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NEW GENERATION OF CALCIUM CARBONATE
                                                  K.K.Mishra
                                       20 Microns Ltd., Mumbai, India


                                           GENERAL OUTLOOK
Paint, as an aesthetic and protective material, has undergone significant transformation over the years from
being just a colour to a performance specific composite material. With this change, the ingredients of paint
have evolved into more sophisticated functional raw materials. Extenders once considered as mere fillers are
today looked upon as functional input to the paint contributing to rheology, adhesion, gloss control, hiding and
PVC optimization. This situation necessitates up gradation of techniques and for the characterization of
extenders.
MANY paint makers still believe that fillers, (extenders, minerals) are of little importance, low cost and widely
available products. But extenders should no longer be viewed in such terms. They have a functional purpose
in the paint end product and their properties and qualities will substantially affect this product. Paint makers
must expand and modernize their production facilities to cope with increasing technological sophistication. In
trying to cut costs, raw materials will be a key consideration. Many paint makers have successfully decreased
the use of expensive titanium dioxide by partial replacement of white extenders which are properly ground to
the extent of sub-microns to 2microns average particle size.


                                       FUNCTIONAL EXTENDERS
Extender pigment or simply extenders are also so called because such materials are used to “Extend” the
effect of expensive white and coloured pigments, so cheapening the paint formulation. However, it is now
recognized that extender pigments contribute much more to paint properties. Careful selection of the type and
quantity of extenders can affect such features in paints & coating as:
1. Opacity or hiding.
2. Gloss or sheen.
3. Flow, leveling and smoothness.
4. Durability and appearance of the paint film.
5. Pigment settlement on storage.
6. Barriers effect and water permeability etc.


Conventionally, extenders have been characterized employing simple techniques like visual colour
assessment, sieving, specific gravity, oil and water demand, pH and microscopic examination. These tests do
give very useful information to the paint formulator in deciding upon fundamental formulation parameters like
PVC, weight per liter, finish and the like. However, if one desires to establish the closer relationship between
characteristics of the extenders on one hand and various paint making, application and performance
parameters on the other, then the use of modern analytical techniques become unavoidable. These
techniques possess the capability to look at the micro structure of extenders in terms of size, shape, surface
chemistry and crystallography. Correlations established between different extender parameters and a paint


                                                 -1-
performance property enables the technologist to diagnose the cause of the quality or performance problem.
More importantly, it provides predictive capability to envisage performance of a paint which incorporates
certain type of extenders.
While examining various modern techniques, it is important to take over view of various particle size analysis
techniques like, electron microscopy forms a very important tool for examination of particle shape which has
significant bearing on RHEOLOGY, GLOSS AND OPACITY AND SURFACE FINISH.
For the sake of simplicity the term “Extenders” will be retained in this article, but it is used in the widest sense.
The main difference between a pigment and an extender is that pigments impart colour and hiding power to
the paint where as extenders have little or no hiding power themselves. The manufacturers of mineral
extenders are generally required to give high technical service back up, and bear above average the R&D
costs. The efficient processing is important, as is the ability to upgrade and modify products term as a “New
Generation Extenders” by using ultrafine grinding technology without any oversized particles (nib
free), calcining or surface modifications.


FUNCTIONAL PERPORTIES OF EXTENDERS
Selection of extenders by the paint maker depends on a number of factors:


GENERAL
The colour should be bright, clear, intense and reproducible. It depends on the mineral, chemical composition,
the brightness, the cleanliness and the intensity on the difference between the refractive indices of pigment
extenders and medium, and on particle size and size distribution, particle shape and crystal habit. The opacity
or hiding power is a function of the difference between refractive indices of the pigment and dispersion
medium. Both pigments and extenders are opaque as dry powders, but when dispersed in media, pigments
are opaque in both organic and aqueous media, whereas the extenders are practically transparent in organic
media but opaque in aqueous media. This is because the refractive indices of extenders are very close to
those of oils and resins.
Extenders have a low refractive index, similar to that of binders and so are effectively transparent. They are
usually white or off-white and contribute either no color or an undesirable one to paint film. How, then, can
extenders increase the efficacy of pigments if they possess neither of the basic properties required. ? There
are five aspects to consider:


1. PARTICLE SIZE DISTRIBUTION.
    The particle size is very important and it is one of the properties which can be altered substantially by the
    processor. Hiding power and tinting strength are both related to the particle size. The particle size also
    influences gross consistency and settlement. Particle sizes have directly co-relation with surface area of
    the particle which effects viscosity, flow characteristics, dispersion stability and oil absorption. Particle
    shape effects flow characteristics settlement and film durability.




                                                 -2-
2. HIGH BRIGHTNESS.
    They should be as bright as possible so that no pigment is, as it were, wasted covering the unwanted
    colour of the extender. The brightness depends on the chemical composition of the deposit. Sometimes
    the colour can be improved by washing or flotation.
3. HINDER RE-AGLOMERATION.
    This is done by introducing sufficient physical barriers so that the likelihood of two pigment particles
    colliding and re-agglomerating in the liquid paint system is reduced.
4. IMPROVED PIGMENT DISPERSION.
    They help to break down the pigment agglomerates. It has been calculated that if all the titanium dioxide
    used were perfectly dispersed, the world demand for titanium dioxide would fall to about 14% of the
    present usage. It is evident that extender producers can help a lot here.
    The extender must itself be easy to disperse. The individual particles collide with pigment agglomerates,
    breaking them up. The extender must be fine since if it is too coarse it encourages “crowding” thus
    defeating the objective. Ideally, the pigment particles should be half the wave length of light in diameter
    and the distance between them should also be half the wave length of visible light. Please note that we no
    longer speak of spacing extenders. This theory has been proved wrong by simple experiment. If the
    pigment and extender are disperse separately in half of the binder and then subsequently mixed, there is
    only a slight increase in opacity and much less than when the extender and pigment are mixed together in
    the first place. The slight increase in opacity is caused by hindering re-agglomeration as mentioned
    above.
5. DECREASE CRITICAL PVC.
    They can decrease the critical PVC to below that of the paint so that there is insufficient binder to
    completely coat each organic particle. Tiny pockets of air are trapped on the surface of some of the
    particles, increasing the amount of light diffracted and hence the opacity or hiding power of the paint film.
    Of course, this also lowers the scrub resistance and increases the tendency of the film to pick up
    atmospheric dirt. The extender must have a high absorption. Suitable ones are calcined clay or synthetic
    aluminium silicate. This usage is only practical for interior paints and even then it is limited due the poorer
    scrub resistance.


