Document pBagjZbjbEbR88ZyJYvMzwqjB

FILE NAME: Union Carbide (UC) DATE: 1974 Mar DOC#: UC223 DOCUMENT DESCRIPTION: Internal Report - Chrysotile Asbestos - Markets & Forecasts CHHYSOTILE ASBESTOS mar kets a w d FORECASTS For Group 7 ( / O ci Me*"eh I97I4. G. J. Weihs CONTENTS Conclusions , . Recommendations ........ The Product............^ The Market (General) ........ Captive Fiber Sources & Product Mfgrs. . . Asbestos Manufacturers and Plant Locations Domestic Markets by End Use ............ Floor Tile ............ Oil Well Drilling M u d s ............. W/B Joint Tape Muds ................ Paints & Miscellaneous Coatings , . . Adhesives & Sealants ................ Ceiling Tile ....................... Paper ................. Export (Floor and Sealing Tile & Paper) Asbestos Filled Phenolic Conpounds . . Nev Developments . . . . . ' Page 2 2 3 3 k 5 6 9 10 16 18 19 19 19 20 21 22 Elastomers (Shoes and Mechanical) .................. Oil Well Drilling M u d s ................ Water Treatments........ . Synthetic Wood ................. Plastic Reinforcement ................... Sources .............. Exhibit I - UCC Asbestos Sales 1973 ............ Appendix I - oil Well, Rig, and Refining Activity 25 25 26 ' 26 27 29 30 Appendix II - Asbestos Reinforced Plastics Technology / ' r: * -> v o I I. -2- SUMMARY U. S. consuaption M b o fiber, Group 7 (ebon) u ..tinted at li>3,800 tone for 157?. tf anticipate a grovth rate of .boo* U 1/2 . 5i per year to I960, vhcu doodle deeand .hould exceed 202,500 too.. So of thi, grovth * ^ and mechanical rubber gooda. 0. u.,., .,,eh reinforced pltle. It^appears that Chryaotile aabestoa is expected to remain in short supply.* our sources Indicate that many sunnlier .r. ,,1 * v many suppliers are planning to increase their prices by about l # in 1974. -- * " * t gsia" ^ the negative effect, of ffilatloo. .nd cooe.uner ettltode. ....... ,l n M th. ,, 1. l^epeodeat monitoring of that peot by OCC and the Induotry. do exception 1. In the f PalntS' Vhe" "faint, by that Induatry .re Irendy In force. CONCLUSIONS 1 . B s o, tile., currently the leading consudng product, v i u renaln dominant to 1980. 2 . ^ illinff muds application will grov at a healthy rate - mostly after 1975. This appears to be the best opportunity for UCC. 3* board tape .joint . w * coatlme to ^ paclng ^ increase in housing starts and, to some extent, commercial and industrial building, it will probably be necessary to introduce precautionary work practices, especially in the sanding operation. "probably not." We understand f ^ r / ? r bestos. The answer was a major supplier of a S b ^ t o ^ h J ^ +U-LS * POVermeilt sources that Russia, Therefore, the coming s h o ^ ^ L ^ L ^ r l d ^ S S ? * ita CU8toaer commitments -3- Ue of Asbestos appears to require a concentrated effort in the areas of both market research and development. 5* Best opportunity for nev markets are: reinforced plastics, and elastomers for the shoe industry. Best (and obvious) opportunity for growth is to inherit the market segment nov held by Johns Manville. Best opportunity for growth in established markets is oil drilling muds. RECOMMENDATI OK i 1 * From a market research viewpoint, plant expansion is justified. the extent of which to be determined by technology, engineer'* n^y, toxicological and marketing considerations. 2* A market study of the possible use of Calidria asbestos in vinyl roll goods, and extended use in paper, should be undertaken. THE PRODUCT Asbestos is actually a group name that refers to fiberous minerals having different chemical compositions, but similar characteristics. Ihe most widely used type is ehrysotile. Hiese fibers are graded according to length with longer fibers priced at 10 - 20 times higher than the shortest grades. UCC's interest focuses on group 7 - one of the shorter fibers. ^o 1 J*- < Asbestos . gros, 7 , included la ^ ^ ^ ^ *Bn' " ^ in the f l w l product. " - ^ naterials end lose. W For the purpose of this study w ere cutting ststis. tie, on asbestos/cesient. packing end g . . , futile. sud other uses for long fiber where UCC does not compete.* THE MARKETS - General Bosestie production of ssbe.to, during 1973 apprnnately 151,000 short tons vith sn average value of J109 per ton. This tots! velue (W ( 390,000) vas 2256 over 1<372 ^ f>.t <# . Calif" -tle ves the prlncipel producing state f72%)i Vermont ranked second * see Tables 1 , 2 , & * (gor, producers, plants and mine location. Apparent u.s. c o n a t i o n , cording to the o. s. Bureau of Mine., of *" CteSOtU' " ie,,t0a to be the major supplier. 871' 000 . P an fro. 1973. Canada continue, As a continue to h e inroai. into the narhet aegneot. served by c a n c a n hestos, the t o f l b e t shrinhs,since that portion of product shipped which is rock, ia eliminated nr -- .a.-. , or greatly reduced. approximately 96* (average) purity. , UCC's product is ' l * ^ t o 7 S S S f ' e r ^ been excluded on the bests of is suamarized.in Exhibit I. *Per enc* selling the various markets nJ J O | Continued after Tables-on Page 11 5 TABLE I CAPTIVE FIBER SOURCES FOR TEE MAJOR ASBESTOS PRODUCTS MANUFACTURING FIRMS U. S. A CANADA Company The Flintkote Co. Captive Mine(s) Flintkote Mines, Ltd. Quebec (wholly owned subsidiary) Fiber-Producing Capacity (short tons/year) 33,000 GAP Corp. Lovell Mine Orleans, Vermont 1*0,000 ASARCO (through CAPO, 1*0^ owned by ASARCO) Lake Asbestos of Quebec Ltd. 130-150,000 Johns -Mansville Products Corp. National Gypsum Co. Canadian Johns-Manville Co., Ltd. Coalings As bestos Corp., Calif. (8o interest) National Asbestos Mines, Ltd. 835,000 15,000 60,000 Jim Walter Corp. H. K. Porter Co., Inc. Raybe stos -Manhattan, Inc. ' General Dynamics Corp. Union Carbide Carp. Atlas Asbestos Corp. Bell Asbestos Mines, Ltd. Carey-Canadian Mines, Ltd. Pacific Asbestos Corp. Caasiar Asbestos Corp. (Partial Interest) Asbestos Corp., Ltd. (5^ interest) Union Carbide Mines San Benito, Calif. Santa Cruz, California Quebec, Canada 250,000 1*0-50,000 110,000 350-500,000 35,000 10-20,000 60,000 Advocate Mines, Ltd. Jaquays Mining Co. Bale Verte, Newfoundland Gila, Arizona 70,000 3,000 . ^ n. - ./ i (1) J. M. may cease operations in California in I97I* L_J * 6 1 TABUS 2 -- *" * ASBESTog m a n u f a c t u r i n g fir^ AMn ` I N THE UNITED STATES Company American Biltrite Rubber Corp. Armstrong Cork Co. Total Number of Employees About ^,500; 20$ involved in as bestos products Estimated Annual Sales ($000.000) l6l .0 Principal Asbestos Based Products Manufactured Floor tiles 21,000; about 80$ involved in asbes tos products 550-600 Caskets & insula ting materials; vinyl asbestos tiles Certain-Teed Products Corp. 7,600 332-0 Roofing products The Flintkote Co. 11,300 W 1.0 3AP Corporation .V c_ CT CO 20,000 It*s subsidiary, Ruberoid, is pro bably the sole producer of asbes tos products 768.0 Asbestos-cement Pipe; vinyl as bestos tiles; roofing products Asbestos-cement products; vinyl asbestos tiles; roofing products; asbestos paper Plants-Establishments Manufacturing Asbestos ______ Producta_____ l1 plants involved to some degree in asbes tos manufacturing Fulton, N. Y. Jackson, Miss. Kankakee, m . Lancaster, pa . South