New Packing: Calcium Carbonate Whisker

Posted: 2023-08-16

• The term "whisker" refers to a microcrystal that grows as a single crystal and has the shape of a short fiber, but with significantly smaller dimensions. Whiskers are novel reinforcing and toughening agents for composite materials, characterized by their high aspect ratio and exceptional mechanical properties. Calcium carbonate whiskers are synthetic single crystal materials that exhibit superior whiteness, heat resistance, wear resistance, among other qualities compared to conventional materials. As such, they hold great promise in various fields.
  The composition of calcium carbonate whiskers is identical to that of traditional granular calcium carbonate, making them suitable for all applications where general calcium carbonate is used. Moreover, calcium carbonate whiskers offer several notable advantages, including the high strength and elastic modulus characteristic of inorganic whiskers, which effectively enhance toughness and strength. Currently, calcium carbonate whiskers find primary application in reinforced plastics, friction materials, paper production, and other industries.
   

  About Calcium Carbonate Whisker

  
  The calcium carbonate whisker is a synthetic single crystal material with the chemical formula CaCO3 and a relative molecular weight of 100.09. It comprises 56.03% CaO and 43.97% CO2, exhibiting a melting point of 759℃ and a density of 2.86g/cm3. In its macroscopic form, the calcium carbonate whisker appears as white loose powder; however, under scanning electron microscopy, it reveals needle-like or fibrous crystal structures measuring between 20-60μm in length and having a short diameter ranging from 0.5-1.0μm. The aspect ratio falls approximately within the range of 20 to 30, indicating its classification as an aragonite phase.
   
   
  
  Currently, there is a wide range of whisker types available, encompassing various metallic options such as nickel and iron, oxide options like MgO, ZnO, SiC, and ceramic choices including TiB2 and ZrB2 borides. Moreover, there are also diverse inorganic and organic whiskers. Among these alternatives, calcium carbonate whiskers demonstrate exceptional characteristics in terms of whiteness, heat resistance, wear resistance, etc., rendering them highly promising for applications across multiple fields.
   

  Application of Calcium Carbonate Whisker in Various Industries

   
   

  Plastic

  Calcium carbonate whiskers possess a high aspect ratio and small crystal size, with minimal internal dislocations, grain boundaries, or other defects commonly observed in crystals. Their mechanical properties are comparable to those of complete crystals, making them highly effective for enhancing the strength and elastic modulus of plastics. When compared to talc powder, glass fiber, and ordinary light calcium carbonate fillers, polyethylene filled with calcium carbonate whiskers demonstrates superior mechanical properties. The addition of calcium carbonate whiskers significantly improves the impact strength of polyethylene while having a lesser impact on the surface smoothness of the product compared to glass fiber.
  In addition, calcium carbonate whiskers possess abundant natural resources and exhibit a wide distribution, distinguishing them from other materials. Chemically reacting with strong acids, calcium carbonate generates carbon dioxide and inorganic salts. Moreover, even if inadvertently inhaled in trace amounts, calcium carbonate will undergo natural breakdown through the human body's reaction without causing harm. Therefore, utilizing calcium carbonate whiskers as reinforcement material for degradable plastics not only avoids secondary pollution to the environment but also effectively mitigates white pollution while safeguarding ecological integrity.
   
   
   

  Rubber

  Calcium carbonate whiskers can be incorporated into natural rubber as a filler; however, due to the inadequate compatibility between the filler and natural rubber, it may lead to surface defects. Therefore, it is imperative to enhance the properties of calcium carbonate whiskers. Experimental results demonstrate that treated calcium carbonate whiskers exhibit elevated surface energy and improved interface with natural rubber, thereby significantly reinforcing its mechanical performance. As a filler, calcium carbonate can augment the volume of rubber, reduce production costs, and enhance processing capabilities without substantially compromising the overall performance of rubber products. Moreover, as a reinforcing agent, calcium carbonate can greatly enhance wear resistance, tear strength, tensile strength, modulus elasticity and swelling resistance in vulcanized rubber.
   
   
   

  Wear Resistant Material

  The calcium carbonate whisker exhibits exceptional temperature resistance, significantly enhancing the wear resistance of friction materials. Moreover, it serves as a cost-effective and ideal substitute for asbestos in such applications. A comparative analysis was conducted on the friction-enhancing and reducing properties of calcium carbonate whisker, asbestos, heavy calcium carbonate, and calcium carbonate whisker when utilized in automobile brake linings. The experimental findings demonstrate that incorporating 15% content of calcium carbonate whisker optimizes the friction coefficient, wear rate, and mechanical properties of automotive brake linings while surpassing the overall performance of alternative options. Calcium carbonate whiskers exhibit commendable high-temperature resistance and effectively enhance the wear resistance of friction materials while maintaining low raw material costs—meeting all requirements to serve as a filler in these applications.
   
