AlphaGary | CeramTec | Chemetall FC | Chemetall ST | Rockwood Pigments | Sachtleben | Southern Clay Products | Viance

The key focus of Chemetall's Fine Chemicals Business is lithium compounds, organometallics, special metals, cesium and metal sulfides for numerous applications. These are used in a wide range of applications including batteries, dyes, glass, lubricants, metallurgy, optical products, rubber and more.

Currently, Chemetall holds 20 critical patents covering the production of lithium and lithium compounds, including 10 U.S. patents for the extraction of lithium salts and compounds from lithium containing brines, the production and purification of lithium from lithium brines and the production of lithium chloride directly from lithium containing brine. Chemetall also holds several U.S. and international patents covering the production, purification and application of LiBOB, a chemical conductive agent that is an effective alternative to toxic, fluorine salts used in large lithium ion batteries and battery packs.

Other environmentally friendly technologies from Chemetall are:

• Concentrated lithium bromide technology for use in industrial refrigeration, which is gaining in importance as a viable substitute for ozone-damaging chlorofluorocarbons
• Anhydrous lithium hydroxide, which are used to remove carbon dioxide from closed air circulating systems, such as submarines and space shuttles
• Lithium carbonate for use in aluminum smelters to reduce bath temperature and save energy through higher conductivity and lower viscosity

As a world leader in lithium supply, Chemetall is working to protect this important raw material. Chemetall is part of a consortium of companies participating in “LithoRec,” a comprehensive research and development project related to the recycling of large-scale lithium ion batteries, such as those used in the automotive industry.

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Rockwood’s Chemetall business provides surface treatment chemicals and services for the pre-treatment of metal prior to coating or metalworking. A key emphasis for Chemetall is the development of ecologically superior processes and materials.

These include:

• Superior metal pretreatment technologies prior to paint applications for various ferrous and non-ferrous substrates
• Pretreatment technologies that are free from zinc, chrome and nickel and result in less wastewater; new developments include chrome-free systems suitable for No-Rinse and Dry-in-Place pre-treatment prior to Cr-free primer painting.
• Cleaning technologies with biodegradable surfactants
• Process chemicals that help to reduce conserve energy
• Solvent-free lubricants that help minimize contamination of tools and downstream cleaning baths

Several examples of these follow.

C-Phos® electrolytic Ca-phosphate free of heavy metals for wire drawing.

Demulsifying Gardoclean® technology, a special blend of biodegradable surfactants, separates organic residue like oil and fat from cleaner solutions. This reduces the volume of wastewater, minimizes energy usage and could help to avoid membrane technology or special surfactants.

Gardobond® X4707 and 4747 replace chromate as pretreatments for aluminum parts such as door and window frames. This contributes to the target of the construction industry to avoid any chrome.

Gardobond® PC 4625 and similar products are thin organic coatings that replace chromate-containing products to enhance the forming process of galvanized steel sheets and prevent corrosion.

Gardobond® 2602 and 2603 adjusted zinc phosphate processes allow the zinc phosphate bath to run at lower temperatures, thereby reducing energy consumption.

Gardomer® polymer-based forming products replace soap lubricants in forming and drawing operations of wire.

Gardolube® SC 6240 to replace phosphate plus lubricant in a one-step process of metal forming process.

Naftoseal® MC-780, low-density sealant, is a chrome-free, solvent-free (respectively low in solvent content) aircraft sealant which helps to save weight in airplanes.

Oxsilan® metal pretreatment technology replaces traditional iron and zinc phosphate products, providing corrosion protection and promoting paint adhesion in the preparation of a wide range of metal substrates. Oxsilan processes also reduce considerably water and energy consumption vs. traditional systems.

Permatreat® 1903 is a Zirconium-based pretreatment technology for enhancing coatings adhesion on aluminum beverage can ends. It replaces chrome phosphate, eliminating the effluent disposal issues associated with toxic chromium chemicals.

SAM, Self Assembling Monolayers, is a unique technology to replace chromates in alloy wheel treatment.

Several technologies being developed include chrome-free passivation of galvanized sheet and pretreatment primer to improve the pretreatment of coil material prior to organic coating.

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AlphaGary is a global market leader in state-of-the-art compounds to enhance the fire safety of wire and cable and to replace known hazardous substances in everyday consumer products.

AlphaGary’s SMOKEGUARD® family of Low Smoke / Flame Retardant PVC compounds was developed for use in the outer jackets of copper and optical fiber data communications cables to minimize flame spread and smoke generation in the event of a building fire. In a typical office, there are volumes of cables above the ceiling and below the floor to support office and computer networks. With SMOKEGUARD in place, people have time to evacuate the building.