Gate, Cal. Santa Clara, Cal. Riverside, Cal. Ambler, pa. Hillsboro, Texas St. Louie, Mo. Los Angeles, Cal. Chicago Heights, 1 1 1 . New Orleans, La. Ravenna, Ohio Chillicothe, Ohio Mobile, Ala. Long Beach, Cal. Joliet, ill. Mlllis, Maas. St. Louis, Mo. So. Bound Brook, N.J. Vailis Gate, N. y. Erie, Pa. (two plants) Whitehall, Pa. Houston, Texas of Line Related to Asheston 5 50 75 20 5 I__ Company Jim Walter Corp. Total Number of Enployees 1,000 In asbestos products manufac ture - (also own Celotex) TABI Estimated Annual Sales (t000,000) 882.0 Johns-Manville Products Corp. 25,000 1* " C. C*1 '0 ) K) fv , (lcolet Indus 350 tries, Inc. National Gypsum 3o. 1^,500 laybestoa Men tation 6,500 796.0 - 15.0 519-0 165 E 2 (coot'd) Principal AsbestosBaaed Products Manufactured Roofing materials Plants-Establishments Manufacturing Asbestos Products Perth Amboy, N. J. Linden, N. J. Memphis, Tenn. Lockland, Ohio Mlaolsburg, Ohio Wilmington, Del. Houston, Texas Tampa, Fla. Cincinnati, Ohio $ of Line Related to Asbestos 12 a u Asbestos-cement products; asbestos roofing; asbestos Insulating materials; millboard Nashua, N. H. Manville, N. J. Pittsburg, Cal. Stockton, Cal. Waukegan, 111. Marrero, La. Long Beach, Cal. Los Angeles, Cal. Green Cove Springs, Savannah, Ga. Billerica, Mass. Tilton, tf. H. Denison, Texas Forth Worth, Texas Fla. Asbestos paper; Ambler, Pa. 100 asbestos millboard Norristown, Pa. Hamilton, (kilo Asbestos-cement pro New Orleans, La. - ducts; asbestos Millington, N. J. roofing; insulating Mobile, Ala. board Broke linings & blocks Bridgeport, Ct. (Home Office) & asbestos products mQm < table J TREKDS Iff SHE IftlMREB rw ' -- S ` aBESTOS m n W C T S (MUMr-roeTM, rnUPA*nrrf PRODUCT ------Asbestos Products . ISAR 19^? 195* 1958 1963 1967 1973 NUMBER o p COMPARTED 85 7k 69 73 81 80 Sources: 11*7-1967 I967-I973 1967 s. Census of Manufacturers Industry Estimates r -i ^ 'j -9- TABU 4 * DOtESIle ET for cfflYsmrr. ------ (S r la a r llly Group 7) USE (1) Floor Tile (2) oil Drilling Muds (3) Elastomers (Shoe) vn\ 105,000 10,000 Neg. Annual Orovth 75 Mechanical Rubbers Adhesives & Sealants i W Reinforced Plastics (Phenolics) Paints (lad. Misc. coatings) Keg. 5,000 * 5-6jt Keg. (Poten. bOOO) - 600 Filled Plasties (Phenolics) "W/B Tape Joint Muds (5) Ceiling Tile Paper 11,000 9,000 1,200 2,000 3* 3* Neg. Neg. (6) Total 1^3,800 short 5* tons I960 129,000 16,000 (5,000) 6,000 7,300 15,000 600 lh,000 11,000 i,4oo 2,200 ^02,500 short tons Z 7 ..T : growth u n til ^ aL d ` ^ . r f n ^ r ^ . P^ ^ 0n- * * * 1 Ohm ;;; ; ; ; ; 7 * 00 ~ - 1. * . **. PosulhmS7 " ***" (5) Totally p e n d a n t en 1 ou a t o - whan, proj e c t . ,, ,,ncurtaln. ( ) hot alloying for poa.lhle r e l a t i v e .otlona by 0SH1 or B . i ' r* "N ^ , ir o H- THE MARKETS (Coat'd) The market break-down and estimated future consunption shown in Table 4 does rot consider che probability that OSHA and/or EPA .11 force regulations on the asbestos mining and consuming industries which may hinder growth or actually eliminate some existing markets - e.g, paint. FLOOR TILE 1973 production of vinyl-asbestos floor tile required about 105,000 tons of asbestos. The remaining portion of a typical vinyl-asbestos floor tile consists of vinyl resin, plasticiser, lubricants, stabiliser, limestone and TiOg. Limestone contributes over 55* to the average formulation. Natur ally, variations- exist depending on manufacturer. The industry suggested growth rate for vinyl asbestos floor tile is 5* P*r year to 1 9^0,but resin suppliers place increasing resin Hwmmri at about 2* with less growth anticipated during 1974. This 1974 slackening of demand is attributed mostly to the shortage,of raw materials. Some of the differences between estimates may be attributed to the desire of tile manu facturers to decrease scarce, expensive resin and increase filler whenever possible. We believe an average annual growth of 3* can be envisioned based on the following assumptions: 1. Resurgence of residential soft (carpet) floor covering nay hinder vinyl/asbestos tile growth. -n 2. Decline in housing starts. 3. Aewptanee o f .o f t flo o r co ro rlo g. 1,, b u .ln e .. ^ estahli shaents. ` 11' Tread to a allr b o o ., and apartm ents. 5. O rab al replacaaeat o f M pbblt t U . by vin yl a sb e .to .. r r - v . f ' TABLE 5 ESTIMATED 1973 ASBESTOS CONSUMPTION IN f l o o r TTt.p COMPANY GAP Corp. Uvalde Rock Asphalt Co. Kentile, Inc. Armstrong Cork Co. American Biltrite Rubber Corp. Flintcote Co. Others CONSUMPTION (short tons) 20,000 5,000 12,000 20,000 10,000 20,000 18,000 U. S. Total 105,000 Source: UCC - Mining & Metals Division rA ''fsTJ o^ c^L 1JN 12 TABLE 6 "CALURIA" ASBESTOS SALES FOR FLOOR TTT.T _ ^EAB 1964 AMER. BILT Tops |m ~ gap Tona M 1965 1966 1967 1968 1969 1878 97 1970 1721 68 1971 2139 109 1972 1760 88 1973 1107 62 1974 est. 720 44 0 0 260 12 3490 157 2618 126 4695 225 3000 159 KEBTILE Tona Si 3190 160 3228 168 2600 122 3Q45 180 2641 127 1590 82 Uvalde Tona Total tons M 141 6 972 54 130 (1)7524 376 7082 355 5630 280 69 6448 326 ll4o 57 1680 84 6349 325 9909 472 2732 136 10955 530 5227 230 (2)13678 644 4800 238 (2)10680 533 (1) UCC announced decision to "go out" of floor tile market and sell all plant production to HP markets, Thi6 did not materialize. (2) Sales limited by production capacity. I c FIGURE I ffiYVTP APHTPAT. TPPA'PTPM fV 'PTfR MA.TOR VTWVT A<^RPt?POQ rmr>o mrrp m mo TM MMrt* ?rrr*rrrn WArnrQ COMPETITION; A number of v u ,, are e n s u e d la the mining aai marketing of K.to. to the floor tile " ufacturer. e a e co^nl.., located I n "" " " St* " * " * <S-- H from chemically different substance la * * u 1 . 3. c o i t i o n gingji and the tenpo increasing " direCtlV'* * " -- EPA precipitate uncertainty. Aaopg these are Ah inorganic her, available ln d a v e l ^ t fora of eluaihe or rerconia fiber - t n * I d . ^ ^ oup I, Cheoicel,le vorking uoder a aecreey agreement vlth " 1 nintCOte t0 de'r'1`* asbeatoa aub.tltute apeclflcally for floor tile. Tbl. development material ia reported to be a W o u e r e a m vith a polycaprolactoa, (facdly) oo^ u n d . - It 1. claimed to handle la the forming equipment equally aa veil an asbestos. Additional information can be obtained on a secrecy basis, if necessary. gev Developments In Floor T U e Marketing Developcents In the Industry include an announcement by Congoleum's resilient flooring group of a atepped-up program for the company1s vinyl asbestos floor tile. They have instituted a number of field and management changes to support this policy. It would appear that at Congoleum, there is little fear of product use legislation at the "ultimate consumer" level. Another new activity involves OAF, which has announced introduction of a vinyl/asbestos "do it yourself" wall tile. Heavy Fall T.V. coverage is planned. (See Figure I - Floor tile plant location.) . TABLE 7 WORLD-WIDE ASBESTOS IN FLOOR T H E * ' Argentina Europe (V. Germany) S. Africa Viet Nam Brazil Taiwan Columbia Chile Tons 5,000 20,000 2,500 11,000 3,000 ^,000 1,300 1,700 Wi,500 Tons Source Canada Canada S. Africa Unknown Canada - JM Taiwan Atlas (AZ-20) JM Coallnga * Known Markets m O O V' -16- OIL WELL DRILT.twt. mttt i A*b**t" is used aa a vi.co.ity control agent m drilling m da - ..tly for aqueous eyateTM but alao for oon-agueou. (oil) ay.t,m .