Manufacturing of polymers
(polyethylene)
Polymers manufacturing
Polymer plants are semi-continuous processes (not up to end application product)
Reactors: fluidized-bed, loop, autoclave, continuous, batch and tubular reactors
Manipulating variables in the reactor: monomer, co-monomer, catalyst, and cooling media
flowrates, can control key quality parameters
Physical properties: density, stiffness, flexibility, opacity, melting point, texture, and strength
Further process: additives, blending and colorings can modify the appearance of the polymer
Contamination: in raw materials or generated in the production system, adversely affects
product quality and is generally reduced by means of filtration
Equipment used mainly depends on the properties of the polymer
Polyethylene (PE): Properties
Molecular formula: -(CH2 -CH2)n -
Molecular weight: 1,500 to 100,000 atomic uinits
Melting point (all): 85 - 150°C
Density: 0.91 - 0.93 (produced at high pressure)
Density: 0.96 (produced at low pressure)
Low-density polyethylene (LDPE): High degree of short chain branching + long chain
branching. Chain branches off in one direction, from that chain another chain branches
High-density polyethylene (HDPE): Linear (or Low degree of short chain branching), polymer
chains line up regularly
Polyethylene (PE): Manufacturing
Currently, there are three processes by which polyethylene is manufactured
High pressure process : This process was developed in the UK by ICI. It uses peroxide
catalyst at 100-300°C and produces low density randomly oriented polymer which have a low
melting point. The process is run at pressure of 1000 - 2500 atms. This process yields Low
Density Polyethylene (LDPE)
Intermediate pressure process : This process was developed in the USA by Phillips
Petroleum Co. for preparing high density polymer with increased rigidity, crystallinity, tensile
strength and softening point. The process uses MoO3 and Cr2O2 on alumina as catalyst and is
operated at 30 - 100 atms
Polyethylene (PE): Manufacturing
Low pressure process : This process was originally developed in Germany for preparing high
density polyethylene (HDPE). The catalyst used in this process consists of aluminium triethyl
activated with heavy metal derivatives such as TiCl4
Process of desulphurization and removal of light ends,
Remove traces of oxygen and its compounds which can possibly deactivate the catalyst
Temperature and pressure maintained should be 70°C and 7 atms
Polyethylene (PE): Manufacturing
The effluent stream then follows across a series of flash drums inorder to remove the solvent
from the catalyst.
The residual catalyst at this point is removed by adding water.
The flashed solvent is thereafter recycled to the catalyst
The slurry which results is then centrifuged to remove the water, and the water is treated to
remove the catalyst before recycle.
The final products of polyethylene solids are then dried, extruded and given the required final
forms.
NPTEL
Polyethylene (PE): Applications
Applications of PE differ according to their molecular weight
Plumbing: pipes and valves for water, sewage, ventilation and heating systems
Containers for liquids, chemicals, fuels, household waste
Utensils: bottles for beverages and storing bowls
Household appliances : chemical resistant flooring, cosmetics
Electrical: fibre optic cable sheaths, power tools
Other: automotive parts, toys,
High-density polyethylene is used for the production of cutting boards, handles, drawer runners
Manufacturing of polymers
(polyester)
Polyester: Properties
Polyester vs PET
PET (polyethylene terephthalate) is the chemical name for polyester. When PET is used for
fiber or fabric applications, it is usually referred to as “polyester
In the 1940s, DuPont began polymerizing PET with the intention of creating a polymer
material that could be used to make textile fibers
Ethylene glycol and terephthalic acid are chemically combined
About 40% of the material’s energy is retained and can be used again after recycling (Life
cycle studies of PET have consistently demonstrated it to be a highly sustainable material with
a favorable impact on the environment)
Polyester: Manufacturing
• Dimethyl terephthalate is first reacted with
ethylene glycol in the presence of a catalyst at
150-210 °C
• Monomeric alcohol (single molecule, not
repeating), is combined with terephthalic acid
and raised to 280°C
• Drying, Melt Spinning (melted at 260-270°C)
to form a syrup-like solution, Fiber Withdrawal
Polyester: Applications
Food packaging since it is chemically resistant and does not react with water or food
High strength-to-weight ratio applications
Durable and shatterproof. Because of this, it can successfully replace glass in many applications
High transparency because of its chemical structure, as compared to acrylic or polycarbonate might
polyester is less transparent
Polyester is a great fabric choice since it is durable and versatile, and it prevent wrinkles,
shrinkage, and tearing, well mixed with other type of fibers
Task
Write down properties, flowsheet of manufacturing, applications of the following polymers,
Polystyrene
Nylon
Polycarbonate