A NEW GENERATION CALCIUM CARBONATES – LEADING THE FIELD
In quantity terms calcite, dolomite and whiting are the most widely used carbonate extender minerals in
paints. Calcite is basically used as a pigment extender for the improvement of pigment efficiency because of
the spacing and refractive index. Paint makers may use any grade size from a coarser grade (400 Mesh) to a
micronized grade (20 Microns and 10 Microns). In general, the finer the particle size, the higher the gloss of
the paint.
Calcium carbonate does not contribute significantly to opacity in itself but a new generation calcium
carbonate is said to “bring out” the opacity of prime white pigments by spacing them correctly. High
brightness and proper micronisation is desirable to improve paint colour characteristics. Properly micronized




                                                -3-
carbonates may be used to improve film cohesion, higher gloss and higher loading (pigment volume
concentration).
In paints & coating, the endless opportunity for modifying the optical and mechanical properties with calcium
carbonate, make this mineral particularly popular main extenders which offer functional properties with
regards to high brightness low oil absorption, dispensability, weather resistance, low abrasiveness, low
electrolyte content, pH stabilizing effect, and improved anti-corrosion and rheological properties.
a. Decorative coating
    Interior emulsion paint is the most important application of the calcium carbonate of the coating industry,
    and calcium carbonate also provide economical advantages and optimize properties performance in
    exterior emulsion paint and decorative enamel, where calcium carbonate filler loading is comparatively
    lower.
b. Industrial Coating
    Industrial coatings are generally formulated with lower filler content, primarily use for protection, where
    durability is a main paint film property against environmental condition.
   Application                                             Extenders Content
   Interior emulsion paints                                Up to 65%
   Exterior emulsion paints                                Up to 45%
   Brushing enamels                                        Up to 10 -15%
   Powder coatings                                         Up to 5 -20%
   Industrial coatings                                     Up to 5 -20%
   Road marking paints                                     Up to 30 -50%
   Primer                                                  Up to 5 -20%
   Inks                                                    Up to 15%


To meet the challenging demands of its customers, 20 Microns Limited now produces New Generation
Calcium Carbonates, mainly


1. O Carb
    Purest, ultra white and closely controlled superfine narrow particle size calcium carbonate from world best
    deposit.
    O Carb is white, closely controlled, micronized purest, natural calcium carbonate selected from world best
    deposit, specially developed for Paints-Coating, adhesives and sealants industry ‘O’ Carb narrow particle
    size distribution optimizes particle packing leaving less void space to be filled by expensive resin, which
    leads to enhance opacity with gloss in all type of premium water base formulation.


2. Vaporlite 90T
    Sub-micron calcium carbonate produced by new engineered wet – milling techniques, which act as a
    spacers between prime pigment and contribute to batter coating opacity and high gloss.
    Vaporlite 90T is an ultra fine sub-micron natural calcium carbonate. The sub-micron particles of
    Vaporlite 90T can act as spacers between TiO2 particles leading to increase the efficiency of TiO2 in the
    paints and coating application. The size and numbers of Vaporlite 90T particles enable efficient
    separation at TiO2 particles and inhibit re-agglomeration after dispersion whereas agglomerates are less


                                                -4-
efficient at scattering light when compared to the fine primary particles. As light beams are refracted at the
   particle surface it follows that smaller and more numerous fine particles offer more opportunities for
   refraction and thus lead to better coating OPACITY and HIGHGLOSS.


Fig 1. SPACING EFFECT OF VAPORLITE 90T WITH PRIME PIGMENT TiO2




                                             Fig-1
3. Vaporcifier
   Modified calcium carbonate for partial replacement of Titanium Dioxide (TiO2)
   Vaporcifier is a new and innovative product designed especially for emulsion paints. Vaporcifier is a
   natural calcium carbonate where particle structures are modified by physical and chemical process which
   creates particle with an amorphous structure to offer excellent opacity of the paint and lower overall cost
   by extension of TiO2. Vaporcifier display a very amorphous structure which leads to the assumption that
   in addition to the external surface an internal surface also exists which significantly increase a specific
   area and oil absorption whereas micronized GCC shows a compact surface structure.
Fig 2. S.E.M. OF VAPORICIFIER – LOW COST OPACIFIER CALCIUM CARBONATE




   Fig 2.


TYPICAL PHYCICAL PROPERTY OF NEW GENERATION CALCIUM CARBONATE

 Tests                         M. Carb 2µ        O Carb               Vaporlite 90T        Vaporcifier
                               Micronized        Superfine            Sub-micron           Modified CaCO3
                             fine GCC            CaCO3                CaCO3
 Average            Particle 2.6 ± 0.2 µm        1.8 ± 0. 2 µm        0.9 ± 0.2 µm         2.0 ± 0.3 µm


                                               -5-
diameter      (d50%)      on
 Marven
 Top cut (d97%)               13±2µm              7±1 µm            4±1 µm               10±2 µm
 Bulk    Density        loose 580±50              520±30            350±50               400±50
 (gm/liter)
 Brightness                 94±2                  94±2              92±2                 90±2
 Oil             absorption 20±3                  27±5              35±5                 75±5
 (gm/100gm)
 Specific surface       area 3-4                  5-6               12-15                22-25
 (BET) m2/gm

EXPERIMENTAL OBJECTIVE
The most widely used pigment in the paint industry is titanium dioxide. The rising titanium dioxide price and
tight supply situation is causing more and more paint manufacturers to seek means of extending this pigment
without loss of opacity or change in colour tone. Based on the experience and global trend in the industry, we
introduce a New generation calcium carbonate, and our product application center had carried out some
experiment which is subsequently fallowed by our esteemed paints & coating customers.


EXPERIMENT NO. 1
PARTIAL REPLACEMENT OF TITANIUM DIOXIDE IN EXTERIOR EMULSION PAINT BY VAPORCIFIER
AND “O” CARB NEW GENERATION CALCIUM CARBONATE


TECHNICAL DATA OF EXTENDERS:
Extender             Top Cut D(97)          Average particle        Brightness           Oil    Absorption
                     µm                     size D(50) µm           %                    gm/100gm
Talc 10 µ            20                     6-8                     94                   55
Vaporcifier          10 ± 2                 2.0 ± 0.3               90±2                 75±5
“O” Carb             7±1                    1.8±0.2                 94±2                 27±5


OBJECTIVE:- This experiment, an exterior emulsion paint formulation was taken and reformulated by
replacing 20% titanium dioxide on weight basis,




                                              -6-
EXPERIMENTAL INTRODUCTION
The standard formulation content 60% by weight of TiO2 and calcium carbonate extender with average
particle size of 2 µm. means “O” Carb in this experiment 20% TiO2were replaced by weight by Vaporlite 90T
as per Table no. 2
The paint was made using a high speed disperser.
Table no. 1
Raw Materials                                 Standard formulation          Reformulation          with
                                                                            Vaporcifier & “O” Carb
Binder                                        306.3                         312

TiO2                                          161.4                         129.1

Talc 10 µ                                     161.4                         102.3

Vaporcifier                                   -----                         72.1

“O” Carb                                      110.2                         120.8

Dispersing agent                              2.8                           2.9

Preservative                                  1.9                           1.9

Defoamer                                      2.8                           2.8

Wetting and dispersing agent                  10.4                          10.5

Thickener                                     100.6                         101.8

Caustic soda, 10% aq. Sol.                    1.9                           1.9

Mineral spirit                                9.5                           9.6

Butyl diglycol acetate                        7.6                           7.7

Water                                         123.2                         124.6

Total                                         1000.0                        1000.0
Technical Data
PVC %                                         50.0                          50.0
Solid content %wt.                            58.4                          58.0
Density (Liquid paint) g/cm3                  1.45                          1.43
Results
Brightness                                    89.3%                         88.6%
Yellowness Index                              1.6                           2.4
Contrast ratio                                94.3%                         94.5%
                                           Cost reduction
Weight %                                      ----                          4.6
By volume %                                   ----                          5.7




                                            -7-
CONCLUSION
 The partial replacement of titanium dioxide by Vaporcifier and “O” Carb in exterior emulsion paint offers
 cost savings without affecting the optical or weathering properties adversely.


