February 17 in Karachi, the launch of the Bryansk region of production — the first Russian production nanosilicates and polymer nanocomposites with their application. Products are used as additives and fillers in the oil and gas, cable, packaging and automotive industries, the construction industry. Total investment in the project amounted to 1.9 billion rubles, including co-financing RUSNANO of 1.1 billion rubles. Has created 164 new jobs. In total there will be 190.
The new plant will initially produce 14,860 tons per year of polymer nanocomposites. For example, it would be enough to create a long-lasting (up to 80), the protective coating 390 kilometers of gas pipes of large diameter, which is equal to the distance from Moscow to Karachev.
The products produced by "Metaclay":
Metalen PE-1 is a black bimodal high density polyethylene. The material has high mechanical strength over a wide temperature range and high resistance to cracking. It is used for applying the outer coating layer with the steel pipeline pipe. Is a proprietary Company "Metaclay."
Metalen AGE-1 — Polyethylene-based adhesive coating for pipeline steel pipes. Specially designed for bonding epoxy anti-corrosion layer and an outer polyethylene layer in three-layer coating of pipes. Is a proprietary Company "Metaclay."
Silanolnosshivaemye composition — Compounds consisting of polyethylene and a catalyst concentrate. Used as insulation self-supporting insulated wires for low-voltage networks, and as a material for the manufacture of hot-water pipes and pipes for the "warm floor".
Thermoplastic elastomers (TEPy) — The thermoplastic polymer material, combining the processability of thermoplastics, as well as elastic rubbers. Used for the production of gaskets, shock absorbers railway rail fastening, and in industry for the inner cable conductor insulation in the automotive industry, in the residential construction industry for the production of window frames of plastic gaskets in electrical and household appliances for the manufacture of fittings.
Halogen-retardant polymer composition. It is used for cable insulation with enhanced fire-safety requirements. CJSC "Metaclay" brings this material to the Russian market for the first time. In contrast to existing non-combustible materials for cable insulation, HFFR not emit toxic gases in case of fire.
It is expected that after the release of the enterprise at full capacity in 2014, the production will be 25,000 tons nanosilicates and 50,000 tons per year of polymer nanocomposites, and the amount of revenue — more than 5 billion rubles.
By 2014, approximately 80% of the products have a monetary value on the polymer nanocomposites — materials composed of polymeric plastic base (matrix), and organo-silicate filler (montmorillonite) with a particle size of 10 to 200 nm. Such materials as compared to conventional composites have a new and improved properties (e.g., improved mechanical strength, fire safety, low moisture and gas permeability).
The basis used in the enterprise technology for the development of polymer nanocomposites are local scientists from leading scientific organizations: the Institute of Petrochemical Synthesis of. Topchiev Academy of Sciences, Institute of Macromolecular Compounds, Russian Academy of Sciences, Federal State Unitary Enterprise "Scientific-Research Institute of Physical Chemistry Karpov", Moscow State University named after MV Lomonosov Moscow State University and the Russian University of Chemical Technology Mendeleyev .
At present JSC "Metaclay" completes the process of certification of products. In July 2011, we received a positive opinion, LLC "VNIIGAZ" on materials for corrosion protection of gas pipes of large diameter. The development of polymers for the production of organo-pads shock absorbers for rail mounting rail track, adjusted output of high-tech nanosilikatnogo material for the production of food packaging, significantly extends the shelf life of food products. Another important area of application of enterprise — the cable industry, "Metaclay" is developing in this area the last two years. Selecting this trend is due to increasing requirements for fire safety of electrical products, increased consumption of flame retardants, as well as the need to improve the consumer properties of cable products. The ability to increase the fire resistance of polymers nanosilicates found practical application, especially in the production of the cable insulation compositions.
"For us it is important that before you run production, we have opened the most modern laboratory. Four of her department (innovative technologies, analyzes, scaling, and physical and mechanical tests) allow us to provide a full life cycle of scientific research: from the idea to study the properties of the final material and production trial runs ", — Says General Director of "Metaclay" Sergei Shtepa.
production line for plastic films in the department laboratory scale technologies "Metaclay"
"I would especially like to emphasize that used in the enterprise technology has been fully developed by Russian scientists, and the products of the project in all of its qualities is unique in the market. Montmorillonite, which is a natural raw material, with proper scientific approach and implementing it into a working technology that can seriously change the traditional production of a number of industries, giving it the innovative quality " — Said RUSNANO Managing Director Alexander Kondrashov.
The raw material for the production of polymer nanocomposites "Metaclay" uses modified nanosilicates own production.
The innovative properties of polymer nanocomposites "Metaclay" provided the influence of nano-sized particles of silica fillers on the properties of the final product.
Silicate particles (aluminum silicate), incorporated in polymeric materials change their ability to crystallize, creating an additional diffusion barrier.
Polymeric material based on nanoclay
The polymeric nanocomposite — multicomponent material comprising a plastic base polymer (matrix) and filler — organomodified nanoclays (montmorillonite). Schemes of a mo
nolayer of polymer nanocomposite structure and options for mikrkompozita.