Fundamentals of Metal Stearates

by
Peter F. Doorley
Crompton Corporation

TAPPI - August, 2001 - 01PLC Conference

Metal stearates

■ metal soaps

■ a.k.a. metal carboxylates

■ metallic salts of straight chain fatty acids

■ fatty acids - 8 to 24 carbon atoms long

■ majority are stearic acid

Fatty acid source
■ animal source
■ vegetable source
■ marine source
■ food grade acids
■ kosher fatty acids
■ standard grade acids
■ higher processed acids, heat stable
Fatty acid typical
■ hydrogenated tallow fatty acid,
– most used - good performer - lower cost

■ saturated stearic acid

– low Iodine value, IV

■ natural distribution is
– 67% stearic (C18)
– 28% palmitic (C16)
– others.
Fatty acid structure
Metal stearate structures
Common metals
• Calcium (PVC, Polypropylene)
• Zinc (PVC, Polyethylene)
• Barium (PVC)
• Aluminum (Nylon)
• Magnesium (ABS)
• Sodium (very little)
• Potassium (very little)
• Lithium (very little)
• Lead (PVC, may be outlawed in Europe)
Metal stearate structure

• layered crystalline platelets

• arranged in parallel planes.
• polar metal groups
• non-polar fatty ends.
Metal stearate crystal structure

Metal stearates lining up, coating surface for mold release

Metal stearate properties
• Most stearates
-not well defined melt points
-wide “softening points”
-plastic flow at soft point

• Only Zinc stearate

- liquefies upon melting.
Metal stearate applications

■ paper coating
■ concrete & cement
■ greases & inks
■ metalworking & powder metallurgy
■ waxes & petroleum products
■ food additives & pharmaceuticals
Metal stearate applications (cont.)

■ Plastics and Rubber

– lubricant

– coating/antiblock

– mold Release
– acid neutralization
Metal stearates as acid neutralizers
METAL EQUIVALENT COMBINING
STEARATE Weight Capacity
Meq./G
Aluminum * 198 5.05
Calcium 295 3.38
Magnesium 287 3.48
Lithium 282 3.54
Sodium 298 3.36
Potassium 314 3.18
Zinc 307 3.36

* Aluminum forms a Lewis acid, not preferred

Methods of manufacture
•Precipitation
−aqueous medium
−formed from water-soluble Na soap
−insoluble metal salt
−water soluble impurities washed away
•Fusion
-direct reaction
-stearic acid + metal oxide or hydroxide
-no soluble salt impurities
Precipitated stearate characteristics
■ Smaller average particle size (4 - 10 um)
– lower bulk density (10 - 15 lb/ft3)
– limited control of particle size
■ Higher Purity for Ca and Mg
– ore impurities washed away
■ Lower Production Rate
– higher energy usage
Fused stearate characteristics
■ Larger average particle size
– higher bulk density (up to 48 lb/ft3)
– more controllable particle size
■ May contain metal oxide/hydroxides
– ore impurities remain
■ Higher production rate
− lower energy usage
■ Method for alkali metal salts (Li, Na, K)
Fused products can be made
with near precipitation quality
■ Specific raw materials
– example; synthetic ZnO

■ Improved processing
– special fused techniques
– complete reaction
– grind to desired particle size