 EXPERIMENT NO. 2
 REPLACEMENT OF SYNTHETIC ALUMINIUM SILICATE AND PRECIPITED CALCIUM CARBONATE BY
 VAPORLITE 90T AND “O” CARB


 Table no. 2
 Raw Material                          Standard Formulation                   Reformulation             with
                                                                              Vaporlite 90T & “O” Carb
 TiO2                                  123.5                                  120

 “O” Carb/Micron Carb 2µ               200.1                                  193

 Ppt. Calcium Carbonate                96.6                                   ------

 Vaporlite 90T                         ------                                 169.1

 Aluminium Silicate                    24.1                                   ------

 Talc                                  100.8                                  93.3

 Styrene acrylate (50% solids)         148.5                                  110

 Water and additives                   306.4                                  314.6

 Total                                 1000.0                                 1000.0
 Physical Properties
 PVC %                                 72.54                                  79.54
 Volume solids content %               40.22                                  40.22
 Optical properties of Finished Paint Film
 Covering power %                      94.8                                   95.2
 Brightness (green filter)             88.8                                   87.8
 Gilsonite porosity                    16.5                                   12.8


 CONCLUSION
 Aluminium silicate can be replaced by an ultrafine, white, natural calcium carbonate as “O” Carb and Vaporlite
 90T. The lower binder absorption of the Vaporlite 90T allows the PVC to be increased so that the final paint
 has the same optical properties as the original. This offers substantial financial savings.




                                                 -8-
EXPERIMENT NO. 3
REPLACEMENT OF SYNTHETIC ALUMINIUM SILICATE BY CALCINED CLAY, VAPORIFIER,
VAPORLITE 90T AND “O” CARB.
EXPERIMENTAL INTRODUCTION
It is evident from the technical data of extenders both calcined clay and synthetic aluminium silicate have
much higher oil and hence binder absorptions than Vaporlite 90T. This means that the PVC can be increased
somewhat when they are replaced by Vaporlite 90T without fear of mud-cracking.
The steps taken in such a reformulation are given below:.
1. Replacement of the extenders with higher binder absorptions e.g. synthetic aluminium silicate and
    calcined clay by Vaporlite 90T.
2. Increasing the PVC by 10 percentage points whilst maintaining the volume solids content by increasing
    the Vaporlite 90T content and reducing the binder volume.
3. Measurement of the brightness, opacity and porosity comparing these values with the standard
    formulation.
4. Fine tuning by mixing the paints.


TECHNICAL DATA
Extender           Top        Cut      Average           Brightness        Oil             Specific
                   (µm)                Particle size     (DIN        53    Absorption      Surface
                                       (µm)              163,      C/2°)   (Gm/100gm)      Area    (BET)
                                                         Ry     (Green                     (m2/gm)
                                                         Filter)
Synthetic          --                  0.2               95                160             100
agglomerated
aluminium
silicate
“O” Carb           7±1                 1.8±0.2           94±2              27±5            5-6
Vaporlite 90T      4±1                 0.9±0.2           92±2              35±5            12-15
Vaporcifier        10 ± 2              2.0 ± 0.3         90±2              75±5            22-25




                                                   -9-
Table No. 3
Raw Material                        Standard Formulation in kg            Reformulation                with
                                                                          Vaporlite 90T & “O” Carb
Copolymer vinyl acetate acrylate    244                                   180
emulsion, 50%
Titanium dioxide rutile             135                                   108

Calcined clay- Glazex 90            53.8                                  53.8

Synthetic aluminium silicate        36                                    ----

Vaporcifier                         ----                                  142.6

“O” Carb / Vaporlite 90T            79.3                                  58.2

Talc                                72                                    68.3

Water and additives                 379.9                                 389.1

Total                               1000.0                                1000.0
Physical Properties
PVC %                               55                                    65
Solids content vol. %               31.5                                  31.5
Solids content wt. %                49.5                                  52
Density gm/ml                       1.36                                  1.43
Optical properties of Finished Paint Film
Brightness %                        89.1                                  88.7
Yellowness Index %                  2.6                                   2.9
Opacity %                           93.7                                  93.8
Sheen (85° angle)                   6                                     7
Wet scrub resistance cycles         >5000                                 >5000
                                             Cost reduction
By Weight %                          ----                                 30
By volume %                          ----                                 8


CONCLUSION
Due to its special particle size distribution curve and low binder absorption, Vaporlite 90T can replace
extenders such as synthetic aluminium silicate and calcined clay.
The PVC of the paints containing Vaporlite 90T can be increased by 10 percentage points whilst maintaining
the volume solids content. The optical properties remain virtually unchanged. Substantial raw material savings
are possible. Using Indian price levels these are about 30% on weight basis and about 8% on a volume basis.




                                              - 10 -
EXPERIMENT NO. 4
REPLACEMENT OF REFINED CHINA CLAY BY VAPORCIFIER, VAPORLITE 90T AND “O” CARB.
EXPERIMENTAL INTRODUCTION
In our countries, water washed china clays are used in emulsion paints of medium PVC. The technical data of
a widely used china clay and Vaporlite 90T are compared. The lower binder absorption of Vaporlite 90T
allows the PVC to be increased by from 3-5 percentage points whilst maintaining the volume solids content.
The reformulation should take place in a number of steps:-
1. Replacement of the natural china clay by Vaporlite 90T
2. The PVC is increased by between 3 and 5 percentage points whilst maintain the volume solids content by
    increasing the amount of Vaporlite 90T and reducing the volume of binder.
3. The brightness, opacity and wet scrub resistance are measured and compared with the standard
    formulation.
4. Fine tuning by mixing the corresponding formulations.