* 0. S. aabeatoa demand vaa about 7000 abort tona in im .ad u. S. p o r t .mounted to an addition* 3,000 abort ton.. Although ve f o m e n t grouth at Ti per year to 1 ?80, ve believe the greater portion of grovth Vill be realized after 1975. Short term grovth ia hindered by lack of equipment oh availability m the U. s. vhloh, during the early I960'., atood at 2,000 unit, id today, at .pproidnately 1,370.** It nay take gj, ^ rig capacity to .net dmjand. and by 1980,there could be 2,300 rig, availtie. m e r e 1 . alao a ahortage of pipe and other part., and a shortage Of .hilled peraonnel vhloh could require 2 - 3 y , ,, t0 ,,pletely Hovev, aa Price, for oil product. Increaae, the attraction of luveator. (money 11 , w aolve the egulpnent problem In a ahorter period of time. Governnent Intervention id priorltlea may alao help. (See section on New Developments - p, 25) \ # Oil systems are used vhere it has been pre-determined that the subterreanean rock formations would be degraded by water. S S t w onn& 1S 'ataotat aoLn ^riigSs"^and w*e?ll?s "- worfld3-/w7i1*d-e. S" I fur ? -17- IABLE S f OBIQW CARBIDE ASBESTOS (Short Tan) TO MOKtELLO FOR BILLING MOP APPLICATIONS Product Designations CSV NCSV IMC/Visquic Visbestos 1970 677 0 120 1242 Total 2039 1971 1671 0 0 750 2421 1972 1175 0 0 642 I817 1973 1319 469 999 249 3036 197^ (Budget) l44o 360 l44o 360 3600* * Sale# limited by plant capacity Problems; ' Problems currently facing asbestos drilling muds are: . Possible restraints by Federal government agencies ` SbortaS*s of asbestos may entice customers and prospects to formulate around the product. Competition on the horizon in cludes biodegradable, long chain polymer systems. However, these are high priced and,along with other chemicals, may continue in short supply. ' . Competition from Johns Manville'a "Flosal" asbestos. This may soon end which will strengthen our position in the market place especially with Phillips Petroleum. * i r- H 0 nn < ,, i 1 Hi . h j , ` n L L. 0 0 -18- <* Order of priorities - sooe of the oonles made available through increased prices may be ear-marked for refinery capacity rather than for drilling. There is now reported to be a short fall of over 2 million barrels per day of refining capacity. . Continuing competition from Bentonite. . (See Appendix I for the number and location of drilling operations - vorld-vide) WALL BOARD "JOIMT" TAPE MUDS 0. S. production of gypsum vail board during 1973 vas approximately lh billion square feet. Assuming a requirement of 5 gallons of (3i con tained asbestos) mud per 900 aq. ft. of vail, ve estimate a current demand of 9000 tons of asbestos for this purpose. Growth of gypsum vail board depends largely on housing starts as veil as, other business and commercial construction. We accept a 3$ average annual growth rate td i960. Projected, this would mean a market for as bestos of about 11,000 tons in i960. According to the Gypsum Wallboard Association and our own internal Information, there is an alleged hazard in the use of asbestos in this application due to sanding of the semi-finished Job. This ndusting" is considered unacceptable by the trade in view of CSHA attitudes. Warning labels may be required. : n -19- PAINTS MINOS ASBESTOS APPLICATIONS * The industry estimates approximately 300 tons of asbestos were consumed in textured paint during 1973 and an additional 300 tons in allied applications. Although the market for textured paint is in creasing, manufacturers, fearing restrictions by OSSA, are substituting asbestos with talc and inert pigments. According to one source, some development work is still being done. We therefore, hesitate to eliminate asbestos paint from our future market picture and elect to carry the volume over on a "no growth" basis. ADHESIVES AND SEALANTS According to information received from the Adhesives nd Sealants Council and others knowledgeable in the field, there ia a current demand for asbestos of about 5,000 tons per year* This requirement is based on the use of asbestos in mastic adhesives, vinyl and rubber based sealants, caulks & putty. Growth is expected to approximate 5-^/year to I960. CEILING TILE Conwed Corporation, Cloquet, Minn, is the only U. S. ceiling tile manufacturer known to he using asbestos. 1973 consumption was 1200 tons - all UCC's "Calidria". Demand for 197^ Is 1000 tons and imtH rmim requirement by 1980 is put at lUoo tons. Since this is a "one customer" market, every thing depends on the whim of the single company - fonwed. Other ceiling tile manufacturers such as Kaiser Gypsum and Armstrong Cork do not use asbestos. -20- Use of asbestos improves tensile strength in board formation, and clay and starch retention. However, major ceiling tile manufacturers can and do obtain satisfactory product substituting various organic chemicals. The contribution of asbestos - to supply the positive charge necessary to keep it and other ingredients clinging to the wire on the Fourdrinier - is important for older but apparently, not newer equipment. Continued domestic use and growth depends substantially on the outome of a legal suit by the Federal government against Reserve Mining Co. for allegedly dumping asbestos-like waste into the Great Lakes. If the government's case stands up, it would have an adverse effect on our future domestic ceiling tile business.* (See Table 9 for UCC exports.) PAPER: ' Three known uses for asbestos in the paper jndnqtry are1. Add to "furnish" for pitch control. 2. Retaining agent for such paper additives as clay. 3 TiOg Extender In some cases, the use of asbestos can have dual purpose. There are reported to be technical problems precluding asbestos use the newer mills, in these operations, the asbestos must be added to the furnish in slurry form, which in many instances, results in lumping, This, the mill can not tolerate. It appears the problem can be overcome, but by costly methods. In the older mills, it is satisfactory to add the as bestos as a dry powder and lumping does not occur. Talc has been suggested to be as good as asbestos and at a cheaper price. Future for foreign shipments still looks bright. r D -21- i * relatively ner uee 1 . far electric paper, Stevens, We.tfleld, 11 ^ toovn asbestos cuetear, the remaining tvo m TM . ' f`Ct"'r` "* r00l"!r * * - * , . Mein, .nd P. J. sotomtaer, ^ Ve believe that thi. nee win r ^ a n restively The 1973 domestic demand for asbestos In paper la about 2000 tons per yser sold to four customers: tcngvlev (pitch control); Boise Cascade ( T ^ Extender); Kimberly O s r h (COntrol of sheet porosity); end Prairie State. (contaminant dispersion end pitch control,. See Table , for W C .rports. TABLE 9 Floor Tile ESTIMATES OF UCC EXPORTS ^000 Tons) - Japan 1973 0 (1 ) Europe 0 0 g*?er. - Japan Europe 0iliug Tile .Tmnn 1,000 100 1,100 3,400 1977 4,000 5,000 9,000 2,300 8oo 3,100 7,900 1980 8,000 10,000 "IB,ooo" 2,600 i,4oo 4,000 9,600 Source: Internal (UCC, KF) to b e ^ e " * * > >*" > W-H. Oceee estiemta. Cl) No material avialable u A ' rr ^ O ry , N \J tj . **% r~ -22- Asbestoa Filled Phenolic Molding Coaponflg* <* According to an Internal report ^ phenolic molding materials are categorized by seven market areas: j> of Total Production r~ 1 ) Applaince parts - toaster handles, 1 i. electrical control knobs, etc. 25 ri1-> 2) Automotive-transmission parts, brake parts, distributor caps, etc. 16 11 3) Electrical - switch gear, high voltage F-' circuit breakers, etc. 30 1 : *0 Wiring devices - electrical parte 1107 switches, plugs, etc. 12 5) Closures - bottle caps, etc. 4 r Ij ; 6) Communications - switch terminal blocks, etc. 7 ni 7) General industrial parts - knobs, ash trays, etc. 6 Asbestos is used largely in appliances and automotive phenolic ap n * [J plications which account for approximately 4o of phenolic molding materials. ! Some asbestos is used in electrical wiring devices and general industrial 1 * applications for specialty high-temperature resistance items, but usage j "j 1 relatively small coapared to the forementioned areas. Asbestos is not normally used in closures or communications parts. (See Table 10) D r-- 1 (1) B. L. Engalls 1-17-74 <, 1 r: .*> ^ ^ ^u7 r "23- . . c"r M a ' 7 RF9" purchased from Carey, (l) i,*o ot M ,,o,t0. * " 3 rtlte' re'," > * .lng occ-. -Ctildri 1) Sloe, both materltt. TM .hipped F0B to di.tm.tlon, ^ freight oo.t. fro. California c o e d thoa. fro. Carer a atlon in Canada. 8> C,1Idrl` '*" * " -- more difficult to disperse. to hdle in bulb, t h * are 3) acc>. e q u i p 1 . ,et up to bundle the =oound ea received fro. Cerey and It uould require production a f o l i a t i o n duu.ge. to convert to "Calidria.*' General M e t r i c Co. recently announced lnteation * ^ he.toe and have changed to a combination of other filler.. 1* 1 . asbestoa free for.il.tion ha. ao far, received ^ d acceptance. While the substitute nay be * actory for some items, asbestos filled phenolics are the best performers in +*. , P rs in high temperature applications. Such i t . a. houaehold eppllancea, which operate at temparatura. above qW <*; a t U l require - b e a t . We underatand that ffl i, purchulng aabeatoa filled Phenouc. for their dl.eatl.fied =uatore. M . 1. alao eonaidered to be vety public relation, eonaciou. and f0r thl. reaaon, * 1 1 promote "ana aabeatoa" to the trade aa an " e n v i r o n . ^ The loa. of aabeatoa bualnea. to thi. e o ^ n y baa been eetlmted at over 1,000 tons/year. Note: melamine but t h i ^ i sdamali! i 0ther ^rmosets uch as urea and(l) (l) Carey's total m n n .1 Bale ^U5 -no imately 2 3 5 ,0 0 0 TFX. * asbestos for all applications is approx- ^ ^ -2^- YEAR I960 1972 1973 1971* 1975 1976 1977 1978 1979 I960 TABLE 10 PHENOLIC m t h j q o CQMPnnwre (l) ASBESTOS POTENTIAL DEMAND lgH-lOfin (OOP Tena) PRODUCTION 100 ESTIMATED PRODUCTION CONTAINING ASBESTOS _____Cg5*) 25 170 1*2.5 190 1*7.5 195 20l* 210 220 230 1*8.7 51.0 52.5 55 57.5 2k0 60.0 250 62.5 asbestos demand (2356) AVERAGE CONTENT (Rounded) 5-8 9.8 11.0 11.2 H.7 12.0 12.6 13.2 13.8 11*.3 Competition is also coming from leas expensive materials such as tale vhich recently replaced asbestos in the auto fan shroud. 1,500-2,000 ton per year outlet.1 This was about a (1) S t a t f ' la 1973> approxloat1y U * of the phenolic molding compo2niti,5 o o HEW DEVELOPMENTS ROBBER (Blast aers) Due to the shortage and increasing price of "high" styrene resins, there is a possibility of an Impending market for 5,000 tons of asbestos by the shoe industry. Interested, prospective customers include EndicottJohnson and Thom McAn (j. ?, McEllvin). ' Present market for asbestos in the shoe industry is shout 500*1,000 tons per year. UCC's "Calidria" does not now compete. Advantages of "Calidria" asbestos are price and expected availability. Again, there could be an environmental probleo^and aince ve believe its uae will be a "go or no go" situation (either all or nothing), ve have not added the market potential to our estimated total demand in 1980. This application must be watched closely to determine outcome. UCC should have more definitive information within the next few months. MECHANICAL RUBBER GOODS Including rubber rollers, shock mounts and belting,hold a potential market of 5 ,000 tons/year for asbestos by I98O-8I. also add another 1,000 tons. Use in rubber tiles will r OIL WELL DRILLING . During 1973 a new development occurred which could markedly increase Union Carbide Corporation*a participating in the oil well drilling business. Dresser Industries has developed, and ve believe have a patent application on, a silane treated asbestos (UCC silane). r j ! . ... P ` r1 ' 1 j ` ` ` r ; n 0 -26- 03X WELL DRTT.T.twq (cont'd) Technical details are meager hut the nev product appears to be Intended f-r oil based systema and increases their useful operating range from O U t 250O? to 350Op- Dreaser *** * e d for 1,000 tons in 1975,and dis cussions are in progress to determine economics and business relationships. WATER TREATMENT A lieensiS distribution agreement has been negotiated vith th* Perautlt Company covering the use of High Purity Asbestos in the treat ment of certain types of vaste water. Sales in 197^ are estimated at 300 tons. It is too early to make firm predictions,but sales in the order of 5,000-10,000 tons/year for this application are quite possible by 1980. SYNTHETIC WOOD A 80811 inventor, Holman Construction of Anderson, South Carolina b*en workia for ^ 3 years on a "synthetic wood." Fiberglass 8trandB Pu21ed throuSb a die while a filled plastic is simultaneously extruded. SG-130 at a loading of 5-10* is a key ingredient for a flow con trol in the extruder. Owens-Coming, as a fiberglass supplier, has become increasingly involved with the project and has recently taken a two year PPtion on the pilot plant. If the project becomes commercial,the asbestos potential could be very large. ' ^^o 2( -27- PLAJSne REINFORCEMENTS , Union Carbide* chryaotile asbestos pellets, treated vith our proprietary phenolic coupling agent, is being offered to the trade as a reinforcing fiber in thermoplastic resin systems. ThlB fiber i6 designed as a substitute for glass at an approximate ratio of 1 :1 . Our offering is designated "RG600." f1 ) See Appendix II for technical % information. Market potential for RG600 is based on a reasonable share of cur* rent consunption of, and growth expectations for, glass fiber reinforcement in polypropylene, nylon, H D P E , s t y r e n i c s , acetates and other thermoplastics. During 1973 thermoplastics were consumed in the amounts shown in Table 11.12 TABLE 11 CONSUMPTION OF THERMOPLASTICS IN 1973 RESINS Polypropylene Nylon Engineering Plastics Polyethylene Styrenics TOTAL OR MM LBS uo 23 34 13 20 130 MM LBS. (65,000 TONS) EST. GLASS FIBER 10 6 8 3 5 32 MM LBS. (16,000 TONS) (1) RG660 is 2.5 microns in length - fully liberated. (2) It jhouid be noted that N gq o and other grade "7" asbestos con be used to convert low density polyethylene to high density, as well as substitute for a portion of high priced, scarce, styrene 1f-' / - monomer in some formulations. ' '' ^ 0 0 ^ - -28Aasuaing a 2 % penetration potential, we .see a current available narket for approximately 8,000,000 lbs. S* 4,000 tons. Our present