Application of water-based carbon black dispersants
Application of water-based carbon black dispersants
I. Technical characteristics and advantages
Super dispersion efficiency
Anchoring-coating synergistic effect: The anchoring groups (such as polycarboxylic acids and phosphates) in the dispersant molecular chain are strongly adsorbed on the carbon black surface through hydrogen bonds, ionic bonds or π-π interactions, while the solvated chains (such as polyethers and polyesters) form a steric hindrance layer, which increases the dispersion efficiency by 3-5 times compared with traditional dispersants. For example, a polyester dispersant can disperse high-color carbon black to D50=85 nm within 15 minutes, while traditional dispersants require more than 2 hours.
Anti-flocculation stability: By regulating the ζ potential (absolute value>35 mV) and steric hindrance effect, the carbon black slurry can maintain a viscosity change rate of <10% and a coarseness rate of <0.8% (laser particle size analyzer detection) after 6 months of storage.
Wide applicability
Cross-system compatibility: It can adapt to different water-based matrices (such as acrylic acid, polyurethane, epoxy resin), and maintain a stable dispersion effect in the range of pH 2-12 and ionic strength 0-1.5 mol/L. For example, a certain zwitterionic dispersant can stabilize the carbon black particle size at <120 nm in both strong acid (pH 3) and strong alkaline (pH 11) coating systems.
Multi-category carbon black adaptation: It exhibits efficient dispersing ability for furnace carbon black (such as FW200), channel carbon black (such as Mogul L) and high-pigment carbon black (such as MA100), reducing the difficulty of dispersant compounding due to differences in carbon black structure.
Process adaptability
Multi-device compatibility: It supports a variety of equipment such as high-speed dispersers (800-1500 rpm), sand mills (linear speed 8-12 m/s), ball mills, etc., and can reduce equipment energy consumption by 20%-30%. For example, in the sand milling process, the use of specific dispersants can increase grinding efficiency by 40% and reduce zirconium bead wear rate by 35%.
Wide temperature range dispersion: Efficient dispersion can be achieved within the range of 5-50℃, avoiding fluctuations in dispersion quality caused by ambient temperature fluctuations.
2. Application value advantage
Product performance leap
Breakthrough in blackness and hiding power: Through nano-level dispersion, the primary particle size of carbon black reaches 20-50 nm, improving blackness (L value reduced by 15%-20%) and hiding power (CIE Y value reduced by 25%-30%). For example, in automotive topcoat, the color difference ΔE<0.8 can be achieved, reaching the international high-end brand standard.
Functional expansion: By regulating the dispersant structure, composite functions such as conductivity (volume resistivity 10²-10⁶ Ω·cm), antistatic properties (surface resistivity 10⁶-10⁹ Ω), and weather resistance (QUV 1000 h ΔE<2.5) can be achieved.
Production efficiency optimization
Cost reduction:
Raw material substitution: By improving the blackness of medium-pigment carbon black, 20%-30% of the high-pigment carbon black dosage can be replaced, directly reducing the raw material cost by 15%-25%.
Efficiency improvement: Dispersion time is shortened by 50%-70%, equipment turnover rate is increased by 30%-40%, and comprehensive production cost is reduced by 18%-22%.
Process simplification: Reduce the number of grinding processes or sand mills. Some companies have achieved "one-grinding method" production, and the single batch production cycle is shortened to less than 8 hours.
Quality stability guarantee
Batch consistency: Through the standardized treatment of carbon black by dispersant, the difference in dispersion effect of different batches of carbon black is less than 5% (such as particle size D90 fluctuation <10 nm), meeting the strict requirements of high-end manufacturing (such as original automotive paint) for color consistency.
Defect rate control: Significantly reduce defects such as pinholes, floating color, and flower blooming caused by carbon black agglomeration, and the product qualification rate is increased to more than 98%.
3. Environmental and safety advantages
Green production
VOCs reduction: Water-based system replaces solvent-based system, VOCs emissions are reduced to <50 g/L, and some companies achieve <25 g/L through dispersant optimization, meeting EU REACH regulations and domestic "oil to water" policy.
Energy consumption reduction: the dispersion process temperature is reduced to <40℃, reducing cooling water consumption; equipment energy consumption is reduced by 20%-30%, and carbon emissions per ton of product are reduced by 0.3-0.5 tons.
Safety upgrade
Occupational health improvement: Eliminate the harm of organic solvent volatilization to workers' respiratory system, and the total volatile organic compound concentration (TVOC) in the workplace is reduced to <50 mg/m³, which meets the GBZ 2.1-2019 standard.
Fire risk elimination: The flash point of the water-based system is >100℃, which reduces the fire risk of the solvent-based system (flash point <30℃) by more than 95%.
Sustainability
Resource conservation: Reduce raw material waste by improving the utilization rate of carbon black (such as the dispersion efficiency of carbon black in the tank method is increased from 60% to 90%).
Recycling: The stable colloid formed by the dispersant and carbon black can be recycled after ultrafiltration concentration, and the COD of wastewater is reduced by 60%-70%, achieving clean production.
4. Comprehensive Benefit Analysis
Economic Benefits: Through raw material substitution, efficiency improvement and energy consumption reduction, the comprehensive cost is reduced by 15%-25%, and the investment payback period is shortened to 6-12 months.
Breakthrough in technical barriers: Solve the industrial application problems of difficult-to-disperse varieties such as high-structure carbon black and conductive carbon black, and promote the upgrading of products to high-end.
Obtaining policy dividends: Meet the requirements of environmental protection regulations under the "dual carbon" goals, and enjoy policy support such as tax exemptions and green credits.
Through technological innovation and process optimization, water-based carbon black dispersants not only solve the pain points of low efficiency, poor stability and high pollution of traditional dispersion systems, but also show significant advantages in blackness improvement, function expansion, green production, etc., and become the core auxiliary agent to promote the high-quality development of coatings, inks, plastics and other industries.