AlphaGary has been a strong advocate of environmental stewardship through participation and contribution to advocacy groups, such as:

• U.S. Environmental Protection Agency (EPA) “Design for the Environment”
• Massachusetts’ “Toxics Use Reduction Institute” and
• University of Massachusetts Lowell’s “Green Chemistry Council.”

For several years, AlphaGary has been helping customers convert to products that do not contain known hazardous substances. AlphaGary has been the leader in introducing “lead-free” compounds, along with finding technologies to eliminate certain brominated flame-retardants.

With its market-leading MEGOLON® “halogen free” wire and cable compounds, AlphaGary has achieved new levels of low smoke and low corrosive products for confined / critical environments such as in Transit Vehicles, Underground / Subways and ships / submarines. Some advocates also consider MEGOLON compounds as more environmentally friendly alternatives to PVC and other halogenated materials.

With these products AlphaGary is uniquely positioned to provide solutions for the application performance, safety and environmental compliance.

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Southern Clay Products, Inc. — along with its sister companies Rockwood Additives Ltd. and Rockwood Clay Additives GmbH — produce and market an extensive range of natural and synthetic additives that are used to perform critical functions by manufacturers of industrial and consumer products. Many of these additives help customers improve the efficiency or enviornmental profile of their products.

Lowering weight for reduced fuel consumption
Cloisite® additives allow composite manufacturers to lower the density (weight) of vehicle parts and personal watercraft. Lower weight means reduced fuel consumption.

Reducing emissions for cleaner air
Garamite® additives let manufacturers of unsaturated polyester resins (UPR) reduce volatile organic compound (VOC) emissions. UPR is used to produce tubs, showers, boats and coatings.

Optiflo® VF additives also are free of VOCs and help the coatings industry reduce emissions from household paint.

Likewise, Laponite® additives are synthetic clays used in water-based OEM coatings. These water-based formulations replace the older solvent containing technology, thereby reducing emissions and waste.

Replacing synthetic chemicals for better cosmetics
Bentolite® and Gelwhite® additives are natural clays which often times replace synthetic chemicals in personal care and household cleaning products.

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Rockwood’s Viance joint venture is a major producer of timber treatment chemicals for the global wood treatment industry. Viance is on the cutting edge of environmentally friendly wood treatment solutions and launched Ecolife Stabilized Weather Resistant Wood, one of the industry’s first nonmetallic biocides for pressure treating wood.

Ecolife Stabilized Weather Resistant Wood for outdoor residential wood is protected with EcoVance preservative — the active ingredient of which was awarded the first U.S. EPA Presidential Green Chemistry Award in 1996. In addition, the American Wood Protection Association (AWPA), the principal consensus-based standards writing organization for the wood treating industry in the United States, has standardized the preservative system in Viance's Ecolife™ Stabilized Weather-Resistant Wood and included it in its 2009 AWPA Book of Standards. Ecolife Stabilized Weather Resistant Wood applications include decking, railings, fencing, steps, gazebos, outdoor furniture, playground equipment, docks and piers, trellis and lattice work, structural framing, outdoor joist supports, wood siding and wood trim.

Viance also offers a full range of other preservative technologies including:

• Preserve® proven soluble copper for added protection against the aggressive effects of decay and termite attack in ground contact applications
• QuanTIM™ patented, EPA-registered mold resistant formulation for framing, trussing and sheathing
• D-Blaze® fire-retardant treated wood for lumber and plywood

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Rockwood’s Sachtleben joint venture is a leading producer of specialty titanium dioxide (TiO₂) products and the largest global manufacturer of precipitated barium sulfate additives and zinc sulfide pigments. Major emphasis is put on the development of special functional particles and additives for applications that promote economic efficiency, safety and a cleaner environment. Its product line includes:

• Photo catalysts: Sachtleben has developed very active photo catalysts for self-cleaning functional surfaces or degradation of air pollutants. By using nano-sized TiO₂ particles for coatings, dirt and air pollutants can be eliminated to prevent health or ecological problems. In combination with (natural) UV light the TiO₂ particles oxidize and eliminate the dirt or air pollutants.
• Pigments for UV protection: Sachtleben’s transparent TiO₂ particles provide outstanding UV protection from the sun’s damaging rays and are available in a wide selection of specially developed grades for diverse applications ranging from personal care sunscreens to food packaging, synthetic textiles and wood coatings.
• Heavy metal replacements: Sachtleben provides several technologies that replace heavy metals. These include chromate-free anticorrosion pigments for coil and thin metal coatings, non-toxic polyethylene terephthalate (PET) catalysts, as well as active additives for chromate reduction in the production of cement.
• Catalysts for environmentally friendly technologies: Sachtleben’s TiO₂ is used as a catalyst, as a photo catalyst, and as an inert ceramic base material for active components. These applications include waste-gas clean up in power generating plants and motor vehicles (DeNOx) and the production of organic products by means of selective oxidation processes. Sachtleben catalysts are also used in the production of biodiesel and as antimonfree catalysts for PET production.
• Additives for medically visible plastics: BLANC FIXE XR pigment by Sachtleben is used as a contrast agent and facilitates X-ray examination of the gastrointestinal tract. It also is incorporated into bone cement compounds and pharmaceutical plastics, such as those used for catheters, drainage tubes and hypodermic needles, to make them visible on X-ray screens and images. For the same reason, BLANC FIXE XR pigments are sometimes used in small plastic toy components that could be unintentionally swallowed by children. In yet another application, these barium sulfate additives are added to plastic gillnets used in deep sea fishing to make them more visible to whales and dolphins that can “see” them using their ultrasonic locating systems and avoid deadly entrapment.
• With its integrated production concept Sachtleben is producing its products with a minimum impact to the environment and is constantly working on process improvements to lower energy consumption and CO₂-emissions.