TECHNICAL DATA
 Extender          Top        Cut    Average           Brightness        Oil               Specific
                   (µm)              Particle size     (DIN        53    Absorption        Surface
                                     (µm)              163,      C/2°)   (Gm/100gm)        Area     (BET)
                                                                                               2
                                                       Ry     (Green                       (m /gm)
                                                       Filter)
 Refined China     5                 0.9               85                35                11.2
 clay
 “O” Carb          7±1               1.8±0.2           94±2              27±5              5-6
 Vaporlite 90T     4±1               0.9±0.2           92±2              35±5              12-15
 Vaporcifier       10 ± 2            2.0 ± 0.3         90±2              75±5              22-25




                                             - 11 -
Table No. 4
 Raw Material                         Standard Formulation in kg           Reformulation                 with
                                                                           Vaporlite 90T & “O” Carb
 Terpolymer       vynil    chloride   197                                  180
 emulsion 55%
 Titanium dioxide rutile              148                                  146.5

 “O” Carb/ Vaporlite 90T              175                                  167.5

 Pigment                              55                                   54.3

 Refined China clay                   100                                  -----

 Vaporcifier                          -----                                124.5

 Water and additives                  325                                  327.2

 Total                                1000.0                               1000.0
 Physical Properties
 PVC %                                63.1                                 66.1
 Solids content vol. %                38.0                                 38.0
 Solids content wt. %                 58.5                                 59.1
 Density gm/ml                        1.51                                 1.53
 Optical properties of Finished Paint Film
 Brightness %                         87.5                                 88.0
 Yellowness Index                     5.1                                  4.2
 Opacity %                            96.4                                 96.5
 Scrub resistance (DIN 53 778, 1      >5000                                >5000
 week) cycles
 Sheen (85° angle) %                  2                                    2


CONCLUSION
By increasing the PVC by 3 percentage points and replacing china clay by Vaporlite 90T, the brightness was
improved and also the yellowness index.
The opacity, scrub resistance and sheen remained unaltered.
Although the density of the finished paint increased by about 1%, savings in raw material costs (using
European prices) were more than 3% when calculated by volume and more than 5% when calculated by
weight.


EXPERIMENT NO. 5
REFORMULATION OF A HIGH GLOSS AIR-DRYING ENAMEL BY VAPORLITE 90T AND “O” CARB.
EXPERIMENTAL INTRODUCTION
The standard formulation contained 29% titanium dioxide and we found that we could replace 7.5% of this on
a volume basis by Vaporlite 90T and the resulting paint had the same optical and rheological properties as
the standard. The improved dispersion of the titanium dioxide by Vaporlite 90T resulted in a higher initial 20°
gloss than in the standard formulation. The paints were made using a high speed disperser.


Table No. 5
 Raw Material                         Standard Formulation in kg           Reformulation                 with
                                                                           Vaporlite 90T & “O” Carb


                                               - 12 -
TiO2 %wt.                             28.07                              26.08
 Vaporlite 90T %wt.                    ---                                1.52
 PVC %                                 20.3                               20.3
 Solid vol. %                          48.6                               48.6
 Wt.%                                  66.8                               66.6
 Density gm/ml                         1.26                               1.26
 Optical Properties ( After 2 days drying at 23°C)
 Yellowness Index                      2.9                                2.9
 Contrast ratio (45µm film)            97.9                               97.4
 Gloss
 20° (after 2 days) %                  85                                 86
 20° (after 28 days) %                 81                                 82
 60° (after 2 days) %                  91                                 92
 60° (after 28 days) %                 90                                 90


EXPERIMENT NO. 6
PARTIAL REPLACEMENT OF TITANIUM DIOXIDE IN A STOVING ENAMEL BY VAPORLITE 90T AND
“O” CARB.
EXPERIMENTAL INTRODUCTION
A further practical example involved high gloss short oil alkyd/melamine stoving enamel. The paint were made
using a high speed disperser. The initial formulation contained 29.5% titanium dioxide. We replaced 6% and
12% by volume. The paints were stoved at 120°C for 30 min. details are given in Table 6. The results indicate
that Vaporlite 90T helps to disperse the titanium dioxide better, allowing 5-10% of it to be replaced whilst
scarcely effecting the optical properties.




                                               - 13 -
Table No. 6
 Raw Material               Standard                  Reformulation 1 with    Reformulation        2
                            Formulation in kg         Vaporlite 90T           with Vaporlite 90T
 TiO2 %wt.                  22.45                     21.08                   25.10
 Vaporlite 90T %wt.         ---                       1.21                    2.36
 PVC %                      20                        20                      10
 Solid vol. %               41.0                      41.0                    41.0
 Wt%                        55.4                      55.1                    54.9
 Density gm/ml              1.26                      1.25                    1.24
 Optical Properties
 Yellowness Index           2.4                       2.3                     2.2
 Contrast ratio %           98.8                      98.7                    98.4
 Gloss at 25%               99                        97                      97




20 MICRONS LTD can set up on site WGCC (WET GROUND CALCIUM CARBONATE) manufacturing plant
in your premises of having any proposed capacity of 1000mt/month. WGCC will get supply in slurry form
having 70% - 75% Solid Content through pipe line to your plant.




Fig 3.WET PROCESS PLANT



                                             - 14 -
Fig 4.ON SITE SATELITE PLANT




20 Microns Scope:-
    Providing Un-interrupted supply WGGCC in slurry form as per the specification attached.
    Provide the slurry at the dosage point in the 75% Solids.
    Installation of the requirement Plant/Machinery and testing instruments at the site.
    Regular running and maintenance of plant.
    Storage tank for slurry.


ADVANTAGES OF WET GRINDING PROCESS
    Wet ground calcium carbonate is superior to dry ground calcium carbonate.



                                             - 15 -
 In wet process-due to floatation method it improves:
     Colour of the material
     Reduces impurity level
     It helps to produce ultrafine mineral where uniform particle size distribution takes place which helps to
         dispersion in the end use.


Advantage of wet ground CaCO3 over dry ground CaCO3
this application particle size plays major role to achieve end product’s performance ,wet ground process
gives the particles of 50 to 98% below 2 microns and it act as a spacers between tio2 particles leading to
increase the efficiency of tio2 in paint and coating application Due to controlled & uniform particle size
distribution, it -


Improves Following Properties:
* Excellent opacity with high gloss
* High brightness of end product
* Spacing TIO2 and color pigments
* Efficient extenders to white pigments
* Outstanding dispersion properties in water and solvent based paint


CONCLUSION
Suitably new generation fine calcium carbonate extenders help to disperse pigments better, thus increasing
the efficacy. This allows the quantity of pigment used to be reduced without affecting the optical and
rheological properties but allowing interesting raw material cost savings.


INOVATIVE PRODUCTS IN-TRANSIT
    1. Low specific gravity Calcined Kaolin – We are in process to lunch low specific gravity with value of
         2.0 -2.1 calcined kaolin compare with exciting specific gravity of 2.6.
    2. Inorganic co-thickener – Hydrogel 90T a white inorganic co-thickener which having brightness of
         85% against exciting trend of 65% brightness.
    3. Low cost synthetic Red Oxide


ACKNOWLEDGEMENT
The authors wish to express their gratitude to Dr. Atul Joshi, Reader, Dept. of Geology, M.S.Univ. Baroda,
Gujarat, Dr.V.S.Patel, Director SICART, S.P.Univ.,V.V.Nagar, Anand, Gujarat, Mr.T.K.Dan,Scientist and
Head, Testing & Calibration Cell, CGCRI, Kolkata & Dr. Harendra Nath, IIT, Mumbai for providing valuable
guidance & necessary facilities.




REFERENCES
1. Paper published on “ FUNCTINAL EXTENDERS AND THEIR ROLE IN MODERN PAINTS by Shree C.
    S. Parikh (Chairman 20 Microns Limited).


