Volume (mL/g) 1.2 1.2 1.8 1.6 1.8
pH (5% aqueous suspension) N N N N N
Oil Absorption, Linseed (g/100g) 250 250 250 250 250
Surface Treatment Paraffin
* High MW PE Wax
Matting Silicas for Solvent and Water
Based INKS and OPV’s
Gasil Silica Gel Products
High Pore VolumeHP210
HP220
HP230
HP240J
HP33C
HP260
HP270
HP280
HP290
HP335
HP380
HP710
HP860
HP870
HP880
HP39
XE3100
UV70C
23F
PQ Corporation Silica-Gel
Products (Gasil)• Medium Pore Volume
– IJ37
– IJ35
– IJ24
– IJ1
– IJ45
• Low Pore Volume
– 200DF
– GM2
Silcron
G100
G130
G300
G500
G520
G601
PQ Corporation Silcron Products
Silica Gels
A high performance
zeolite-based product
for the partial replacement
of TiO2 in paints, offering
significant cost savings
ADVERA® Ti
ADVERA® Ti
What is ADVERA® Ti
• A high performance zeolite-based product
• Allows partial replacement of TiO₂ with no adverse
effects on paint properties.
Typical Properties of
ADVERA® Ti
Average Particle Size (Malvern Mastersizer) 3.0-4.0µ
Loss at 800°C 18-21%
Specific Gravity 2.0-2.3
pH (1% aqueous solution) 10.5-11.5
Oil absorption (Linseed) 20-30 g/100g
Color (L Brightness) 97-98%
Bulk Density 30-50 Lb/ft³
Retained on 325mesh screen <0.5%
Benefits of ADVERA® Ti
• Improved hiding
• TiO₂ spacing
• Fine particle size
• Low oil absorption
• High hydrophilic characteristics
• Low specific gravity
Matting Agent Efficiency Test
Coating FormulationQuantity of silica to achieve a gloss of 20
DFT of 1.0 mils
0 1 2 3 4 5
4.5
4.3
3.6
3.3
2.9
2.8
Silica type
Wt % silica to achieve Gloss of 20
6.4
6.6
8.0
8.7
10.5
12.0
APS
• Wax treated products are recommended when hard settling problems are
encountered.
• Acidic grades are recommended to enhance dispersion characteristics in
solvent based systems.
• Neutral grades are recommended in water-base formulations.
• Gloss reduction result of silica particles creating uneven surface which
scatters light.
• Efficiency of silica matting agent increased by increasing pore volume and
producing a narrow particle size distribution.
• The use of high efficiency matting silica can reduce raw material and plant
manufacturing costs and improve physical properties of coating.
• Consistency of synthetic silica can only achieved by using state-of-the-art
plants that controls Pore Volume, Particle Size, and pH.
Summary
Questions?