Unique Amorphous Silicon Dioxide a new additive for the PVC Formulator With Practical Case Studies

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1 PVC Brighton, April 2008 Unique Amorphous Silicon Dioxide a new additive for the PVC Formulator With Practical Case Studies Stuart MacDonald - Technical Sales Manager Elkem Materials

2 History of SIDISTAR Timeline Elkem R & D in Polymers begins 1998 Work with Institutes to prove theory (s) First Industrial trials in PVC SIDISTAR launched First commercial sales in PVC 2004 SIDISTAR Second plant commissioned 2007

3 What is SIDISTAR Amorphous silicon dioxide Mean particle size: 150 nm Spherical particle shape Surface area 20 m 2 /g SIDISTAR Primary Particles TEM 41kx Magnification SIDISTAR has two functionalities in PVC :

4 SIDISTAR the Impact Modifier Traditional Organic IM: Absorption of Impact Energy SIDISTAR : Dissipation of Energy

5 Application Window Profiles Successful results have been achieved in the application area Window profiles. For optimised results some production adjustments were carried out : (1) Mixing protocol adjustment - the densified SIDISTAR particles must be fully dispersed throughout the PVC matrix in order for them to successfully dissipate the impact energy. It is best if the filler is added later in the cycle. Hot Mixing Sidistar into PVC (2) SIDISTAR does not affect the gelation time like traditional impact modifiers, therefore the gelation must be re-adjusted to the correct level. SIDISTAR and gelation

6 SIDISTAR in Window Profiles (i) USA Impact test results from USA window profile customer : ASTM D (Impact covered by D ) Gardner Drop Height (in.lbs) Standard Pre-trial 248 Sidistar recipe incorrect processing 88 Sidistar recipe correct processing 320 In the USA the recipe technology is somewhat different to Europe. A higher level of TiO 2 is generally used this tends to lend this technology more towards the incorporation of the Silicon Dioxide impact modifier since the colour change is significantly smaller.

7 SIDISTAR Colour Limitations Effect of Sidistar T120 on L-Value L - Value Zero Sidistar T120 Sidistar T phr Trend Lines Sidistar T phr Sidistar T phr TiO 2 Level

Heat Ageing EN478 Pass Weldability EN514 Pass T- Bar section Vicat >75C Pass Tensile Impact EN ISO 8256

8 SIDISTAR in Window Profiles (ii) Europe 50 : 50 SIDISTAR : Acrylic Impact Modifier (3.25phr each) Door Frame Specification : BSEN : 2003 Falling Weight EN477 Pass Reversion EN479 Pass Heat Ageing EN478 Pass Weldability EN514 Pass T- Bar section Vicat >75C Pass Tensile Impact EN ISO 8256 Pass Charpy Impact EN ISO Pass E modulus >2200N/mm2 Pass Weathering artificial generic completed - outdoor on going.

In fence extrusion Sidistar replaces acrylic impact modifier.

9 SIDISTAR Impact Modifier : Fence and Soffit In soffit extrusion Sidistar replaces CPE impact modifier passing internal specification. In fence extrusion Sidistar replaces acrylic impact modifier. Impact Results : ASTM F964 (C.125 Impactor Spec min 1.2inlb / mil) Control MFE/mil 1.37 Sidistar MFE/mil 1.42

10 SIDISTAR Impact Modifier Examples others SIDISTAR in Vinyl Siding Vinyl Siding ASTM D a Control (H.25 Impactor min 60 inlb) MFE 62.4 inlb Sidistar MFE >64 inlb SIDISTAR in Corrugated Land Drainage Pipe

11 SIDISTAR the Mechanical Processing Aid The unique properties of SIDISTAR are derived from its precise particle size distribution, low surface area and smooth spherical shape. These small spherical particles roll within the PVC melt acting as a viscosity modifier and homogenising the melt flow. In foamed Vinyl production the small spherical particles also help disperse the additives and acts as nucleating points for an homogenous cell structure. Following are examples of SIDISTAR as a processing aid :

