1. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 PMT- Jetmill GmbH New Developments in Filler Micronization Jürgen Roth, Veronika Mayer Ultrafine Grinding ’06, Falmouth, UK12.-13. June 2006

2. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Outline  Requirements of the Filler Industry  Compound Reinforcement  Comparison of Grinding Technologies  Basics of Jetmilling  PMT Spiral Jet Mill  Some Application Results  Conclusions

3. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Requirements of the Filler Industry Increasing Technical Demand from CompoundersIncreasing Technical Demand from Compounders Change from 'Extender Fillers' to 'Functional Fillers'Change from 'Extender Fillers' to 'Functional Fillers' Importance of the Processing Stage to Enhance the Functional Properties of MineralsImportance of the Processing Stage to Enhance the Functional Properties of Minerals The Future

4. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Requirements of the Filler Industry Fillers are now High-Tech Products Compounders are looking for a Solution, not for a “Crushed Rock”

5. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Requirements of the Filler Industry Finest Particle Sizes (d 50 )Finest Particle Sizes (d 50 ) Exact Top Cut (d 97 )Exact Top Cut (d 97 ) Improvement of the Functional PropertiesImprovement of the Functional Properties Lower Specific Energy ConsumptionLower Specific Energy Consumption Industrial Scale Size OutputIndustrial Scale Size Output Guaranteed Operational ReliabilityGuaranteed Operational Reliability The Target - Finest Products

6. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Compound Reinforcement E c …. Modulus CompoundE c …. Modulus Compound E m … Modulus MatrixE m … Modulus Matrix A … Aspect RatioA … Aspect Ratio B, C … Empirical Functions of Filler Modulus, Packing Fraction,B, C … Empirical Functions of Filler Modulus, Packing Fraction, Filler Loading Filler Loading  ……. Filler Volume Fraction  ……. Filler Volume Fraction Nielson Equation Fillers with High Aspect Ratio Reinforce Better

7. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Aspect Ratio (after W. Hohenberger) A.......... Aspect RatioA.......... Aspect Ratio O s......... Specific SurfaceO s......... Specific Surface r F........... Filler Densityr F........... Filler Density d 50, d 84... PSD Valuesd 50, d 84... PSD Values Grinding Method B.E.T. [m 2 /g] d 50 [µm] d 84 [µm] Aspect Ratio Spiral Jetmill 16.76.915.380 Opposed Jetmill 14.16.313.763 Vertical Ball Mill 12.26.416.740 Table Roller Mill 11.85.514.532 Stirred Media Mill 10.46.118.523

8. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Aspect Ratio – Lamellarity

9. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Comparison of Grinding Technologies Best operational area Mohs 4 to 10 orBest operational area Mohs 4 to 10 or –cubic shape or –metal powders Wearless and iron free grindingWearless and iron free grinding Comminution by particle - particle collisionsComminution by particle - particle collisions Best operational area Mohs 1 to 4 withBest operational area Mohs 1 to 4 with –laminar, layered or porous structure Comminution by high velocity differencesComminution by high velocity differences –high delamination effects Lower particle collisionsLower particle collisions Best operational area Mohs 4 to 10Best operational area Mohs 4 to 10 Big wear of the target plateBig wear of the target plate Not an iron free productNot an iron free product Opposed Jetmill Spiral Jetmill Impact - Jetmill

10. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Suitable Minerals Suitable Minerals GraphiteGraphite BariteBarite MicaMica TalcTalc WollastoniteWollastonite ZeoliteZeolite etc.etc. Soft to middle hard minerals Lamellar or porous structure

11. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Spiral Jetmill Scheme Injector FeedInjector Feed Nozzles Around the CircumferenceNozzles Around the Circumference Spiral Stream ClassifyingSpiral Stream Classifying

12. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 PMT Spiral Jetmill SJ Constant Loading  Constant Loading Concentration of the Grinding Energy Higher Milling Chamber Special Feed Control System Coarse Product Outlet for Hard Grindable Materials

13. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Advantages of PMT Jetmill System 1.Exact Top Cut (d 97 ) 2. Coarse Product Outlet 3. Energy Consumption 4. Operational Reliability

14. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Cumulative Mass Percent Passing 1. Exact Top Cut Particle Size Distribution after Sympatec Helos e.g. Graphite Equivalent Spherical Diameter [µm] Legend:d 97 [µm] d 50 [µm] rpmkWh/t Graphite Sample 1 Graphite Sample 1 8.4 3.389,7002,060 GraphiteSample 2 Graphite Sample 212.9 5.166,7001,190 Graphite Sample 3 Graphite Sample 320.9 8.123,700 485

15. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 1. Exact Top Cut Particle Size Distribution after Sedigraph e.g. Barite Equivalent Spherical Diameter [µm] Legend: d 97 [µm] d 50 [µm] rpmkWh/t Barite Sample 1 Barite Sample 1 2.65 0.887,200 1,260 Barite Sample 2 Barite Sample 2 6.40 1.743,200 240 Barite Sample 3 Barite Sample 312.10 2.541,500 85 Cumulative Mass Percent Passing

16. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 1. Exact Top Cut Äquivalenter Kugeldurchmesser [µm] Dchgangs-% e.g. Mica Particle Size Distribution after Sedigraph Legend:d 97 [µm] d 50 [µm] rpmkWh/t Mica Sample 1 Mica Sample 1 7.6 2.185,7001,340 Mica Sample 2 Mica Sample 211.2 3.004,200 810 Mica Sample 3 Mica Sample 314.8 3.963,000 475 Mica Sample 4 Mica Sample 423.1 6.222,200 290 Equivalent Spherical Diameter [µm] Cumulative Mass Percent Passing 1 10

17. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 1. Exact Top Cut e.g. Talc Particle Size Distribution after Sedigraph Legend:d 97 [µm] d 50 [µm] rpmkWh/t Talc Sample 1 Talc Sample 1 3.9 1.016,8001,250 Talc Sample 2 Talc Sample 2 5.7 1.754,000 540 Talc Sample 3 Talc Sample 3 9.0 2.812,700 290 Talc Sample 4 Talc Sample 415.8 4.581,700 145 Äquivalenter Kugeldurchmesser [µm] Durchgangs-% Equivalent Spherical Diameter [µm] Cumulative Mass Percent Passing

18. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 2. Coarse Product Outlet 1... Talc 2... Quartz 3... Dolomite 4... Calzite 7... Feldspar 8... Montmorillonite 5... Chlorite 6... Muscovite Final Product Reject Product e.g. Talc

19. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 3. Energy Consumption

20. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Integrated Motor - Rotor - Unit 4. Operational Reliability Circumferential Speed up to160 m/s Exact Top Cut Simple Disk Assembly Specially Developed Rotor Shape Only One Bearing System Maintenance Free and Operational Reliability

21. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 PMT Spiral- Jetmill SJ Up to 30% less Energy Consumption Increase of the Grinding Efficiency due to the Closed Grinding- and Classifying Circuit Easy Adjustment of Fineness by Regulation of Rotor Speed Coarse Product Outlet THE LATEST GENERATION

22. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Application Results 1234567891020304050 3000 3125 3250 3375 3500 3625 3750 3875 4000 Filler Consulting 40 % Talc in PPh Modulus [N/mm 2 ] Top Cut [µm] PMT Jetmill SJ Stirred Media Mill Feed Material

23. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 Application Results

24. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 PMT Spiral Jetmill – Plant Layout

25. © PMT-Jetmill GmbH - Austria UFG’06 June 2006 PMT – Jetmill GmbH http:\\www.powder-maker.com jetmill@powder-maker.com PMT – Jetmill GmbH Industriepark 1 A-8773 Kammern, AUSTRIA Tel: +43 3844 80350-0 Fax: +43 3844 80350-20 Vienna Graz Kammern