Periodic Reporting for period 2 - UFPCC (Scale up of the Continuous Production Method for Nano-sized Precipitated Calcium Carbonate, and market Introduction for Industrial End Use)
Période du rapport: 2017-11-01 au 2018-10-31
In addition to current products, FP-Pigments has developed a novelty manufacturing method for pigment material called ultra-fine precipitated calcium carbonate (UFPCC), which have been tested in several new applications. The most interesting ones are:
1) the replacement of the plastic barrier material used in paper and board applications;
2) the replacement of the most widely used opacity pigment TiO2 in paints; and
3) additive in sealants and adhesives in order to improve strength and other material properties.
Compared to the current pigments, the manufacturing process of UFPCC enables vast savings in terms of carbon footprint, water consumption, and cost. For example in comparison with TiO2, the annual CO2 emission reduction potential is up to 90%.
FP-Pigments has manufactured UFPCC samples with both laboratory scale and pilot scale equipment for laboratory, pilot and plant scale application testing. Target of the UFPCC-project is to scale-up the production capabilities from laboratory/pilot scale to environmentally friendly, continuous industrial scale process, and to introduce the new nano-sized UFPCC -products to the market. Project includes the design and construction of the industrial scale pilot plant, application testing together with selected customers, as well as investment plan for FP´s factory in Leuna, Germany.
Both wet UFPCC and dry, surface coated UFPCC products have been tested in paper, coatings, sealants, concrete, plastics and printing ink applications. Product samples have been provided to potential customers for evaluations and feedback has been promising. There are both technical and commercial benefits to use UFPCC in various application fields.
UFPCC product has potential impact on several large market segments; i) barrier coatings for the packaging industry (paper and board), ii) TiO2 replacement in paints and coatings, and iii) functional fillers in sealants and adhesives. These market segments play an important role in Europe. The packaging industry is one of the biggest in world, therefore the need for competitive products for conventionally widely used polyethylene (PE) film are of outmost importance. The European automotive and aerospace industries are very dependent on coatings, sealants and adhesive of highest standards. UFPCC will positively affect the whole European industry as it enhances the performance, is very cost efficient, and has a significant positive impact on the environmental aspects to the final products.
The new UFPCC complies with current regulations and FP-Pigments, as a member of Calcium Carbonate Association, will be among the first to react if any actions are needed to maintain the compliance.