                                                - 16 -
2. Paper published on “CHARCTERISATION OF EXTENDERS BY MODERN TECHNIQUES AND ITS
    CORRELATION WITH PROPERTIES by V. M. Natu ( Paint Consultant).
3. Paper published on “ IMPORTANCE OF EXTENDERS IN PAINT AND COATING FORMULATION” by Dr.
    K. Srinivasan (Ex-ICI india Limited)
4. Experiment and formulations details provided by 20 Microns technical center.
5. Product performance details provided by Indian Major Paint Industry
6. Ciullo, P.A. (ed.), Industrial Minerals and Their Uses, Noyes Publications, Westwood, NJ, 1996
7. Adams Reg, Artikol Ltd., Journal on Alternative White Pigments and TiO2 Extender for Coatings, Paper
    and Plastic by Intertech, USA on November 8 –10, 2000
8. Hocken Jorg, Sachtleben Chemie GmbH, Journal on Alternative White Pigments and TiO2 Extender for
    Coatings, Paper and Plastic by Intertech, USA on November 8 –10, 2000, PP 1 – 10




                                             - 17 -

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T6 new generation calcium carbonate by k.k. mishra

  • 1. NEW GENERATION OF CALCIUM CARBONATE K.K.Mishra 20 Microns Ltd., Mumbai, India GENERAL OUTLOOK Paint, as an aesthetic and protective material, has undergone significant transformation over the years from being just a colour to a performance specific composite material. With this change, the ingredients of paint have evolved into more sophisticated functional raw materials. Extenders once considered as mere fillers are today looked upon as functional input to the paint contributing to rheology, adhesion, gloss control, hiding and PVC optimization. This situation necessitates up gradation of techniques and for the characterization of extenders. MANY paint makers still believe that fillers, (extenders, minerals) are of little importance, low cost and widely available products. But extenders should no longer be viewed in such terms. They have a functional purpose in the paint end product and their properties and qualities will substantially affect this product. Paint makers must expand and modernize their production facilities to cope with increasing technological sophistication. In trying to cut costs, raw materials will be a key consideration. Many paint makers have successfully decreased the use of expensive titanium dioxide by partial replacement of white extenders which are properly ground to the extent of sub-microns to 2microns average particle size. FUNCTIONAL EXTENDERS Extender pigment or simply extenders are also so called because such materials are used to “Extend” the effect of expensive white and coloured pigments, so cheapening the paint formulation. However, it is now recognized that extender pigments contribute much more to paint properties. Careful selection of the type and quantity of extenders can affect such features in paints & coating as: 1. Opacity or hiding. 2. Gloss or sheen. 3. Flow, leveling and smoothness. 4. Durability and appearance of the paint film. 5. Pigment settlement on storage. 6. Barriers effect and water permeability etc. Conventionally, extenders have been characterized employing simple techniques like visual colour assessment, sieving, specific gravity, oil and water demand, pH and microscopic examination. These tests do give very useful information to the paint formulator in deciding upon fundamental formulation parameters like PVC, weight per liter, finish and the like. However, if one desires to establish the closer relationship between characteristics of the extenders on one hand and various paint making, application and performance parameters on the other, then the use of modern analytical techniques become unavoidable. These techniques possess the capability to look at the micro structure of extenders in terms of size, shape, surface chemistry and crystallography. Correlations established between different extender parameters and a paint -1-
  • 2. performance property enables the technologist to diagnose the cause of the quality or performance problem. More importantly, it provides predictive capability to envisage performance of a paint which incorporates certain type of extenders. While examining various modern techniques, it is important to take over view of various particle size analysis techniques like, electron microscopy forms a very important tool for examination of particle shape which has significant bearing on RHEOLOGY, GLOSS AND OPACITY AND SURFACE FINISH. For the sake of simplicity the term “Extenders” will be retained in this article, but it is used in the widest sense. The main difference between a pigment and an extender is that pigments impart colour and hiding power to the paint where as extenders have little or no hiding power themselves. The manufacturers of mineral extenders are generally required to give high technical service back up, and bear above average the R&D costs. The efficient processing is important, as is the ability to upgrade and modify products term as a “New Generation Extenders” by using ultrafine grinding technology without any oversized particles (nib free), calcining or surface modifications. FUNCTIONAL PERPORTIES OF EXTENDERS Selection of extenders by the paint maker depends on a number of factors: GENERAL The colour should be bright, clear, intense and reproducible. It depends on the mineral, chemical composition, the brightness, the cleanliness and the intensity on the difference between the refractive indices of pigment extenders and medium, and on particle size and size distribution, particle shape and crystal habit. The opacity or hiding power is a function of the difference between refractive indices of the pigment and dispersion medium. Both pigments and extenders are opaque as dry powders, but when dispersed in media, pigments are opaque in both organic and aqueous media, whereas the extenders are practically transparent in organic media but opaque in aqueous media. This is because the refractive indices of extenders are very close to those of oils and resins. Extenders have a low refractive index, similar to that of binders and so are effectively transparent. They are usually white or off-white and contribute either no color or an undesirable one to paint film. How, then, can extenders increase the efficacy of pigments if they possess neither of the basic properties required. ? There are five aspects to consider: 1. PARTICLE SIZE DISTRIBUTION. The particle size is very important and it is one of the properties which can be altered substantially by the processor. Hiding power and tinting strength are both related to the particle size. The particle size also influences gross consistency and settlement. Particle sizes have directly co-relation with surface area of the particle which effects viscosity, flow characteristics, dispersion stability and oil absorption. Particle shape effects flow characteristics settlement and film durability. -2-