comaer d a l penetration is nil. Market available in 1980 (assuming no growth for 1974) is about 15,000 tons. UCC's ability to penetrate this market, in view of the entrenchment of glass, and ecological considerations,'is highly problematic. Besides overcoming the negative publidty which surrounds asbestos, it will be necessary to sell at a reasonably lower price to entice those users now wed to glass and glass reinforcing technology. We have avoided a discussion of reinforced theraoset resin reinforce ment because, as of this analysis, there is no satisfactory coupling agent for asbestos in this system. However, work is proceeding with thermoset/ asbestos at UCC - Bound Brook and future developments are possible. If successful, a market potential for UCC's RG600 is 8-10 times greater than that for thermoplastics alone. S o34 CODS: 11 3 5 1 8 8 11 v 6 4 U 2 6 3 11 -29SOURCES External < Asbestos Magazine N. L. Industries (Market Research) N. L. Industries (Research & Development) Gypsum Vail Board Assoc. Oil and Gas Journal Montello Bureau of Mines (U.S.) Rubber Age Magazine Adhesives and Sealant Council Fluid Sealing Assoc. Resilient Tile Institute PPG Industries Glidden U.S.D.C. Internal UCC Chemicals & Plastics ' 2 A. Constantine 6 R. Lindberg 6 D. Barry 8 J. Madden 7 M. Ranney 10 G. Shlpston 10 P. Potter 10 V. DeFaber UCC Asbestos Group 11 Marketing & Development Personnel - Nev York, Niagara Falls, Chicago and Atlanta UCC Group I R & D 7 F. Ancker - Bound Brook 8 T. Foster - South Chas. 8 S. Livengood - Tarrytovn CODES: 1) Vailboard 2) Floor Tile 3) Paints *0 Adhesives & Sealants 5> Paper 6) Elastomers 7) Plastics Reinforcement 8) Oil Drilling Muds 9) Ceiling Tile 10) Plastic-Filled Fhenolics 11) General 0 o 4- r exhibit t " CALIORIAw ASBPST0 <;_3 W g g . (Domestic A E xporh)' ' _ Product /o x 3G-J30 >3-200 *5-200 5G-2I0 H3P -=0 HPO-J T-J35-P T -I35-0 ! CG-I35-P 00 ! 10 I44 3X-I4 P. SX-24 /isbestos mcobest SV 33V in er -------------- - Floor T ile M astics Resin f i l l e r Ci 11ng T ile Appf ic a tio n s _______ Tape J o in t Compounds, M astics, Sealants C e ilin g T ile , Paper, Rubber Rasln f i l l e r , Warfe Water Dri||ing Fluid 'Paper C o a tin g s Coatings Res in f i l l e r Undercoat, M astics, etc. Adhesives, Sealants, etc. Same as RG-144 T h ix o tro p e Same as RG-244 D riIIin g F luid Treatment Drilling Fluid Drilling Fluid D ri||in g Fluid TOTAL M T1WolnMnPaCJi< 1970 1973 6400 190 0 0 917 5612 13493 278 100 750 3946 5151 502 351 o 55 438 587 419 13 13 0 106 650 754 407 616 33 50 185 808 34 Ii8 1032 254 0 999 668 1344 0 127 -- .. ',308 463 -- 65 30.725 t 19 7 4 (Budget) 10680 360 1000 1400 4800 5900 360 _ 240 480 280 75 100 1080 700 H5 882 230 360 1440 1440 360 0 32,282 > O o JLM T r-- r V rI . l; L I nLi appendix I Rotary-rig activity by states fui Ha. Alatemi .. .. .. . Il Aiuto .. . .. 10 Intani . .. I Offtton. . ... 3 Arkansas . . 23 Ariana . . S California se Wand ss Offshore 4 Colando .. ss fiondi 15 Gnau 2 Mate 2 Illinois 11 Indilo 2 fona 1 Kansas 4S Kentucky 3 Louisiana 253 Nortft 31 tnland rstori 66 South 76 Offshore 97 Maryland 1 Michifan 26 Missssippi 44 Missaari 1 Montana zs Kcbnsto 10 tonda 2 Mar Mexico ss New York 6 torti Carolina 0 torth Oakota 17 Oh 44 Oklahoma ISO Ortfon 1 Ptrwsylwania 19 South Oakota 3 Tenesse 2 Tea ... . 454 Golf Coast 143 Offstera . 11 torth .. . Pantondi* . East .. . West Central Wast .. Utah Virarne Washinftao W*t wr|inia Wjom.qj - 29 29 . 37 104 115 49 3 0 32 10S Tatal ILI Canada West . Canada Eut .. . 1.449 272 ... 9 Li Ns. un 7 13 0 S 0 4 0 1 1 15 0 2 34 SI 33 49 0 2 23 42 5 9 0 I 0 1 1 C 0 0 0 1 I 21 0 1 161 205 15 23 43 SS 37 56 56 71 0 0 10 20 23 29 0 1 9 19 1 5 0 0 40 0 1 0 0 5 10 21 36 00 115 0 0 6 11 0 1 9 0 321 376 C 109 6 9 14 22 15 23 15 30 73 G G 101 29 31 0 1 0 0 t 20 33 70 079 1.194 70 175 0 4 1172 15 5 4 1 1S 1 46 45 1 3$ 10 0 0 14 1 0 24 2 214 19 M 59 G 1 17 37 0 20 6 0 55 0 0 272 90 0 1 I 0 322 91 6 2126 26 71 90 34 0 0 16 vlaa6n0 4 Aventi nf aitmty..ari 1170 10 1951 IK7 a 7 6 3 2 5 14 21 20- 21 5 12 11 3 5 0 2 10 17 16 15 13 16 7 8 ! 0 2 1 3 46 52 71 17 S3 . 40 42 61 65 67 6 10 17 22 16 30 25 23 17 16 11 4 1 I 2 0 0 0 0 0 0 0 0 0 0 13 14 17 22 30 1 1 1 2 3 1 0 0 0 0 29 30 38 35 41 2 1 2 5 9 .194 204 230 233 235 16 12 19 19 20 so 57 57 64 66 $4 56 69 59 58 74 79 85 91 91 0 0 1 1 0 12 11 10 10 10 39 43 40 36 33 0 0 0 0 0 17 17 31 34 22 5 6 10 5 5 1 0 0 2 1 47 40 64 68 56 l 0 0 I 1 0 0 0 0 0 22 22 9 9 12 13 11 '17 24 18 90 98 120 106 101 0 0 0 0 0 9 9 7 5 ; 1 2 1 1 0 1 2 1 0 1 291 302 322 329 340 79 73 77 88 90 5 6 10 6 7 15 17 25 25 28 16 19 19 20 21 23 2S 37 34 38 76 77 74 67 67 77 15 80 91 17 12 12 12 15 I 1 0 0 0 0 0 0 0 1 17 16 18 16 15 45 71 SI 56 44 976 1,021 1.194 1.130 1.134 120 131 149 ISO 144 4 3 2 1 1 tra* Tstaf 1.077 1.043 U73 1230 1,100 1.1 1343 1301 1270 Sautw; HuefiTootCo. Nor* Peak and lew finir my not add to fetal*. 00 10 ISM 2 1 2 13 i 5 5 3 3 3 2 10 11 9 1 1 2 79 99 93 70 O 87 9 6 6 16 19 21 2 4 1 0 0 0 0 0 0 30 24 20 5 5 6 1 0 0 55 70 67 13 12 1 2S6 270 2G 23 30 27 72 72 83 63 73 81 98 95 91 4 2 2 9 11 13 34 3$ 39 1 0 0 24 26 21 6 10 11 sa1 2 1 65 7 1 1 1 0 0 0 22 12 12 14 14 56 141 163 158 1 1 0 10 9 II 0 2 1 1 0 0 387 425 477 103 112 135 1 5 2 31 34 23 25 31 36 40 43 G 102 121 102 107 103 14 14 17 0 I I 1 0 O 19 24 16 4 so 41 1373 1387 1302 156 163 149 1 2 I VAIO; ^ ^ 524.,1.653 A P P E N D I X I ( Con'tl Worldwide oil at a giance couxm RESERVES 1-1-74 WELLS r< OIL PR 0 6 Predacmg Onlhnc Estimated (1.000 bn (billion eu ID ail 12-1-73 1973 tram 7-1-73 (13)00ft/d) 1672 REFINING Capacity <1.800 b/cd) kefinenes Crude kitennCracking tng ASIA-PACIFIC Afghanistan Australia Bangladesh Brune -Malaysia Burma China Rep (Taiwan) Guam India Indonesia Japan Khmer Republic Korea. South Ne Zealand Okinawa (R.U Pakistan Philippines Singapore Sri Lanka Thailand Tetal Asa-Paerffc fCondcmata t89.S40 2500.000 1.600 000 67.800 14.000 779.000 10.500 000 19,000 t224.000 31,200 10,200 15,635.040 4.900 37,700 8,000 20.000 200 400 2.000 15.000 700 15,000 10,120 110 1142M 13 394 126 700 50 1,500 2567 13)84 4 16 25 6.479 4 02 7 42033 235 1 5 32C0 17.7 7 23.0 ISO 2 02 9 150.0 - 05 25 1,300.0 226 11 153) 1 3.6 330 5 8.0 -11.1 3 2 02 - 12 22452 2033 10 680.9 1 30.6 3 1232 2 255 2 2100 1 295 10 4991 8 427.7 45 4.939 8 I 125 3 420.0 1 54.0 3 212.0 3 805 4 2835 4 699 6 144J 90 361 115 277 4 21.7 1 38.0 4 1662 7,0 -- in i 106 1.932.7 515.4 156.7 1-S 5.7 20.0 215 75 486.0 .15 275 18.0 110 25 42.6 205 35 235 " 1505 T EUROPE Austra 157.000 589 1250 5 50.0 1 2200 163 24.0 Belgium 8 816 7 55.3 901 1 150 2.7 Cyprus Denmark 248.500 1.800 4 1 31 -1 1 4 3 2263 18.0 195 Finland France 2 196.0 32.0 25.8 80000 6.500 284 5 26.3 - 12.6 23 3.1400 182.4 389.6 Getmany. West 544.000 12508 2,782 6 133.0 - 3.4 33 2.825.7 126.1 332.9 4 313.6 2L5 Greece! Irelandt 1 S85 135 7 225 3.7 34 3.882.0 304.7 3745 Italy Sicily Netherlands 212.000 5500 125 251.000 92.000 319 9 285 - S.6 7 1.6253 75.0 163.9 Norway 4.000,000 233)00 4 6 375 13.6 3 1683) 6 145.8 135 110851 Poland* Portugal 2 110.0 1231 156 Romania* Spam 10 32031 60.000 500 26 4 222 788.0 9 1,163JO 1385 Sweden 5 24831 47.8 2 1400 23.0 n Switzerland United Kingdom 10.000.000 50.000 63 IS 15 -llJ 20 2.7625 3802 Yugoslavia " 438.000 1.800 1,012 8 71.0 9.7 Li Total Earape 15590500 193,797 5569 69 3955 j 1S8 18.110.1 2.011 ( n foil or gas discovered but not developed. 