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In the chemical separation area, Dow Corning has developed Smart SilicaTM –
a ground-breaking tool that aids in the removal of targeted chemicals during
the manufacturing process. When fully implemented, this revolutionary
technology will lead to safer beverages everywhere. It is of particular
interest in India – removing pesticides contained in the water used to make the
product. Many states throughout India have banned the sale of popular sodas due
to high levels of pesticides in the water. Smart SilicaTM effectively removes
the pesticides, and gives beverage manufacturers an opportunity to re-enter the
market in that area.
Meanwhile, in the automotive industry, Dow Corning silicone products are
enabling new fuel injection processes for diesel injection systems. These
processes rely on piezo technology to help manufacturers reduce carbon dioxide
emissions by about 20 percent and deliver fuel savings of up to 30
percent.
A piezo stack, made of thin ceramic layers alternated with metal layers, is key
to the technology. Dow Corning silicones are used to surround the piezo stack,
protecting its electrical parts from heat, humidity and chemical attack, while
helping it to remain both strong and flexible.
When subjected to an electrical charge, the stack expands predictably and
reliably to inject a precise volume of fuel quickly into the engine. It is this
quick, consistent performance, enabled by Dow Corning silicones, that leads to
the emissions reduction and fuel savings.
At Dow Corning, changes to our internal processes have created opportunities as
well. Silica fume, a very fine solid material generated during silicon metal
production, has historically been considered a waste product at many locations.
The CBCC (Brazil) site for Dow Corning is incorporating a process to change
that scenario, building on an existing process at Dow Corning’s Simcala (U.S.)
site.
Ultra-fine particles of silica fume are captured in ducts installed on top of
the metal production furnaces. After the larger silica particles are removed,
the remaining silica fume is filtered, treated, packaged and shipped as a
marketable product. It can be used to improve the properties of
high-performance concrete, protect the surface of polymers from chemical
breakdown, and provide superior high-temperature resistance for bricks.
The CBCC (Brazil) site is in the process of implementing upgrades that will
allow the site to begin capturing and selling silica fume in 2009.
Delivery processes can also offer opportunities for improvement. This is
certainly the case with a revolutionary new method of transporting bulk
sealants from Dow Corning. Traditional delivery of bulk sealants involves
loading metal drums filled with product onto a trailer, unloading the drums at
another location, and then packaging the product for delivery to the customer.
In the new process, Dow Corning actually fills the tanker with bulk silicone
sealant, which it dispenses directly into the customer’s packaging at the
destination.
This bulk delivery system eliminates the customer’s need for drum storage
and handling, cutting related labor costs while improving worker safety. It can
significantly reduce customer energy costs and waste. For example, a key
materials exporter reduced waste by 7 percent using this delivery system, in
addition to saving 10,000 square feet of storage space.
About three dozen specially equipped tankers deliver Dow Corning bulk
sealants around the world. Simple. Safe. Sustainable.
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