  • 3. 2. HIGH BRIGHTNESS. They should be as bright as possible so that no pigment is, as it were, wasted covering the unwanted colour of the extender. The brightness depends on the chemical composition of the deposit. Sometimes the colour can be improved by washing or flotation. 3. HINDER RE-AGLOMERATION. This is done by introducing sufficient physical barriers so that the likelihood of two pigment particles colliding and re-agglomerating in the liquid paint system is reduced. 4. IMPROVED PIGMENT DISPERSION. They help to break down the pigment agglomerates. It has been calculated that if all the titanium dioxide used were perfectly dispersed, the world demand for titanium dioxide would fall to about 14% of the present usage. It is evident that extender producers can help a lot here. The extender must itself be easy to disperse. The individual particles collide with pigment agglomerates, breaking them up. The extender must be fine since if it is too coarse it encourages “crowding” thus defeating the objective. Ideally, the pigment particles should be half the wave length of light in diameter and the distance between them should also be half the wave length of visible light. Please note that we no longer speak of spacing extenders. This theory has been proved wrong by simple experiment. If the pigment and extender are disperse separately in half of the binder and then subsequently mixed, there is only a slight increase in opacity and much less than when the extender and pigment are mixed together in the first place. The slight increase in opacity is caused by hindering re-agglomeration as mentioned above. 5. DECREASE CRITICAL PVC. They can decrease the critical PVC to below that of the paint so that there is insufficient binder to completely coat each organic particle. Tiny pockets of air are trapped on the surface of some of the particles, increasing the amount of light diffracted and hence the opacity or hiding power of the paint film. Of course, this also lowers the scrub resistance and increases the tendency of the film to pick up atmospheric dirt. The extender must have a high absorption. Suitable ones are calcined clay or synthetic aluminium silicate. This usage is only practical for interior paints and even then it is limited due the poorer scrub resistance. A NEW GENERATION CALCIUM CARBONATES – LEADING THE FIELD In quantity terms calcite, dolomite and whiting are the most widely used carbonate extender minerals in paints. Calcite is basically used as a pigment extender for the improvement of pigment efficiency because of the spacing and refractive index. Paint makers may use any grade size from a coarser grade (400 Mesh) to a micronized grade (20 Microns and 10 Microns). In general, the finer the particle size, the higher the gloss of the paint. Calcium carbonate does not contribute significantly to opacity in itself but a new generation calcium carbonate is said to “bring out” the opacity of prime white pigments by spacing them correctly. High brightness and proper micronisation is desirable to improve paint colour characteristics. Properly micronized -3-
  • 4. carbonates may be used to improve film cohesion, higher gloss and higher loading (pigment volume concentration). In paints & coating, the endless opportunity for modifying the optical and mechanical properties with calcium carbonate, make this mineral particularly popular main extenders which offer functional properties with regards to high brightness low oil absorption, dispensability, weather resistance, low abrasiveness, low electrolyte content, pH stabilizing effect, and improved anti-corrosion and rheological properties. a. Decorative coating Interior emulsion paint is the most important application of the calcium carbonate of the coating industry, and calcium carbonate also provide economical advantages and optimize properties performance in exterior emulsion paint and decorative enamel, where calcium carbonate filler loading is comparatively lower. b. Industrial Coating Industrial coatings are generally formulated with lower filler content, primarily use for protection, where durability is a main paint film property against environmental condition. Application Extenders Content Interior emulsion paints Up to 65% Exterior emulsion paints Up to 45% Brushing enamels Up to 10 -15% Powder coatings Up to 5 -20% Industrial coatings Up to 5 -20% Road marking paints Up to 30 -50% Primer Up to 5 -20% Inks Up to 15% To meet the challenging demands of its customers, 20 Microns Limited now produces New Generation Calcium Carbonates, mainly 1. O Carb Purest, ultra white and closely controlled superfine narrow particle size calcium carbonate from world best deposit. O Carb is white, closely controlled, micronized purest, natural calcium carbonate selected from world best deposit, specially developed for Paints-Coating, adhesives and sealants industry ‘O’ Carb narrow particle size distribution optimizes particle packing leaving less void space to be filled by expensive resin, which leads to enhance opacity with gloss in all type of premium water base formulation. 2. Vaporlite 90T Sub-micron calcium carbonate produced by new engineered wet – milling techniques, which act as a spacers between prime pigment and contribute to batter coating opacity and high gloss. Vaporlite 90T is an ultra fine sub-micron natural calcium carbonate. The sub-micron particles of Vaporlite 90T can act as spacers between TiO2 particles leading to increase the efficiency of TiO2 in the paints and coating application. The size and numbers of Vaporlite 90T particles enable efficient separation at TiO2 particles and inhibit re-agglomeration after dispersion whereas agglomerates are less -4-
  • 5. efficient at scattering light when compared to the fine primary particles. As light beams are refracted at the particle surface it follows that smaller and more numerous fine particles offer more opportunities for refraction and thus lead to better coating OPACITY and HIGHGLOSS. Fig 1. SPACING EFFECT OF VAPORLITE 90T WITH PRIME PIGMENT TiO2 Fig-1 3. Vaporcifier Modified calcium carbonate for partial replacement of Titanium Dioxide (TiO2) Vaporcifier is a new and innovative product designed especially for emulsion paints. Vaporcifier is a natural calcium carbonate where particle structures are modified by physical and chemical process which creates particle with an amorphous structure to offer excellent opacity of the paint and lower overall cost by extension of TiO2. Vaporcifier display a very amorphous structure which leads to the assumption that in addition to the external surface an internal surface also exists which significantly increase a specific area and oil absorption whereas micronized GCC shows a compact surface structure. Fig 2. S.E.M. OF VAPORICIFIER – LOW COST OPACIFIER CALCIUM CARBONATE Fig 2. TYPICAL PHYCICAL PROPERTY OF NEW GENERATION CALCIUM CARBONATE Tests M. Carb 2µ O Carb Vaporlite 90T Vaporcifier Micronized Superfine Sub-micron Modified CaCO3 fine GCC CaCO3 CaCO3 Average Particle 2.6 ± 0.2 µm 1.8 ± 0. 2 µm 0.9 ± 0.2 µm 2.0 ± 0.3 µm -5-
