Portfolio Companies

METACLAY

Nanosilicates and Polymer Nanocomposites

Operating Factories

Shareholders in Portfolio Company 
RUSNANO, Management Company METACLAY

Industry Sector 
New materials (Nanomaterials)

Production Location 
Karachev, Bryansk Oblast
Jobs created: 210

Investment Started:  2010

Total Budget

2.06  bln rubles
Co-investment by RUSNANO
1.10  bln rubles

Production of new-generation modified layered nanosilicates, masterbatches, and polymer nanocompositesProduction of new-generation modified layered nanosilicates, masterbatches, and polymer nanocomposites

Basis of the technology used for production of polymer nanocomposites includes inventions of Russian scientists from leading scientific organizations of the country: A. V. Topchiev Institute of Petrochemical Synthesis, RAS (TIPS RAS), Institute of Macromolecular Compounds, RAS, Karpov Institute of Physical Chemistry, the Federal State Unitary Enterprise, Lomonosov Moscow State University and  D. Mendeleev University of Chemical Technology of Russia.

Metaclay’s coverings increase service length of metal pipes by half: up to 60-80 years, improve their persistency and durability at extreme temperatures (from -60ºС to +80ºС), decrease gas permeability as well as prevent material damage under solar radiation influence. Test of Gazprom VNIIGAZ confirmed that such coverings may be effectively used for the large-diameter pipes for main gas pipeline construction.

Metaclay’s coverings, used among other things, in production of pipes at the Chelyabinsk Tube Rolling Plant, apply for anticorrosion protection of the Power of Siberia Gas Pipeline. The Company also plans to certify the use of pipes with nano-coating in the projects of Transneft and Rosneft. Due to technological advantages and low cost of Metaclay’s products it has become possible to put significant competitive pressure on foreign players in the Russian market, first of all Borealis Company. For this purpose import three-layer insulation was used. One-layer coatings of Metaclay are more cost-efficient (while saving protective and performance characteristics), because less equipment is used in application.

Areas of Application

  • Additives and fillers in oil & gas, cable, packing and automobile industry, construction sector

Market

  • Pipe manufacturers for oil and gas main pipelines
  • Cable industry
  • Manufacturers of railway components and products for rolling stock
  • Manufacturers of automotive components
  • Manufacturers of construction materials, varnishes and paints
  • Manufacturers of food packing

Competitive Advantages

  • Superior characteristics over competing products at lower production costs

METACLAY produces modified nanosilicates that it uses as base material for manufacturing polymer nanocomposites.

Innovative features of METACLAY’s nanocomposites due to the nanosized particles in the silicate fillers.

The silicate (aluminum silicate) particles introduced into the polymer materials change their ability to crystallize, adding another diffusion barrier.

Polymer composite based on nanoclay

Polymer base (matrix) and filler—a modified-organic nanoclay (montmorillonite). The structure of the  onolayer of polymer nanocomposite and variations of organized microcomposites are illusstrated below.

Polymer composite based on nanoclay

Nanostructures, formed in polymer composites, imbue final products with new qualities:

  • Greater impact resistance
  • Lower gas permeability
  • Lower combustibility, as low as zero
  • Longer exploitation terms
  • Smaller number of materials used
  • Improved imperviousness of materials to fractures or cracks
  • Lower fluidity of materials
  • More even coating applications
  • Better resistance to ultraviolet rays.

Silicate particles in the polymer matrix

Silicate particles in the polymer matrix

METACLAY is manufacturing polymer nanocomposites using modern European oscillating extrusion units that raise the performance of the finished material by mixing components into a homogeneous state.