'Not Included in ooiKommunW total Government estimate adjusted. L MIDDLE EAST Abu Dhabi 21500.000 12500 142 4 12855 225 Bahram 360.000 4.000 215 63.7 - 8 J 1 2S05 342 145 n Dubai Iran 2,500.000 1.000 39 2 2235 418 61000.000 270.000 350 9 6,0005 195 5 6600 36.0 415 Iraq 31.500,000 22500 133 9 1,8882 305 6 985 55 Israel 2,500 25 29 1 tioo.o - 75 2 2125 1 14.1 27.0 25 15 Jordan Kuwait 64,000500 32500 692 l 25902 - 3.6 5 646.0 205 D Lebanon Neutral Zone 17.500.000 8500 362 1 5075 -1 1 2 2 535 72 75 tt Oman Qatar 5250.000 2,000 97 2 2715 -- 3-5 6,500.000 8.000 92 3 5555 152 1 10 Saudi Arabia 132.000.000 50,900 627 3 7.4175 29.4 2 4285 ill Shariah 1,500.000 1500 2 South Yemer uien) 1 162.0 U Syra . . Turkey . 7.100,000 450.000 700 123 1 1017 -12.1 200 286 6 65.0 1 515 4 3055 285 iu . Tetal Middle East 350.1(2.500 413525 3,187 44 21574.1 11.1 31 25822 1015 85 tindudes captured Smai fields. `Not yet producing, ttlnciuded in Kuwaiti figures, M 'j O 9 4 - 7 n A P P E N D I X I f Con*t ) C0UKTR RESERVES M'74 on (t,oaabko 6 (bittiea c* ft) WELLS 9 OIL PROOIICTION Pradaciag OrilHeg Estimated % ebantt ell 12*1-73 1971 from 7-'-73 (1,000 t i n 1577 Reft*enei REFINING Capacity (1.000 k/efi 1.1. 4 Crude Cracking > Retar. mf MICA Algeria '7.640.000 105.945 574 10 1,035.4 - 26 4 1154 305 Angsla^abinda 1.SOO.OOO 1500 169 5 1604 14.7 2 24.5 19 Congs Bramville 4.888.000 1.000 19 3 394 490.9 Oahcmeyt Egypt 5.125.000 4,200 261 4 1804 -15.0 4 1800 Ethiopiat 1. 14.4 1.9 Gabon 1.500,000 5500 122 4 1454 15.4 f 170 2.0 Ghanat 1 25.3 94 Ivory Coast 1 442 10 Ktnya 1 480 4.0 Liberia 1 100 20 Urn 2S500.000 27,000 S95 9 2,116.6 - 45 5 114 15 Maiagasay 1 1.5 04 Morocco 750 25 22 2 0.9 44 2 $85 3.6 7.6 Mozambiquet 1 170 2.5 Nigeria 20,000,000 40,000 898 28 2.0000 104 1 604 60 Rhodesia 1 (not operating-not include mtotal) Senegal . , 1 18.0 2.0 Sierre Leone , . 1 10.0 Sudan 1 220. 20 Tanca ma 1 17.0 26 Tunisia 9SO.OOO 1400 56 4 67.0 4.6 1 21.4 20 r~ Union of South (next Zairet t 200.000 50 5 331.0 55.9 411 1 211 27 Zambia ... ... 1 24.6 5.6 Total Africa S7.303.750 187.720 3,01 S SS 5,763.5 1.8 39 1,0922 4 13I.S 'Revised, to il or gas discovered but not developed. ttTo go on production at 25,000 b/d in 1975. WESTERN HEMISPHERE Antique 1 17.3 1.9 Argentina 2.500.000 8.000 4496 30 442.0 24 14 6216 1014 514 Banamas 1 500.0 Barbadost 250 l 3j0 Bolivia 26aaoo 10.000 253 4 474 7J s 255 Bradi 799.000 92) 1465 25 170.0 34 10 7914 1685 204 Chde 124.000 3.400 466 6 30.0 -1 2 8 3 1235 264 104 Colombia 1.432.000 2.500 2423 8 1864 - 54 6 166.1 495 20 Costa Ricat 1 7.6 1.1 Cuba 3 1224 146 11.7 Dominican Republict 2 410 74 Ecuador r El Salvador 5.675.000 5.000 829 . . . .... 64 1974 1411 3 354 l 13.7 21 Quaternalit 2 210 &Q Honduras . .. l 144 1J iamaiti t , 1 33.0 24 Martinique 1 14.0 23 Menco 3,600.000 11.000 4445 45 4784 14 6 6210 - 109.0 513 Netherlands Antilles 2 9410 354 15.0 Nicaragua 1 134 23 Panama .... . . 1 710 73 Paraguay . . 1 SJ) Pern 1.050.000 3.5 2,499 3 684 14 5 1QU 17 14 Puerto Rico 3 3074 474 753 D Trinidad A Tobago 2400.000 5,000 2.932 is 1594 124 3 461.0 215 274 Uruguay . 1 43.0 4.0 3.0 VeoeiueU 14,000,000 42.000 12,461 20 34700 4.7 12 1531.6 416 !9J Vtrpar islands I 590.0 United States *34.700,249 247410 503.505 1,4111 9425.0 - 24 247 13483.0 45125 34711 0 Canada 9,424.170 " 50299 22.99 171 1.7504 140 41 1.798.1 427.6 2904 Total W. Hemisphere 75.7t4.SC8 i 341930 557,670 1,754 16,1224 20 380 toa or gas discovered but not developed. " 0oes not include Arctic gas. ' Includes Alaska 101illiofl. Total arcuare* 524,156,483 1487472 S7S4Z1 201* 43500L7 84 714 22436.8 83,454.8 S57SJ 74*9.1 3.8974 7,1424 Camaeist Werld *103,000.008 7735,400 13124 45 ___ - Tetat arid S27.15S.459 2.033,372 554127 SI ['i Ktmu 706 tntliOA. flttfChi 20 tnllton, Kurtpiy 3 trillion,*M other* 64 trillion. L/ A P P E N D I X II 1. t COUPLED CHR*SOTILE ASBESTOS REINFORCED THERMOPLASTICS F. H. Ancker, R. G. Azrak and M. D. Bertolucci* Union Carbide Corporation Chemicals and Plastics Division Bound Brook, New Jersey , ' cr ' / ^ w J o / 2. Ir.tr oc.uctio*. Chrysotile asbestos il) is a serpentine mineral occurring in nature as macroscopic bundles of colloidal-size fibers. Union Caroide's 'Calidna' asbestos is a domestic chrysotile asbestos which by specially developed wet process beneficiation techniques has been highly purified and liberated into individual fibers having diameters of 2S0-300 and average lengths of 2-5;i, i . e . aspects ratios in the range of 65-200. 'Calidria' asbestos is ' commercially available as 1/8" diameter pellets which can be readily handled and processed with a minimum of dust generation. A r.aw grade of `Calidna` asbestos has recently been introduced (RG SOO) where the asbestos surface has been pretreated with a novel, proprietary coupling agent. Tne coupling agent treatment has markedly increased the reinforcing efficiency of chrysotile. asbestos in thermoplastic resins, especially in the polyolefins, and has also enabled dramatic improvements m process heat sta bility and heat aging of polypropylene (PP)anc poly (vinyl chloride) 'P'/C) com posites. The new `C alidna1grade RG 500 provides the fcrmulator and molder of tr.ermoplastic composites with a highly cost-effective reinforcing agent which can be used to obtain unique combinations of material properties. Mechanisms of Reinforcement . Colloidal chrysotile asbestos has many mnerent.properties which make it interesting as a reinforcement for plastics: a) the stiffness is more than twice that of E-glass; b) the tensile strength is at least equivalent to E-glass; c) me surface of ex->. truded or molded 'Calidna' composites is smooth m contrast to fiberglass composites which have a rough and abrasive surface ' texture; d) the 'Calidria' compounds can be processed and repro cessed without fiber attrition, i . e . 'without deterioration of mechanical properties whereas glass fibers undergo severe break age during normal extrusion and molding processes. On the negative side, e) the practical reinforcement efficiency attainable with chrysotile fibrils has been very much below theoretical e x pectations, especially in polyolefins; and f) the thermal and oxidative stability of labile polymers such as polypropylene and ?VC ere adversely affected" by incorporation of natural chrysotile fibers. . m Core micromechanics theories of short fiber composites' ' have been utilized to help identify the principal causes of the low practical reinforcement efficiency of chrysotile fibrils in thermo plastic rasir.s. Tr.ese studies have shown that two principal causes are low fiber/matnx adhesion and difficulties m achieving satisfactory fiber dispersion at the colloidal level during normal compounding processes. In retrospect, it is perhaps not too sur prising that these two phenomena have such large effects on the- n D r 3. reinforcing efficiency of colloidal asbestos f& ers. Chrysotile asbestos has a Brucite (magnesium hydroxide) surface with poor wetting characteristics