/SGOA GRANT ## DEFGO1-94 CE1502 QUARTEXLY REPORT. February 3, May I, I996

Transcription

1 /SGOA GRANT ## DEFGO1-94 CE152 QUARTEXLY REORT February 3, May, 996

2 DSCLAMER This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, make any warranty, express or implied, or assumes any legal liability or respomibiiity for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

3 ortions of this document may be illegible in electronic image products. mages are produced from the best available original dolnment

4 As outlined in the last quarterly report, we repeated the testing of control formulas due to instability of the Ti2 dispersion being used Additionally,we compared the calcined clay controls to the performance of layered pigments of the instant invention in coatings on brown natural kraft paperboard fkom Mead Corporation. Figures 1 and 2 summarize dispersion properties of layered pigments made with a cationic water soluble polymer and a cationic latex,respectively. With both dispersing agents for dry Ti2 an acceptable Viscosity of 2-3 cps at % solids is obtained. As the amount of Ti2 increases in the layered pigment in which the Ti2 was dispersed by cationic polymer, the wet void volume increases. Using cationic latex, however, results in a considerably lower wet void volume. This is clearly seen in Figure 3. Figure 4 shows that the layered pigment is stable to a variety of shear conditions. The amount of anionic sodium polyacrylate (Colloids 211) post added to minimize final viscosity was determined for each layered pigment. n the process of optimization of Viscosity of the layered pigments, the pigments were tested in coatings at each incremental addition level of Colloids 211 dispersant for brightness compared to the non layered control pigment blend. Brightness was measured as a function of coatweight on precoated board. n Figure 5 it is seen that the addition of the anionic dispersant did not affect board brightness and that a major improvement was obtained over the loose blend of Ti2 and EZ clay. n Figure 7, the performance of layered pigment using 7655 dispersant for Ti2 is compared to the standard coating using Ti2 and dcined clay. Calcined clay definitely improves coating performance but the layered pigment gave 2-3 points even better brightness. t was not just using the engineered clay EZ that accounted for the difference in performance but rather the layered pigment process as seen in Figure 8.

5 Figures 9 and 1 show that these same benefits are obtained after 1nip steel to steel calendering. Figure 11 shows the significant improvement in paperboard gloss using the layered pigment compared to the blend with calcined clay. Figures 12 and 13 show the major improvement possible in ink gloss with layered pigments. Huber Clay Company manufactures a board pigment called BC. We have found that we could significantly upgrade it optical performance by submitting it to the layered pigment process ( Figures 14 and 15). t was of interest to learn more about the effect of the layered pigment process on BC pigment. To a mixture of Ti2, BC and water the cationic latex Basoplast was added followed by Colloids 211 dispersant. As seen in Figure 16 a substantial drop in performance is seen, probably due to homoflocculation of Ti2. n a second experiment Basoplast was added to BC followed by Colloids 211 then Ti2 slurry. A fwrther drop in brightness is observed. t was concluded that Ti2 must be dispersed with the cationic latex in order for the distribution of Ti2 to be controlled and preferred porosity to be developed. n Figure 17 it is M e r seen that a significantly greater loss in brightness on calendering is observed with the control loose blend than with the layered pigment. t was then of interest to determine the performance of the layered pigment compared to loose blends of Ti2 and commercially available chemically structured pigments. n figure 18 the wet void volume, a measure of structuring is shown. n Figures 19 and 2 the mcalendered and calendered brightness data are presented. Clearly,the layered pigment offers improved optics over alternative chemically structured systems. Figures 21 and 22 show that the layered pigment is competitive in ink gloss to alternative structured pigments and superior to calcined clay. The same is true for overprint varnish gloss (Figures 23and 24).

6 Using the cost data in Figure 25, the pigment costs per ton are summarized in Figures 26 and 27. The cost to achieve an 8.1 calendered brightness using the traditional Ti2, clay, calcined clay blend compared to layered pigment system which requires much less Ti2 and no calcined clay is shown in Figures 28 and 29. A major cost savings is possible. The same is true if one were targeting an 8.1 brightness but using a non traditional system incorporating blends of Ti2 and chemically structured pigments. From a business perspective, Dry Branch Kaolin has temporarily ceased working with us due to manpower restrictions. We anticipate resumed joint work in the third quarter. Meanwhile, we are attempting to interest Engelhard Minerals and Chemicals Corporation in these pigments. For the next quarter we will be making layered pigments with Miragloss pigments for EMC and evaluating their performance. Additionally, we will be examining other latex dispersants as well as new Brazilian clays using this technology.

7 GMENT ROERTES T76552 T EZ EZ T76553 EZ * * Gels but thins rapidly with shear.

8 GMENT ROERTES Material % Colloid 21 1 (on TiO,) % Solids Brookfield % Wet Void Viscosity, 6 Volume TB2 EZ.27 * TB25 E TB3 E *.2% is all that is needed

9 RELATVE STRUCTURNG 1

10 e SHEAR STABLTY OF LAYERED GMENTS T b 2 E2 Uncalender Calendered Shear Viscosity,Brightness Brightness Treatment % Solids (6 rpm) % bs/msf None rr. \ r$?i?' t

11 BRGHTNESS 4 4 h, 4 4 h, h, h) A + A + A + U 3 rn? 2? Q, N rn N + ( 8 2 h,

12 e 4 l Q\ u M M u M N 8 u M M N + u O 4 um N + w s \o g "+ MN w \o u l o\ V tq M o\ c. w w \D c., w h, V c-r w c) oaif

