Current approaches and good practices by producers of ... · 29.10.2009 Dr. Mertler, BASF SE - NEW...

29.10.2009 1

Current approaches and good practices byproducers of nanomaterials

Dr. Michael Mertler

BASF SE – Process Engineering

Dust Removal and Aerosol Technology

29.10.2009 Dr. Mertler, BASF SE - NEW OSH ERA Forum on new and emerging OSH risks, Brussels 2

Outline

Introduction

Production of nanomaterials

Integrated process: key to safe production

Nanoaerosols: dynamics, measurement, risks

Transparency, dialogue and BASF‘s activities on jointnanosafety research

Summary


Nanotechnology:Convergence of the disciplines

Source: Hörber / Bachmann / Rohrer


Market potentials [billion €]

500

50

0.05Value-adding chain

0.5

5

Materialse.g. organic and inorganic particles, ...

Materials and Formulationse.g. modified thermoplastics,formulations of actives, surfaces,nano-porous structures, …

Componentse.g. for automobiles,displays, solar cells, textiles, ...

ForecastAnnual growth > 10%

Market volume 2015 about €750 billion

Sources: Growth forecast: European Commission, DG Bank, BCC Consumer Market Data from Sal. Oppenheim,In Realis and Evolution Capital.

Market potentials


Nanoparticles

e.g. UV absorber in sun screens

Components

e.g. Organic Light Emitting

Diodes (OLEDs)

Materials &Formulationse.g. light, stable and transparent

packaging

100-200 nm

100 nm

Nanoproducts made by BASF


Technology PushParticles

Nanoparticles

Nanotubes

Nanolayers

Materials

Nanomodified Plastics

Nanomodified Coatings

Nanoporous Foams

Nanostructured Devices for

Information & CommunicationTechnology

Medicine (Diagnostics & Therapeutics)

Market PullLight-weight Materials

Functional Packaging

Scratch-resistant Coatings

Functional Textiles

Insulation Materials

Energy Storage

Efficient Lighting

New Cosmetics

Water Treatment (Membranes and Filters)

Information & CommunicationTechnology

Medicine

The two sides of nano


Technology overview for synthesis of high-performance nanoparticles

Liquid-based processes:

Nano-grinding Precipitation (Nozzle, Co-Precipitation, Miniemulsions, HIGRATEC)Sol-Gel-SynthesisHydrothermal decomposition

Gas-based processes:Flame synthesisHot wall reactorPlasma technologiesDesublimationChemical vapor depositionPhysical vapor depositionAtomic layer deposition


Integrated process chain

Flamesynthesis

Gas quenching

Electrostaticstabilization

Organic coating Transfer intoliquids

Adjusting process conditions upstream affects process chain downstreamDemand for online measuring technology


Agglomerate Size Distribution

Primary Particle Size

State of agglomeration

Intrinsic Parameters- Surface Area- Volume- Mass- Density of the bulk material

Chemical Composition

Crystallinity

200 nm

Particle properties to be measured on-lineSMPS + Offline analytics is state of the art

TSI SMPS (USA) Grimm SMPS (D)

Scanning Mobility Particle Sizers

- Number distribution

Offline analytics

- SEM/TEM


„Universal NanoParticle Analyzer“

Primary particle size

Agglomerate particle size distribution

Agglomerate typeSurface- and volume concentration

80 100 120 140 160 1800.00

0.02

0.04

0.06Room Temperature

Sintering Temp. 200 °C

Sintering Temp. 600 °C

UNPA Sensitivity S / fA/cm³

Mobility Diameter dm / nm

Lack of online-measuring systems to derive clear correlations between aerosolproperties and effects


Principle of a flame synthesis

precursor(solid/liquid/gaseous)

quenching gasand/or additives

evaporation of precursors (s/l)

reactor quenching zone

(fuel)

air orshield gas

electrostaticstabilizationpossible

Flame synthesis is a high throughput process for nanoparticle synthesisVarious nanomaterials and material combinations possibleQuenching gas to avoid aggregation and sinteringElectrostatic stabilization possible to prevent further agglomeration