  • 6. diameter (d50%) on Marven Top cut (d97%) 13±2µm 7±1 µm 4±1 µm 10±2 µm Bulk Density loose 580±50 520±30 350±50 400±50 (gm/liter) Brightness 94±2 94±2 92±2 90±2 Oil absorption 20±3 27±5 35±5 75±5 (gm/100gm) Specific surface area 3-4 5-6 12-15 22-25 (BET) m2/gm EXPERIMENTAL OBJECTIVE The most widely used pigment in the paint industry is titanium dioxide. The rising titanium dioxide price and tight supply situation is causing more and more paint manufacturers to seek means of extending this pigment without loss of opacity or change in colour tone. Based on the experience and global trend in the industry, we introduce a New generation calcium carbonate, and our product application center had carried out some experiment which is subsequently fallowed by our esteemed paints & coating customers. EXPERIMENT NO. 1 PARTIAL REPLACEMENT OF TITANIUM DIOXIDE IN EXTERIOR EMULSION PAINT BY VAPORCIFIER AND “O” CARB NEW GENERATION CALCIUM CARBONATE TECHNICAL DATA OF EXTENDERS: Extender Top Cut D(97) Average particle Brightness Oil Absorption µm size D(50) µm % gm/100gm Talc 10 µ 20 6-8 94 55 Vaporcifier 10 ± 2 2.0 ± 0.3 90±2 75±5 “O” Carb 7±1 1.8±0.2 94±2 27±5 OBJECTIVE:- This experiment, an exterior emulsion paint formulation was taken and reformulated by replacing 20% titanium dioxide on weight basis, -6-
  • 7. EXPERIMENTAL INTRODUCTION The standard formulation content 60% by weight of TiO2 and calcium carbonate extender with average particle size of 2 µm. means “O” Carb in this experiment 20% TiO2were replaced by weight by Vaporlite 90T as per Table no. 2 The paint was made using a high speed disperser. Table no. 1 Raw Materials Standard formulation Reformulation with Vaporcifier & “O” Carb Binder 306.3 312 TiO2 161.4 129.1 Talc 10 µ 161.4 102.3 Vaporcifier ----- 72.1 “O” Carb 110.2 120.8 Dispersing agent 2.8 2.9 Preservative 1.9 1.9 Defoamer 2.8 2.8 Wetting and dispersing agent 10.4 10.5 Thickener 100.6 101.8 Caustic soda, 10% aq. Sol. 1.9 1.9 Mineral spirit 9.5 9.6 Butyl diglycol acetate 7.6 7.7 Water 123.2 124.6 Total 1000.0 1000.0 Technical Data PVC % 50.0 50.0 Solid content %wt. 58.4 58.0 Density (Liquid paint) g/cm3 1.45 1.43 Results Brightness 89.3% 88.6% Yellowness Index 1.6 2.4 Contrast ratio 94.3% 94.5% Cost reduction Weight % ---- 4.6 By volume % ---- 5.7 -7-
  • 8. CONCLUSION The partial replacement of titanium dioxide by Vaporcifier and “O” Carb in exterior emulsion paint offers cost savings without affecting the optical or weathering properties adversely. EXPERIMENT NO. 2 REPLACEMENT OF SYNTHETIC ALUMINIUM SILICATE AND PRECIPITED CALCIUM CARBONATE BY VAPORLITE 90T AND “O” CARB Table no. 2 Raw Material Standard Formulation Reformulation with Vaporlite 90T & “O” Carb TiO2 123.5 120 “O” Carb/Micron Carb 2µ 200.1 193 Ppt. Calcium Carbonate 96.6 ------ Vaporlite 90T ------ 169.1 Aluminium Silicate 24.1 ------ Talc 100.8 93.3 Styrene acrylate (50% solids) 148.5 110 Water and additives 306.4 314.6 Total 1000.0 1000.0 Physical Properties PVC % 72.54 79.54 Volume solids content % 40.22 40.22 Optical properties of Finished Paint Film Covering power % 94.8 95.2 Brightness (green filter) 88.8 87.8 Gilsonite porosity 16.5 12.8 CONCLUSION Aluminium silicate can be replaced by an ultrafine, white, natural calcium carbonate as “O” Carb and Vaporlite 90T. The lower binder absorption of the Vaporlite 90T allows the PVC to be increased so that the final paint has the same optical properties as the original. This offers substantial financial savings. -8-
  • 9. EXPERIMENT NO. 3 REPLACEMENT OF SYNTHETIC ALUMINIUM SILICATE BY CALCINED CLAY, VAPORIFIER, VAPORLITE 90T AND “O” CARB. EXPERIMENTAL INTRODUCTION It is evident from the technical data of extenders both calcined clay and synthetic aluminium silicate have much higher oil and hence binder absorptions than Vaporlite 90T. This means that the PVC can be increased somewhat when they are replaced by Vaporlite 90T without fear of mud-cracking. The steps taken in such a reformulation are given below:. 1. Replacement of the extenders with higher binder absorptions e.g. synthetic aluminium silicate and calcined clay by Vaporlite 90T. 2. Increasing the PVC by 10 percentage points whilst maintaining the volume solids content by increasing the Vaporlite 90T content and reducing the binder volume. 3. Measurement of the brightness, opacity and porosity comparing these values with the standard formulation. 4. Fine tuning by mixing the paints. TECHNICAL DATA Extender Top Cut Average Brightness Oil Specific (µm) Particle size (DIN 53 Absorption Surface (µm) 163, C/2°) (Gm/100gm) Area (BET) Ry (Green (m2/gm) Filter) Synthetic -- 0.2 95 160 100 agglomerated aluminium silicate “O” Carb 7±1 1.8±0.2 94±2 27±5 5-6 Vaporlite 90T 4±1 0.9±0.2 92±2 35±5 12-15 Vaporcifier 10 ± 2 2.0 ± 0.3 90±2 75±5 22-25 -9-
  • 10. Table No. 3 Raw Material Standard Formulation in kg Reformulation with Vaporlite 90T & “O” Carb Copolymer vinyl acetate acrylate 244 180 emulsion, 50% Titanium dioxide rutile 135 108 Calcined clay- Glazex 90 53.8 53.8 Synthetic aluminium silicate 36 ---- Vaporcifier ---- 142.6 “O” Carb / Vaporlite 90T 79.3 58.2 Talc 72 68.3 Water and additives 379.9 389.1 Total 1000.0 1000.0 Physical Properties PVC % 55 65 Solids content vol. % 31.5 31.5 Solids content wt. % 49.5 52 Density gm/ml 1.36 1.43 Optical properties of Finished Paint Film Brightness % 89.1 88.7 Yellowness Index % 2.6 2.9 Opacity % 93.7 93.8 Sheen (85° angle) 6 7 Wet scrub resistance cycles >5000 >5000 Cost reduction By Weight % ---- 30 By volume % ---- 8 CONCLUSION Due to its special particle size distribution curve and low binder absorption, Vaporlite 90T can replace extenders such as synthetic aluminium silicate and calcined clay. The PVC of the paints containing Vaporlite 90T can be increased by 10 percentage points whilst maintaining the volume solids content. The optical properties remain virtually unchanged. Substantial raw material savings are possible. Using Indian price levels these are about 30% on weight basis and about 8% on a volume basis. - 10 -
  • 11. EXPERIMENT NO. 4 REPLACEMENT OF REFINED CHINA CLAY BY VAPORCIFIER, VAPORLITE 90T AND “O” CARB. EXPERIMENTAL INTRODUCTION In our countries, water washed china clays are used in emulsion paints of medium PVC. The technical data of a widely used china clay and Vaporlite 90T are compared. The lower binder absorption of Vaporlite 90T allows the PVC to be increased by from 3-5 percentage points whilst maintaining the volume solids content. The reformulation should take place in a number of steps:- 1. Replacement of the natural china clay by Vaporlite 90T 2. The PVC is increased by between 3 and 5 percentage points whilst maintain the volume solids content by increasing the amount of Vaporlite 90T and reducing the volume of binder. 3. The brightness, opacity and wet scrub resistance are measured and compared with the standard formulation. 4. Fine tuning by mixing the corresponding formulations. TECHNICAL DATA Extender Top Cut Average Brightness Oil Specific (µm) Particle size (DIN 53 Absorption Surface (µm) 163, C/2°) (Gm/100gm) Area (BET) 2 Ry (Green (m /gm) Filter) Refined China 5 0.9 85 35 11.2 clay “O” Carb 7±1 1.8±0.2 94±2 27±5 5-6 Vaporlite 90T 4±1 0.9±0.2 92±2 35±5 12-15 Vaporcifier 10 ± 2 2.0 ± 0.3 90±2 75±5 22-25 - 11 -