13 UNCALENDERED BRGHTNESS: COATED ON RECOATED NATURAL KRAFT 84 e #1 Clay #1 Clay t 5% Ansilex #1 Clay t 1% Ansilex T 7655 EZ YO Ti2

14 UNCALENDERED 3.5 bs/l sf OF LOOSE BLENDS OF Ti2 AND EZ: COATED ON RECOATED NATURAL KRAFT v) v) W 1 81 z ~ k a a , 1 T 1 + 1! T Loose Blend EZ) * 2 ' % Ti2 4 Layered igment ( 2-Baso)

15 4 ul BRGHTNESS 4 4 4, 4 (D

16 CALENDERED BRGHTNESS: COATED ON RECOATED NATURAL KRAFT #1 Clay 79 T % Ansilex #1 Clay + 1% Ansilex #1 Clay % Ti Baso EZ

17 CALENDERED GLOSS: COATED ON RECOATED NATURAL KRAFT 7 6 DBK-1 + 5% Ansilex + DBK-1 + 1% Ansilex % Ti DBK-1 Layered igment (Baso)

18 CALENDERED NK 2. NK DENSTY D 3 c) 6 v) v) z a

19 T hl a, a,

20 UNCALENDERED BRGHTNESS VS % Ti2: H,UBER BC Loose Blend Layered igment (EZ--Baso) 81 Layered igment (BG-Baso) 8.5 ~ % Ti2 3 Layered igment (E )

21 CALENDERED BRGHTNESS VS % Ti2: HUBER BC Loose Blend Layered igment (BC-Baso) + Layered igment (EZ--Baso) % Ti2 3

22 3.5 LBS133 SF a3 h, 1 c z =! R F + r- ill Q 2 U m m rn =p U t.. f?, D - rn U z z 5c 1 F r

23 CALENDERED 3.5 bs/l sf: COATED ON RECOATED NATURAL KRAFT 78'4 T LL v) z ' Lc! v) E aa OE L *8 t + 2 Ti2 t 8 BC T b 2 BC 18 BC+2 Ti2 +Water t Basol + C [8 BC +Water + C Basol + 2 Ti2

24 t 1

25 ERFORMANCE OF GMENTS AT 25% Ti t T Baso 2 5 EZ t 75% Astraplus t 75% BC t 75% Exsilon t t 75% DBK-1 7 % DBK-1 + 5% Ansiex t 65% DBK-1 + 1% Ansilex Uncalendered 3.5 bdmsf: coatings contain 25% Ti2, 4 pph rocote 4 and 17 pph Dow 62, coated on precoated natural kraft

26 ERFORMANCE OF GMENT SYSTEMS AT 25% Tib a T Baso 25 EZ t 75% Astraplus % BC 75% Exsilon 75% DBK-1 7% DBK-1 5% Ansilex + 65% D B K ~t 1% Ansilex Calendered 3.5 bs/msf: coatings contain 25% Ti2, 4 pph rocote 4 and 17 pph Dow 62, coated on precoated natural kraft.

27 CALENDERED NK 2. NK DENSTY aa(d (D ~ ~ g 2 ~ g $? % % z a w o ~ N. t t

28 t NK GLOSS COMARSON cn 85 cn sc3 E Y T b 3 EZ 3 Ti2 1 Ansilex 6 #1 Clay 3 Ti2 7 BC 3 Ti2 7 Astraplus

29 23 GLOSS CD cn CD CD u1 CD m E.6 3 n D z; D z m F d -. 3

30 a GLOSS co 2 tu (D co. co (D V m 5, al a CT.o U 5 a h,.. co )

31 Z t m 5 s '6, z 9, h, V x 5 8 W n e c m 4 6 N a" 69 \o V U N

32 GMENT COSTS--l2/95 $/TON TiO,, DBK-1, and ANSLEX GMENT BLENDS Yo Ansilex YOTiO, COMETTVE GMENT BLENDS igment 15% TiO, + 85% Huber BC Cost ($/ton) % Huber BC 25% TiO, + 75% Huber BC 3% TiO, + 7% Huber BC 58. 4% TiO, 91. 2% TiO, + 6% Huber BC 15% TiO, + 85% Astraplus 25% TiO, + 75% Astraplus 35.5% TiO, % Astraplus

33 27 STRUCTURED GMENT COSTS $/TON igment Cost ($/ton)

34 TRADTONAL VS LAYERED GMENT COST FOR 8.1 CALENDERED BRGHTNESS igment System Cost ($/ton) Savings Using TB2 E2 ($/ton) T,2 E TiO, + #1 Clay TiO, + 5 Calcined + #1 Clay 35 TiO, + 1 Calcined + #1 Clay

35 TRADTONAL VS LAYERED GMENT COST FOR 81.4 CALENDERED BRGHTNESS igment System Cost (Won) Savhgs Using TB25 EZ ($/ton) TB25 E TiO, + 5 Calcined + #1 Clay 41 TiO, + 1 Calcined + #l Clay

36 w 4 6 N + V 4 g h, + N w 4 c3 5 N c3 W h, m N Q\ OQ CK, L C n ff) 2 V et W o\ M N

37 31 w 5 O + N h, O c3 Nij. + 4 W h, V m N z! os Et ( E V m w v, 4) 4) 4 \Q h) o\ \o 'h, V.., c E' B w V h, \o m N