Adjustable size & morphologyon a nano-scale

Most important process parameters:Temperature profile (adjustable by quenching rate)Residence time Concentration of precursors

Faster temperature decrease


Coated metal oxides from flame synthesis

SiO2 shell on TiO2 core

20 nm

SiO2 shell on ZnO core

50 nm


Separation of nanoparticles by a wetelectrostatic precipitator

Wastegas

stabilized suspension

Liquid withadditives

(Wet-)ESP

flame synthesis

suspension

H2O + additives

Off-gas

after-treatment ofoff-gas with high efficiency filters


(Wet-)E-Filter

Stabilized suspension

H2O withadditives

Wastegas

Powder

Hot wallreactor

N2

DesublimationOrganicmaterial

N2

Flame synthesizedmaterial

The Integrated ProcessProduction of core shell nanoparticles


Test equipment for desublimation


Modification of nanoparticles during time after generation

Utilization of agglomeration for safe and efficient separation of nanoparticlesExample: Agglomeration of SiO2-nanoparticles in plug flow

0,0E+00

2,0E+05

4,0E+05

6,0E+05

8,0E+05

1,0E+06

1,2E+06

1,4E+06

10 100 1000Particle size dm [nm]

Num

ber C

once

ntra

tion

tm=0stm=0,66stm=1,33stm=2,65s

[Par

ticle

s/cm

³]


Sealed production plantSealed feedingPartly sealed discharging withadditional suctionPersonal protection equipment, e.g. respiratory filters (retentionrates > 99 % for nano-objects)

Risk management at the workplaceCase study production

Particle concentration during discharging comparable to backgroundexposure (up to 20.000 P/cm3), during discharging up to 35.000 P/cm3


Based on our commitment to Responsible Care®, we defined clear principles:

We identify sources of risk for employees in our laboratories, production plants, packing and storage facilities and eliminate these using appropriate measures in conduction with safety actions

We take the risks of new technologies in products and processes seriously and work continuously to identify potential environmental and health risks.

We are committed to transparency and contribute constructively to public debateand drawing up legislation.

www.corporate.basf.com/de/sustainability/ dialog/nanotechnologie/verhaltenskodex.htm

Clear principles for nanotechnologyBASFs Code of Conduct Nanotechnology


Joint research to face health and safetyissues

Start: 1st march 2006

duration: 3 years

Project volume: 8 Mill. €

BMBF: ca. 5.2 Mill. €

Industry part: ca. 2.8 Mill. €

Partners:BASF SEBayer MaterialScience AGEvonik-Degussa AGForschungszentrum Karlsruhe GmbHIBE e.V.IGFItN Nanovation GmbHIUTA e.V.SOLVAY Infra Bad Hönningen GmbHSusTech GmbHUniversität BielefeldUniversität des SaarlandesUniversität Münster

BMBF Project NanoCare:Companies and scientific institutions join forces to research the effects of industrially-produced nanoparticles on human health and the environment.

BASF is taking part in more than 10 European projects and networks regardingNanotechnology Safety IssuesBASFs Code of Conduct Nanotechnology, commitment to Responsible Care®


Summary

Free handling of nanopowders should be avoided

Transfer of gasborne particles into a matrix is preferably realized within an isolated process

Consistent characterization of aerosols is necessary for different disciplines

Fast measuring systems are required due to high dynamic changes of aerosols

Characterization has to be carried out in a multi-dimensional way to derive clear correlations between aerosol properties and effects

Open discussion on a reliable data base is highly recommended


Questions?

ManyMany thanksthanks forfor youryour attentionattention!!

Date post:	25-Jun-2020
Category:	Documents
Upload:	others
View:	0 times
Download:	0 times

Current approaches and good practices by producers of ... · 29.10.2009 Dr. Mertler, BASF SE - NEW...

Documents