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CeramTec sets the standards in the area of high performance ceramics. CeramTec’s various manufacturing centers for the medical, automotive, electronics and OEM markets provide solutions that enhance quality of life, energy efficiency, product performance and safety.

Enhancing the quality of life
Among the most successful products in CeramTec’s portfolio are ceramic ball heads and cup inserts for prosthesis systems in hip replacement surgeries. CeramTec is the market leader of the ceramic ball heads and cup inserts and the only company with approval to market this product combination in the United States. The ceramic joint is extremely wear resistant.

Managing energy efficiently
CeramTec is one of the leading manufacturers internationally of metallized substrates on an aluminum oxide (Rubalit®) and aluminum nitride (Alunit®) basis. Over 30 years of experience makes CeramTec a highly qualified partner for the hybrid industry, for manufacturers of electronic components and for the power electronics industry. Applications include power electronics, thermo-electrical applications, optoelectronics and electronic applications.

The ceramic material Aluminum Titanate (ATI) is well known for its excellent thermal-shock resistance. Used in aluminum foundries, its low thermal conductivity helps to save energy and, due to its good chemical and abrasive resistance, it guarantees molten masses with a high degree of purity.

CeramTec’s CeramCool® Metallized Ceramic Heat-Sink for Efficient Thermal Management CeramCool® is the ideal heat sink for energy-saving high-power LEDs and high power electronics. It offers a strong solution for thermally sensitive components and circuits due to its excellent thermal conductivity and stability characteristics and its compact form.

The CeramTec Electronic Applications division also develops solid oxide fuel cells (SOFC) under the name CeramCell. CeramTec AG’s Electronic Applications division has been actively involved in the development of components for solid oxide fuel cells since as early as 1995 and, today, delivers the heart of the systems – the cells.

Operating safely
Ceramic components are included in a wide ray of safety and surveillance applications, from telecommunications equipment and radar systems to automotive airbags and cardiac pacemakers, hearing aids and oxygen supply systems.

Conserving Natural Resources
In millions of kinds of sanitary fittings, single-handle mixers, two-handle faucets and diverters, CeramTec ceramic seal- and regulator discs help to save water. Due to the fact that solids carried in the water, such as sand, rust and lime, are unable to impair these discs, and ceramics are chemically inert, the discs remain permanently tight and have an unbeatable longevity compared to other materials used in this application.

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Rockwood Color Pigments, a primary manufacturer and processor of iron oxide color pigments and a supplier of a wide range of natural and synthetic inorganic pigments and handling systems, demonstrates its environmental stewardship in several key ways:

• Using recycled materials in the manufacture of its products
• Creating new alternative products that are free of heavy metals
• Reducing pollutants like NOx and Volatile Organic Compounds (VOCs)

Ferroxide® nontoxic, color pigments
Rockwood’s Ferroxide® color pigments are made of non-toxic iron oxide and manufactured from 60% post-industrial recycled content.

Granufin® dry, micro-granulated color
Granufin® color pigments are free-flowing, easy to handle and virtually dust-free. This gives Rockwood’s customers a cleaner working environment. Granufin® products are also non-toxic and made from 60% post-industrial recycled content.

Solaplex® new class of pigments
The Solaplex® range of color pigments offers a new class of inorganic bright yellow and orange pigments developed specifically to replace old-technology pigments that contain lead and chromium. Solaplex® pigments are light and weather fast and they help replace toxic metals in paints and coatings.

Solarox™ color pigments that help clean the air
Solarox™ color pigments (under development by Rockwood) with properties so unique, they are being patented. In addition to adding color to exterior surfaces of buildings and structures, Solarox™ pigments harness light from the sun to remove air pollutants (NOx, VOCs) from the atmosphere. They even reduce mold growth and give surfaces self-cleaning properties.

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