The synthesis technology used by OCSiAl for graphene nanotubes is based on research by one of the company's founders, Mikhail Predtechensky, OCSiAl's Chief Technology Officer and a member of the Russian Academy of Sciences. The technology is notable for producing SWCNT in tonnes to enable low enough pricing for industrial applications to become economically feasible. The company's initial synthesis facility, named Graphetron 1.0, was built at the company's scientific and prototyping center in Akademgorodok, Novosibirsk. The first industrial-scale batch of graphene nanotubes – 1.2 tonnes – was synthesized by OCSiAl in 2015, which at the time exceeded the entire volume of this material ever produced since its discovery in 1991. In February 2020, OCSiAl announced the launch of its second synthesis facility, named Graphetron 50, with a production capacity of 50 tonnes of grahene nanotubes per year. The Graphetron 50 facility is currently the world’s largest plant for graphene nanotube production and increases OCSiAl’s production capacity to 75 tonnes per year. In 2017, together with Luxembourg's Ministry of Economy and Ministry of Finance, OCSiAl signed a Memorandum of Understanding to construct a graphene nanotube factory in the Grand Duchy. The commissioning of the first production line with an annual capacity of up to 100 tonnes per year is scheduled for 2023.
History
In December 2014, Frost & Sullivan recognized the OCSiAl Group with its 2014 North American Award for Technology Innovation for OCSiAl's TUBALL SWCNT products. The award was given for the high purity and large-scale production capability of TUBALL products, which has significantly increased the commercialization potential of single wall carbon nanotube products. In 2015, the National Nanotechnology Initiative, a United States government program to accelerate nanotechnology commercialization, recognized OCSiAl for expanding its matching grant program for exploratory research with SWCNT. In September 2016, OCSiAl registered its core product TUBALL through the EU's Registration, Evaluation, Authorisation and Restriction of Chemicals regulation under the number 01-2120130006-75-0000. As of November 2016, OCSiAl is the only company with the license toproduce and commercialize up to 10 tonnes of nanotubes in Europe annually. In 2019, OCSiAl was added to the list of unicorn startup companies,a list of startup companies valued at $1 billion or more, according to CB Insights and Techcrunch.
Products
The company's core product is TUBALL, high-purity graphene nanotubes that can be used as a universal additive for a wide range of materials. Graphene nanotube is an extremely thin rolled-up sheet of graphene. The key advantage of graphene nanotubes centers around the very low loadings, starting at 0.01%, that are sufficient for achieving uniform and permanent conductivity while also reinforcing mechanical properties. The very low loadings made possible by SWCNT provide the ability to maintain the original color and minimally impact secondary properties of most materials. OCSiAl has also developed nanotube-based concentrates that simplify graphene nanotubes use in various materials. In 2015, the company opened a research facility focused on nanotubes applications for batteries, elastomers, paints and coatings, thermoplastic, and thermoset materials.
Applications
Elastomer applications
TUBALL-based masterbatches use rubber polymers, fillers and oil plasticizers as nanotube carriers, allowing performance improvements with minimal changes to the composition of a rubber compound. In October 2016, LANXESS and OCSiAl announced new nanotubes products targeting reinforced and conductive latex rubbers.
Energy storage applications
TUBALL nanotubes bring performance improvements to Li-ion and lead–acid batteries, and to supercapacitors and fuel cells. In these applications SWCNT has the potential to replace carbon black and other carbon-based additives, with a study by Aleees demonstrating 10% higher volumetric energy density and decreasing cathode thickness by 18% in 10 Ah pouch cells. In another study by Aleees, SWCNT-coated foils showed an increase in energy delivered to cells by 0-252%, depending on the discharge rate. In trials of lead-acid batteries 0.001% of SWCNT in the electrode paste increased cycle life and rate capability five-fold.
Paints & coatings applications
TUBALL nanotubes provide conductivity to colored and transparent coatings with minimal impact on color or transparency, while maintaining or increasing mechanical properties. Conductivity may be employed for ESD-control properties or electrostatic painting methods.
Resins & composites applications
In November 2016, OCSiAl announced an agreement with BÜFA Composite Systems in Europe to provide TUBALL nanotubes and TUBALL MATRIX nanotube concentrates for BÜFA-developed resin formulations. In 2017 BÜFA hit the market with its line of conductive gelcoats with colored, smooth and glossy surfaces. There are some particular applications where nanotube-based gelcoats can almost completely replace standard gelcoats. Pipes and tanks for chemicals, ventilation systems, printing rollers, control boxes for electronics, floor coatings at industrial production plants, tooling gelcoats and resins for composites, to name just a few. The companies noted that using graphene nanotubes in composites provides a conductive and reinforcing network at low loadings, enabling conductive parts to retain color and improve mechanical strength.