   
   

  Paper making

  The use of granular calcium carbonate as a filler material in the paper industry has significantly enhanced paper performance and printing speed. Moreover, incorporating calcium carbonate whiskers as fillers in paper production improves printing adaptability, resulting in higher whiteness and smoother texture. Owing to its distinctive morphology and properties, paper made with calcium carbonate whiskers demonstrates superior printability, increased strength, and improved retention compared to papers made with calcite. Therefore, due to these inherent advantages, calcium carbonate whiskers hold promising prospects for development in the paper industry, particularly for various types of papers with diverse requirements.
   
   
   

  Medical Material

  Calcium carbonate whiskers are extensively utilized in both medical materials and industrial manufacturing. Calcium is an indispensable element within the human body, predominantly present as calcium phosphate and serving as the primary constituent of bones. By incorporating calcium carbonate whiskers to enhance material mechanical properties, artificial bone composites can be fabricated. Xu Zhiyang et al. employed a mixed solution method to fabricate artificial bone composites. The experimental results demonstrate that these artificial bone materials exhibit no cytotoxicity and possess significant medical value. Moreover, calcium carbonate whiskers are also recognized as environmentally friendly and non-toxic biomedical stimulants, finding application as active materials in the medical field for media creation.
   

  Grinding Mill Recommended

  
  
   
  HGM Ultrafine Grinding Mill
  Capacity: 0.2-45 t/h
  Feed Sive: ≤20 mm
  Powder Fineness: 325-3000 mesh
   
  The complete configuration of the HGM ultra-fine mill comprises a hammer crusher, bucket elevator, storage bin, vibration feeder, micro-grinding machine, frequency conversion classifier, double cyclone collector, pulse dust removal system, high-pressure fan, air compressor and electrical control system. It boasts exceptional efficiency and energy-saving capabilities. When compared to air mills, stirring mills and ball mills with equivalent motor power for achieving the same fineness of finished products, it exhibits superior output. The wearing parts have an extended service life due to their composition of special materials such as grinding roller and grinding ring that significantly enhance their utilization degree. In terms of identical fineness of finished material, its service life is 2-5 times longer than that of wear parts in impact crushers and turbine crushers. Generally speaking it can last more than one year but when processing calcium carbonate and calcite it can reach up to 2-5 years. Furthermore,it offers elevated safety and reliability owing to the absence of rolling bearings or screws in the grinding chamber which eliminates vulnerability issues with sealing parts or loosening problems that could potentially damage the machine. The product's fineness is exceptionally high; in fact D97≤5μm can be achieved by utilizing HGM series ultra-fine grinding products. Additionally,it demonstrates environmental friendliness as it employs pulse dust collectors for capturing dust while mufflers reduce noise.
   
   
   
  CLUM Ultrafine Vertical Grinding Mill
  Capacity: 1-20 t/h
  Feed Size: ＜20 mm
  Powder Fineness: 300-3000 mesh
   
  The ultrafine vertical mill addresses the challenges encountered in processing ultrafine powders, surpassing the limitations of traditional mills when it comes to grinding high hardness, high moisture, and high fineness products. This achievement holds significant importance in achieving large-scale production of various materials. Its primary applications encompass limestone, calcite, marble, heavy calcium, kaolin, barite, bentonite, gypsum phyllite and 200 other materials for ultrafine powder processing. In comparison to similar mills on the market, the ultrafine vertical mill boasts stable quality with a uniform particle shape and narrow particle size distribution that enhances fluidity. Moreover, its comprehensive investment cost is low as it integrates crushing,drying ,grinding ,grading,and conveying into one streamlined process with fewer system equipment requirements and a compact structure layout which directly reduces enterprise investment costs. Additionally,it exhibits low energy consumption due to its specialized design for ultra-fine powder grinding featuring a roller sleeve and liner grinding curve that facilitates easier material layer formation resulting in higher grinding efficiency leading to increased yield; its energy saving effect is 30%-50% greater than ordinary mills . Furthermore,it demonstrates excellent environmental performance with minimal vibration system ,low noise ;the entire system is sealed allowing full negative pressure operation without any dust spillage thus essentially achieving a dust-free workshop while fully complying with national dust emission standards.Furthermore,it showcases high reliability by utilizing a roller limit device to prevent violent vibrations caused by materials during milling time;it employs an improved roller sealing device ensuring more reliable sealing without requiring a sealing fan thereby reducing oxygen content in the mill further enhancing explosion suppression performance.
   

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