  • 12. Table No. 4 Raw Material Standard Formulation in kg Reformulation with Vaporlite 90T & “O” Carb Terpolymer vynil chloride 197 180 emulsion 55% Titanium dioxide rutile 148 146.5 “O” Carb/ Vaporlite 90T 175 167.5 Pigment 55 54.3 Refined China clay 100 ----- Vaporcifier ----- 124.5 Water and additives 325 327.2 Total 1000.0 1000.0 Physical Properties PVC % 63.1 66.1 Solids content vol. % 38.0 38.0 Solids content wt. % 58.5 59.1 Density gm/ml 1.51 1.53 Optical properties of Finished Paint Film Brightness % 87.5 88.0 Yellowness Index 5.1 4.2 Opacity % 96.4 96.5 Scrub resistance (DIN 53 778, 1 >5000 >5000 week) cycles Sheen (85° angle) % 2 2 CONCLUSION By increasing the PVC by 3 percentage points and replacing china clay by Vaporlite 90T, the brightness was improved and also the yellowness index. The opacity, scrub resistance and sheen remained unaltered. Although the density of the finished paint increased by about 1%, savings in raw material costs (using European prices) were more than 3% when calculated by volume and more than 5% when calculated by weight. EXPERIMENT NO. 5 REFORMULATION OF A HIGH GLOSS AIR-DRYING ENAMEL BY VAPORLITE 90T AND “O” CARB. EXPERIMENTAL INTRODUCTION The standard formulation contained 29% titanium dioxide and we found that we could replace 7.5% of this on a volume basis by Vaporlite 90T and the resulting paint had the same optical and rheological properties as the standard. The improved dispersion of the titanium dioxide by Vaporlite 90T resulted in a higher initial 20° gloss than in the standard formulation. The paints were made using a high speed disperser. Table No. 5 Raw Material Standard Formulation in kg Reformulation with Vaporlite 90T & “O” Carb - 12 -
  • 13. TiO2 %wt. 28.07 26.08 Vaporlite 90T %wt. --- 1.52 PVC % 20.3 20.3 Solid vol. % 48.6 48.6 Wt.% 66.8 66.6 Density gm/ml 1.26 1.26 Optical Properties ( After 2 days drying at 23°C) Yellowness Index 2.9 2.9 Contrast ratio (45µm film) 97.9 97.4 Gloss 20° (after 2 days) % 85 86 20° (after 28 days) % 81 82 60° (after 2 days) % 91 92 60° (after 28 days) % 90 90 EXPERIMENT NO. 6 PARTIAL REPLACEMENT OF TITANIUM DIOXIDE IN A STOVING ENAMEL BY VAPORLITE 90T AND “O” CARB. EXPERIMENTAL INTRODUCTION A further practical example involved high gloss short oil alkyd/melamine stoving enamel. The paint were made using a high speed disperser. The initial formulation contained 29.5% titanium dioxide. We replaced 6% and 12% by volume. The paints were stoved at 120°C for 30 min. details are given in Table 6. The results indicate that Vaporlite 90T helps to disperse the titanium dioxide better, allowing 5-10% of it to be replaced whilst scarcely effecting the optical properties. - 13 -
  • 14. Table No. 6 Raw Material Standard Reformulation 1 with Reformulation 2 Formulation in kg Vaporlite 90T with Vaporlite 90T TiO2 %wt. 22.45 21.08 25.10 Vaporlite 90T %wt. --- 1.21 2.36 PVC % 20 20 10 Solid vol. % 41.0 41.0 41.0 Wt% 55.4 55.1 54.9 Density gm/ml 1.26 1.25 1.24 Optical Properties Yellowness Index 2.4 2.3 2.2 Contrast ratio % 98.8 98.7 98.4 Gloss at 25% 99 97 97 20 MICRONS LTD can set up on site WGCC (WET GROUND CALCIUM CARBONATE) manufacturing plant in your premises of having any proposed capacity of 1000mt/month. WGCC will get supply in slurry form having 70% - 75% Solid Content through pipe line to your plant. Fig 3.WET PROCESS PLANT - 14 -
  • 15. Fig 4.ON SITE SATELITE PLANT 20 Microns Scope:-  Providing Un-interrupted supply WGGCC in slurry form as per the specification attached.  Provide the slurry at the dosage point in the 75% Solids.  Installation of the requirement Plant/Machinery and testing instruments at the site.  Regular running and maintenance of plant.  Storage tank for slurry. ADVANTAGES OF WET GRINDING PROCESS  Wet ground calcium carbonate is superior to dry ground calcium carbonate. - 15 -
  • 16.  In wet process-due to floatation method it improves:  Colour of the material  Reduces impurity level  It helps to produce ultrafine mineral where uniform particle size distribution takes place which helps to dispersion in the end use. Advantage of wet ground CaCO3 over dry ground CaCO3 this application particle size plays major role to achieve end product’s performance ,wet ground process gives the particles of 50 to 98% below 2 microns and it act as a spacers between tio2 particles leading to increase the efficiency of tio2 in paint and coating application Due to controlled & uniform particle size distribution, it - Improves Following Properties: * Excellent opacity with high gloss * High brightness of end product * Spacing TIO2 and color pigments * Efficient extenders to white pigments * Outstanding dispersion properties in water and solvent based paint CONCLUSION Suitably new generation fine calcium carbonate extenders help to disperse pigments better, thus increasing the efficacy. This allows the quantity of pigment used to be reduced without affecting the optical and rheological properties but allowing interesting raw material cost savings. INOVATIVE PRODUCTS IN-TRANSIT 1. Low specific gravity Calcined Kaolin – We are in process to lunch low specific gravity with value of 2.0 -2.1 calcined kaolin compare with exciting specific gravity of 2.6. 2. Inorganic co-thickener – Hydrogel 90T a white inorganic co-thickener which having brightness of 85% against exciting trend of 65% brightness. 3. Low cost synthetic Red Oxide ACKNOWLEDGEMENT The authors wish to express their gratitude to Dr. Atul Joshi, Reader, Dept. of Geology, M.S.Univ. Baroda, Gujarat, Dr.V.S.Patel, Director SICART, S.P.Univ.,V.V.Nagar, Anand, Gujarat, Mr.T.K.Dan,Scientist and Head, Testing & Calibration Cell, CGCRI, Kolkata & Dr. Harendra Nath, IIT, Mumbai for providing valuable guidance & necessary facilities. REFERENCES 1. Paper published on “ FUNCTINAL EXTENDERS AND THEIR ROLE IN MODERN PAINTS by Shree C. S. Parikh (Chairman 20 Microns Limited). - 16 -
  • 17. 2. Paper published on “CHARCTERISATION OF EXTENDERS BY MODERN TECHNIQUES AND ITS CORRELATION WITH PROPERTIES by V. M. Natu ( Paint Consultant). 3. Paper published on “ IMPORTANCE OF EXTENDERS IN PAINT AND COATING FORMULATION” by Dr. K. Srinivasan (Ex-ICI india Limited) 4. Experiment and formulations details provided by 20 Microns technical center. 5. Product performance details provided by Indian Major Paint Industry 6. Ciullo, P.A. (ed.), Industrial Minerals and Their Uses, Noyes Publications, Westwood, NJ, 1996 7. Adams Reg, Artikol Ltd., Journal on Alternative White Pigments and TiO2 Extender for Coatings, Paper and Plastic by Intertech, USA on November 8 –10, 2000 8. Hocken Jorg, Sachtleben Chemie GmbH, Journal on Alternative White Pigments and TiO2 Extender for Coatings, Paper and Plastic by Intertech, USA on November 8 –10, 2000, PP 1 – 10 - 17 -