for non-polar polymers. Due to the colloidal dimensions of liberated chrysotile fibrils, it has not bee possible to determine experimentally the adhesion (interfacial shear strength) between various matrix resins and chrysotile fibrils. However, even for the case of perfect fiber/ matrix adhesion, the critical fiber length is of the order of the average actual fiber length o f 'Calidrxa ' fibrils. For lower levels of adhesion, the critical fiber length w ill be much longer which " 1 means that the reinforcement efficiency is in the range of extreme"' sensitivity to interfacial adhesion. Similarly, low levels of n fiber dispersion on the colloidal level have the effect of reducing i ; the apparent aspect ratio of the fibrils which again w ill have a ` pronounced negative effect on the reinforcement efficiency in this fiber length range. A novel class of proprietary coupling and dispersing agents has now been developed which conveniently can be applied d i rectly to the chrysotile asbestos prior to pelletizing. The r coupling agent used in RG600 was designed specifically to pro mote adhesion between the Brucite surface of chrysotile and poly olefins, especially polypropylene, but it has csnericial effects in thermoplastic resins in general. The establishment cf true f" interfacial activity of the coupling agent Is presented in Table I. It is seen that the coupling agent in and of itself dees not signi ficantly alter the tensile strength, modulus or heat distortion temperature (HDT) of a thermoplastic resin such as HD?E. How ever, when the coupling agent is present in chrysotile reinforced composites, improvements over uncoupled chrysotile of 63% in r* tensile strength, 79% in tensile modulus and 52% m HDT are found. Figure 1 illustrates the approximate concentration depen r dence of mechanical properties with weight percent fiber surface coverage. An abrupt change in slope of plots comparing tensile u strength, tensile modulus and HDT with %coupling agents based on the total composite weight is found at approximately 1.8% addi tive. Assuming- 6 0 mz/g surface area for well liberated chrysotile u fibers, this value corresponds quite closely to monolayer coverage of the fibrils. Little improvement in mechanical properties or a further reductions in mold shrinkage are observed at levels of additive above 2%. These results are c la ssic illustrations of interfacial activity. . . The improvement in dispersibility of chrysotile fibers effec ted by the coupling agent- is shown in Figure 2. Chrysotile/poly- styrene composites were prepared from natural (RG144) and . n modified chrysotile (RG600) with idntica compounding conditions t * and shear history. The electron micrographs shoy clearly the in crease m apparent fiber aspect ratios caused by the coupling agent treatment. - . . The relative efficiency of the coupling agent in various ther moplastic polymers is sKown in Table II. The tensile strength of a composite (Cfc ) can be expressed by the rule of mixtures'2' - e *CT{ v f + 3 ^ ( 1 " Vf> ` where 0# and Grm are tensile strengths of fiber and matrix, re spectively, Vf is the fiber volume fraction and e is an over-all efficiency factor. The coupling agent efficiency (CO is defined as* i . e . the efficiency factor ratio between samples with fec) and ' without (ec ) coupling agent. Table II shows that the coupling agent is highly effective in the polyolefins, exceptionally so in polypropylene, but marked efiects are attained in a broad range of thermoplastics. ' RG 500 Composite Properties Tr.e following ASTM test methods were used to evaluate the composite materials: tensile properties (D-63 8-547), flexure properties (D -790-66), HDT (D -648-S6). specific gravity (D-79264T), coefficient of linear thermal expansion (D-6S5-44). notched Izod impact strength (D-256-56). The thermal stability of chrysotile/PP blends is a particularly important property; therefore special attention was given to its determination. Since subjective tests such as thv time to 10% or 25% crazing of the surface of a composite are a dubious measure .of thermal stability, we report the induction time for a calori metric response to the onset of oxidative degradation as measured by a differential scanning calorimeter (DSC). Tests or thermal oxidative stability were performed on 10 mil films pressed from injection molded bars. A Perkin Elmer Model 1-3 DSC was used throughout. The stability at 230C in air was measured. Tables III and IV show that at all levels of filler between 18 and 3o% marked improvements' in tensile and flexure strengths are obtained in HDPE and PP resins reinforced with RG50G over natural wall liberated chrysotila fibers. At the optimum loading of approximately 30% by weight, use of RG50C to reinforce a standard grace polypropylene yields, as shown m Table V, substantial im provements in all mechanical and thermal properties when com pared :o commercially available asbestos reinforced polypropylene Lompos.:3s. Table VI compares improvements in mechanical prop -z '.e s between coupled and uncoupled asbestos and glass poly propylene composites, respectively. Coupled asbestos/PP is close to standard glass reinforced PP in overall properties and in 5. ger.sral w.U compare favorably with all g la ss/? ? composites on a cost/performance basis. ` figures 3 and 4 respectively illustrate the improvements ob tained with RG600 m HDT and flexure modulus compared with uniilled PP and a RG144/PP blend. It is clear that RGoOO at the 13% level has superior properties compared with unmodified cnrysotile at twice the fiber loading. At the optimum level of 30% RGSGO, improvements of 112% m HDT ar.c 275% in flexure modu lus are obtained over the base resin. VI1 and VI11 Sh0w the Pr0?er- e s of Nylon 5 reinforced witn RG6C0 vs RG144 and other commonly used inorganic rem - n torcements. The superior combination of high moduli, strength and neat distortion at low loadings is evident. ! ; Unlike fiberglass reinforcement, chrysotile fibers have been long known to accelerate the thermally induced oxidative degrada r-> tion oi thermally labile polymers such as PP and ?7C. Tne coupling agent present in RG600 inhibits this tendency as shown in Figure r--< 5 wr.ere at chrysotile loadings of 40% improvement cf 535% in the i i thermal stability under accelerated conditions are attained. With the surface modification present in RG600, as ;s shown m Figure 6, adequate thermal stability cf cnrysotile/P? blends car. be achieved with reasonable levels of standard antioxidants. Fortt-lations of RG600 at the 30% level in PP with 0.7% hinderec pnenol (based on the composite wt.) and showing stabilities of 55 mnr.S 230C by DSC retain their mechanical strengths in excess of re: hrs at l > 150 C in an air circulating oven. At times approaching 2000 hrs r similar composites show no sign of surface craning in a 150G i oven aging test. The improvements attained in RG600 remicro ad thermally i-- labile polymers are particularly striking the the case's: ?VC com U,' posites where oxidative'degradation of the matrix d-rmg hot com pounding m the presence of natural chrysotile .s a savare problem. A 200% increase in the time to significant thermal cxidativedegra C dation has been found in comparisons between untreated and sur face modified chrysotile filled rigid PVC blends by a high speed D OT.