Disruptive Technologies: Ocsial's Industrial-Scale Single-Wall Carbon Nanotubes, TUBALL™

Single-walled carbon nanotubes are increasingly used worldwide at a rapid pace, creating patentable new applications across sectors and enabling paradigm shifts in design and implementation methods (for example: electrostatic painting of composite parts without sanding and primer application, production of conductive flooring in very light colors, application of conductive surface coating on all wind turbine surfaces instead of lightning rods, ...). In short, TUBALLTM Single-Walled Carbon Nanotubes (SWCNT) offer significant opportunities to enable domestic industry and ultimately end users to benefit from the advantages this technology brings by extending the boundaries we have become accustomed to in our way of thinking. While it has long been known that single-walled carbon nanotubes—previously synthesizable only at laboratory scale—can enhance electrical conductivity, improve static and dynamic mechanical properties, and achieve effectiveness at very low usage rates enabling production of final products in light colors, the lack of commercially viable technology and the absence of effective methods for homogeneous dispersion of nanotubes have severely limited industrial applications. In 2013, OCSiAl launched the TUBALL™ product by commissioning the world's only industrial facility to synthesize single-walled carbon nanotubes, containing more than 93% SWCNT and usable as a versatile reinforcing material for various materials and applications. To facilitate effective incorporation of TUBALLTM into materials, OCSiAl has also developed easy-to-use concentrates, masterbatches and suspensions compatible with industry standard formulations. Unlike traditional additives such as carbon fibers and most carbon black types, TUBALLTM single-walled carbon nanotubes achieve significant improvements in various properties of most materials at only 0.01-0.1% by weight. TUBALLTM nanotubes with a diameter of 1.2-2 nm and length exceeding 5 μm, when properly dispersed, create a three-dimensional electrically conductive network structure that has minimal impact on the original color and other important properties of the reinforced material.

Key characteristics of TUBALLTM single-walled carbon nanotubes:

• One of the best conductors in the world and 5 times lighter than copper, • 100 times stronger than steel, • Thermal resistance: up to 2,800°C under vacuum, • Highest aspect ratio (3,000 and above). Achievement of homogeneous sheet resistance levels on the order of 102 Ω/sq—technically meaning "conductive"—at TUBALLTM incorporation levels of 0.1-1.0%, enables attainment of electrical properties such as continuous antistatic, electrostatic discharge and electromagnetic shielding that are "independent of humidity and time" by optimizing TUBALLTM incorporation rates. Through incorporation of very small quantities, this additive can deliver serious improvements in both desired electrical conductivity and mechanical strength and surface quality in all types of paints, coatings, sealants and adhesives without sacrificing color, while also providing opportunities to reduce weight and lower application and component costs. Increasing success stories worldwide across resins and composite materials, paints and surface coatings and adhesives, elastomeric materials and energy storage sectors, as well as cement, glass, ceramics and metals, are opening pathways for Turkish manufacturers to innovate with this material, reach patentable fields, develop high-value-added products, and most importantly, differentiate themselves from competitors. Foreseeing that this disruptive technology will affect 70% of industry, OCSiAl's initial capacity of 1 ton/year in 2013 has increased to 60 ton/year as of the first quarter of 2018 through planned investments. With increasing approvals and expanding applications, the capacity target for 2020 is projected at 310 ton/year with factory investment in Luxembourg. Çağatay Özdemir Executive Board Member Engineering Plastics & Specialty Chemicals Business Group Director Chemical Engineer Hayim Pinhas A.Ş.