12 SIDISTAR in Foam Core Pipe 110 x 3.2mm Foam Core Pipe (core contains 1.5 phr SIDISTAR ) 0.6 mm 0.4mm Minimum 3.2mm A typical starting point recipe for Foam Core Pipe with SIDISTAR is : Skins Recipe: PVC K CaCO3 (filler) Stabiliser In the application area of foam core pipes SIDISTAR helps the foaming process assisting in the formation of a fine core cell structure and supplementing impact resistance. Core Recipe: PVC K57 or K CaCO3 (Filler) Stabiliser SIDISTAR T (or SIDISTAR T120 if light colour is required) Blowing Agent ADC % (added in mixer or on-line)

13 SIDISTAR in Foam Sheet (1) Trimboard 1 inch Foam Trimboard containing 5.0 phr SIDISTAR and 8.5 phr P.Aid A 25mm Thickness fine cell structure

14 SIDISTAR in Foam Sheet (1) Trimboard 1 inch Foam Trimboard containing 5.0 phr SIDISTAR and 8.5 phr P.Aid A Trimboard Characteristics : STANDARD 13.5 phr P.Aid A 5.0 phr SIDISTAR phr P.Aid A Density g/cm Tensile Strength (MPa) Youngs Modulus (MPa) Flexural Modulus (MPa) Izod 23ºC (kj/m 2 ) HDT B ( ºC) 61 68

15 SIDISTAR in Foam Sheet (2) Advertising Board Advertising Foam Sheet containing 3.25phr SIDISTAR and 3.25 phr P.Aid B Density as standard (6.5phr P.Aid B) Digital printing quality surface finish. 3mm advertising board

6 phr P.Aid C : 2.6 phr SIDISTAR Density 0.56 g/cm 3 0.48 0.51 0.50 0.54 Thickness 9.16 mm 8.

16 SIDISTAR in Foam Profile Standard Pre-Trial 6.5 phr P.Aid B Density 0.62 g/cm Thickness 8.64 mm Foam colour : L 93.2 a 0.33 b : phr P.Aid C : 2.6 phr SIDISTAR Density 0.56 g/cm Thickness 9.16 mm Optimised lubrication Result as Standard Foam colour : L a 0.00 b 7.80

17 SIDISTAR in Foam Profile Comparison of cell formations Standard Pretrial 6.5 phr P.Aid B 50 : phr P.Aid C : 2.6 phr SIDISTAR

other inorganic additives : SIDISTAR Increases tensile modulus (stiffness) and

18 SIDISTAR in WPC Sidistar can have multi-functional* properties in WPC SIDISTAR recipe Sidistar improves extrusion properties Other inorganic additives * In WPC Compared to other inorganic additives : SIDISTAR Increases tensile modulus (stiffness) and tensile strength. Increases impact strength - Charpy Increases HDT Reduces water absorption

19 Conclusion : SIDISTAR The unique amorphous Silicon Dioxide (SIDISTAR ) has now been proven in several application areas. It is cost effective and can enhance the physical properties of bith rigid and cellular PVC products. The PVC formulator should add Sidistar to the materials toolbox and consider its attributes when formulating for new products. For further Information : Elkem Materials Tel : Elkem Materials (USA) Tel : info@sidistar.com

20 References and Acknowledgements : Inorganic Impact Modifier and Process Aid for PVC Presented by Dr G.Schmauks PVC Conference Brighton 2005 G.Schmauks, B,Friede, A.Sørhuus, J.O.Roszinski ElkemASA M.Gilbert, D.J.Hitt IPTME Loughborough University Multifunctional impact of a new inorganic material in vinyl cellular foam Presentaed by M. Kager Currents Trends in PVC Technology Loughborough University November 2006 To all or Industrial Partners Thankyou.

21 SIDISTAR from Elkem Materials Thank you for your attention. Our Values: Forward-looking Enthusiasm Empathy Credibility Elkem is one of the worlds leading companies for environment-friendly production of metals and materials. Elkem a company in the Group.

SolutionProvider. Donglin Chem

SolutionProvider. Donglin Chem HMW Processing Aid PVC Foam Regulator Melt Strength and Melt Elasticity are Two critical elements that are critical in the development of an effective rigid cellular foam PVC formula. When the balance