^J'eQ^* ^ a milling speed of 110 ft/min and roll temperatures 0 significant discoloration and evolution of volatile cnloridas occurred only after 9 minutes for 20% RG600 blends as compared to 3 minutes for 20% RG144 biends. The stability of the asbestos blencs under standard milling conditions is therefore significantly improved. RGoOO/poiyolefir. composites have exceptional wet strength retention, far exceeding those attainable with fiberglas reinforce ments. The data m Table IX show that even after 2 and 7 days S immersion in boiling water, there is no decrease but an actual increase in the mechanical and heat distortion properties of the ^ w Sj V-/ composites. This is a singularly important advantage m a number of practical applications. * t mother important pi^per^y in formulating reinforced thermo plastics is impact strength. Often practical requirements will dictate a certain minimum impact strength combined with high modulus and strength. As is well known, short reinforcing fibers generally contribute little and often even detract from the impact properties of a polymer. However, unique composite properties are often attainable by the proper choice of base resin. For example, impact modified PVC and high impact polyolefins com- * b:ned with RG600 enable formulation of PVC and polyolefin base ' composites having overall property combinations similar to those : iinPact polystyrene and ABS. In general. RG600 in the hands of skilled formulators of the plastics industry should open up many unique and novel applications for reinforced thermoplastics. References: (1) R. E. Byrne: 'Asbestos Fibers', Modern Plastics Encyclopedia, 386-330, 1969-1970. (2) L. Ongchin, W. K. Olender, F. H. Ancker: 'Fiber/Matrix Adhesion and the Fracture Behavior of G'.ess Reinforced High Density Polyethylene' 27th Annual Techn. Corf.. Reinforced Plastics/Composite Institute, Soc.Plastics Ind., 1972.  . r . hours 1 7. INTERFACIAL ACTIVITY OF COUPLING AGENT (20% wt. Chrysotile-HDPE Composites) 1 .2.0 II I i.O M o l d S h r i n k a g e (%) P 1) ., < L, Resin supplied by Union Carbide (Grade DMDWQGel test specimens. am injection molded Calculated w t. % coupling agent for monolayer coverage =f a sb esto s. FIGURE 2 . ELECTRON MICROGRAPHS OF C H R Y S O T I L S / P O i y ; C O M P O S I T E (Magnification 14,000 times) L i tziiiaucr: rr'.. c i : -- . HEAT distortion ttm pcrature or g tuasorujL&ritjfQ&ctP-jakYPngrtuiig 120 it 7t 3 5 t X 14 /OoO w w limati couruno munt crrccn oh thermal stability or ` ciiRYSOTitJ/rOLmomxHt ilesos----- ISO (O 1 l 8 O.I I cn 14 0 i r. i il ar*-ir Wt. * HCU4 t i-- w t. Vn--atoar flQWJE.1 miBM*iJ>iwiUTx or.c m iT S o n it/w im o m m t. mura Wl. AMIOlldtM 'i i.r r er r~3 .z~i tAt,K ir trncicW T factors ron CQ-Ufixf? chuvs o t i u -iso ^flo} H U ID thm v.o p u stic s efficiency rector. Pply.tmld*11 Poi ye tert21 PS< HDPC141 PP(S1 1.27 t.l( 1.14 l . l f .IO Il Nylon t (100-0011 luppllad by rilettone U) ` Tonile 7DHO' tu pp Iled by Cltmen Ol Polyttyion (PS) SMD-1SU0 tupplled by Union Cerblde C o p , (4) lllh Oontlty Polyethylen IltDPCI DMDJ-7001 upplled by Union C tib ld Corp. (1) Polypropylene (PP) 1124S upplled by Shell. 5JJU J t tiSIU -S JJ. EKQT11.P f CNST5QTUX lUINrpncrp fOLTOUriNS' Wl. X SC 144 * 27 It 0 Wl.%fltaPA IS 21 1t HDPC>(pII 4191 4020 -- PpW fp!) 4110 1100 soto m < - ___ 1P S4S0 1120 ISSO 1)00 tlOO 1400 (I) peni in|ecilon molded ber U l Ulgh Oentily folyolhyleno (UCC - DMO!-100t) (1) Polypropylen (Shell SS24S) JtMUUY. n atjfiiLATOC^ TU.QE CMjaQiifjaUHf<gpiLfeatrjj.NA `11 W 1.E8Q1H IS 27 It M ort!" loti) MIO 210 - ___ 0 0 - tE P i Jpi) 1,100 10,400 10,200 1.710 W t.il J g l M 1 27 It 1.100 11,000 11.410 11,900 12.900 11.400 (I) Sem Injection molded ber |21 Hloh Dendly Polyclhylono (UCC - DMDI-T008I ()J Polypropylene (Shell SS24S) I 1AUIU ( jMTCRrAO A i. a c t i v i u j i t ; j K j j ' i i i m :_a i;i: n v V^ Additive^! wt.% None 2% Coti)dii) Agent 10.0X Cliryi-nillu 1U% C h rysotile t 2% Coupling AgentJ _IViVdJe ]|Kj) Sti.it.iili Klo.lviltin tHIMI 'JiHI A20IJ 6851 1 I2.U0U U S .000 200.000 SU0.000 m * T f"C) 1' i.U a il 44 JO bO 91 (1) lliqlt d en sity polyethylene c o m p o s ite s (2) Additives compounded individually into the fluxed re sin on a twin rol I mil I IW-V Roper ty Measured A sn tsto s/ro tm o ry u ric composites 1 _______ 2_ 4 0 % Anihophylllte* 40% Chrysolite " _____ 40% A sb esto s** Tensile Strength (psl) riesure Etrsnglh Ipsl) Flexure Modulus (pl> Ck. fUcloni u| I Hit)11 1 <* lit -/*V.l Mnlil ftlHltiMiji 4100 1 00 (S O .000 1.1 l.U't -- 4S00 7500 00.000 2.0 1.0% -- 4SOO -- SS0.000 _ 0.01 In/ln ttfwsl DlMmllitti Tompcrtitnie (C) 9 ( pet 144 9 2(4 P(l -- no -- -- SS 4 30% ttCt.00* ntio 12,900 942.000 1.9 ~ a.IX 0.00A In/ln ISO m * Ololorm U K Amoco Atpytono APPN1040 - Turner Brother A ib cito i C o. ftopathene 22/44 Black 9040- 1 Coupled ahou Utter Chryiotll retnhxeed ft S h e ll SS24S) TABLE. VI REINFORCED POLYPROPYLENS R einforcem ent 27% RG144 W 27% RGCOO 30% G lo ss 30% G la ss T ensile (d sU S trength M odulus 5 .9 0 0 7 ,3 0 0 8 ,1 0 0 1 4 ,0 0 0 4 6 0 .0 0 0 5 8 0 ,0 0 0 7 3 5 ,0 0 0 8 0 0 ,0 0 0 F lexure, fell) S trength io,<;o 1 2 .9 0 0 M odulus 5 8 0 ,0 0 0 9 9 2 ,0 0 0 14,000 850,000 2 4 ,0 0 0 . 900,000 (1) P olypropylen su p p lied by S hell (5524S) (2} M odified polypropylene su p p lied by H ercu les (PC 072) HDT PC ) (264 Dsi) 87 123 124 153 IM LEJO I CHRttOTltl REINfORCCD NYLON 6< Reinforcement*?? Terullc (all) Strength Modulu flexure (pet) Strength Modulu HOT (C) Notched Icod (254 pel) fftlb/in> IS S 1 12,400 725,000 22,000 754,000 151 0.54 I S * ftGSOO 14,000 20,000 24.100 114,000 154 1.01 (1) Nylon 5 supplied by rireetone (Gride 200-001) - Ren Injection molded test specimens. 12) Semple conte tn 0.11X potyemtde lU b lllier beted on the re tin content. :*iu rm KYLQN 6 REINFORCEMENT*1* frtree ted Minerei Filiere Flenjre Strength (pel) Modulu U 19"1 pel) (x TnUe Strength (pill Madulu* 19"* pel) NOTCHED COD (ft-lb/ln. notch} ES2U221 254 pit Unfilled01 12.000 ISO 1,400 330 1.31 74 IS RG400 5 0 * Welle.tontU01 24.100 034 15.S04 550 14,000 20 4,100 534 1.01 1.04 154 15 1S*G !*41 3 0 * Glee*** 11.300 4SS .*0 0 too Il.tSO tit 15.700 *75 1.21 l.tl 117 its (U feet Injection molded bar (2) Nylon 5 applied by fTreecane - 290-4)01 (5) Wotleetanite F-l pretreeted with 1 * wt. eiinaitlene . " (4) Sllene treeted pie* reinforced nylon applied by rireitone - 415-001 end 410-001 lia iu a DRY-WET MECHANICS TOR CYRYSOntr/IHERMOflASTIC COMPOSITES* Sdcxol F ille r 30* RGW4 30**3500 IJ* RGI44 ace;o 1.4R3IOO R<*ln ?P* * HDPE*41 * TtJ a iooc Ideye) 7 7 2 2 2 ... Tenille (pel)! Strength (8) Stre-ethtt) 4150 4910 310 5500 mo 3730 5510 5550 5S40 5150 Temtle (oil * 10"1) Mod.n) Mod. (A) :* 251 507 S4S 1(4 its 405 425 535 SIS HDT(C> ff 264 n l 1 52 ss IS 105 51 45 11 s* 55 11 (1) JUa injection molded text specimen* (!) Tat', irjserelon In bailing wsur (3) f # Polypropylene supplied by Shell (5324S) M) KDFE High D ensity Polyethylene polled by Union C erblde (DMDJ-700)