Presented by: PARISA KHOSHNOUD Materials Science and Engineering PVC Foam-Fly Ash Composites A profitable solution to boost Fly Ash utilization in the polymer industry Research Advisor: Nidal Abu-Zahra Presented by: PARISA KHOSHNOUD Materials Science and Engineering 9/21/2018

Outline Introduction to Polymer Foams Introduction to Fly Ash Objective Evaluating the Effect of Chemical Composition of Fly Ash on PVC Foam Composites Properties Summary and Conclusion 9/21/2018

Introduction to Polymer Foams Materials containing gaseous voids surrounded by a denser matrix. Global market size in 2012: $82.6 bln estimated to reach $131 bln by 2018. Polymer foam types: PU, PS, PE, PP, PVC, PC, etc. Extrusion Foaming Process The 2 manufacturing techniques which are widely used in traditional polymeric foams are soluble foaming and reactive foaming Soluble foaming employs a blowing agent dissolved into the polymer solution at high pressure. A reduction in pressure causes the vaporization leading to the nucleation and bubble growth. Reactive foaming leads to gas generation due to a chemical reaction in the polymeric mixture, more widely used technique. 3 steps - Gas discharge, Expansion and Stabilization of the foam Figure: Extrusion: most commonly used technology in the foam industry. single- and twin-screw extruders can be used for plastic foaming. Picture: CO2 Foaming gas is first injected into the barrel and mixed with the polymer the homogenous polymer/gas mixture passes through a die Rapid pressure drop induces phase separation and cell nucleation. Extra shaping die is used to control the product shape and foam expansion. 9/21/2018 http://bergeninternational.com/extrusion-extruding-chemical-foaming-agents-plastics-processing-guide.php Sriram Kiran Annapragada, PhD. Thesis, Georgia Institute of Technology, 2007

Introduction to PVC Foam Third most widely produced polymer in the world. Commercial PVC is generally produced by addition polymerization. PVC cell type: Closed General Features: High thermal and acoustic insulation properties Fire resistant, water proof Cost effective - acid, heat, light, vibration and noise resistant PVC foam is third most widely produced in the world. Image: structure of PVC. + Closed cell Commercial PVC is generally produced by addition polymerization. Features: Cost effective, Fire resistant, water proof, High thermal insulation, Uses of PVC : Wide like: in houses, cars and sport equipment Filler increase cost effectiveness of polymers while, can extend resin, increase stiffness and strength, improve impact performance. Replacement of traditional fillers with new materials to improve mechanical and thermal properties has been a sight of interest In past few years, use of FA has been extensively reported in different applications Applications: Interior and exterior decoration Automotive Sport equipment 9/21/2018 http://www.epvcmaker.com/PVC/What-is-Pvc-Foam-Board.htm http://www.gossencorp.com/ http://www.ecoste.in/what-is-pvc-foam-board/

Introduction to Fly Ash Fly ash (FA) is one of the residues created during the combustion of coal in coal-fired power plants. Approximately, 45 million tons of FA is produced annually in the Unites States Nearly half of the produced FA is currently disposed in landfills. FA: by-product of coal combustion in coal-fired Power plants Figure: Product of burning finely ground coal in a boiler to produce electricity. Formed in electrostatic precipitators, or bag houses 70 MT of FA is produced annually in the US less than half is consumed in different areas Currently the greatest challenge before the processing and manufacturing industries is the Utilization of the residual waste products. 9/21/2018 http://www.catf.us/fossil/problems/power_plants//

Introduction to Fly Ash Chemical Composition Fine, powdery material Contains: Quartz , Mullite, Hematite, Magnetite, Lime, and gypsum Two classes (ASTM C618) : Class C Generally contains more than 20% lime (CaO) Particle size: 1-180 µm Coarser than F type Class F Min major oxide (SiO2 +Al2O3 +Fe2O3): 70% Contains less lime Particle size: 0.1-150 µm very fine, powdery material, composed mostly of silica. Most particles are spherical in shape. Consists mostly of silt-sized and clay-sized glassy spheres. Mainly contains quartz, mullite, hematite magnetite, lime and gypsum 2 Classes: F contains less than 20% lime. On the other hand, C fly ash (FA-C) contains more than 20% lime. The density of 2.4 and 2.5 g/cm3 C particles are found to be coarser than F particles. The particle size distribution of FA-F particles were found to be in the range of 0.1 to 150µm, while those of FA-C particles were in the range of 1 to 180µm. Component Class F (Wt %) Class C (Wt. %) Silicon 23.95 26.39 Sodium 1.05 1.27 Oxygen 17.28 13.75 Titanium 1.04 0.71 Aluminum 14.25 15 Sulfur 3.11 1.15 Iron 22.65 5.77 Magnesium 1.08 2.10 Calcium 13.22 26.78 Carbon 0.53 0.57 Potassium 1.58 1.77   9/21/2018

Evaluating the Effect of Chemical Composition of Fly Ash on PVC Foam Composites Properties Study the chemical composition effect of FA as a filler on PVC foams to For this purpose: 4 different FA loaded composites containing two different classes of FA (C and F) were prepared in Triplicates Raw Materials (phr) FA-F6 FA-F40 FA-C6 FA-C40 PVC resin Compound 100 FA-F 6 40 FA-C 9/21/2018

Results and Analysis Mechanical Characterization Objective #2 Results and Analysis Mechanical Characterization Modulus increases by adding FA Higher tensile and flexural strength in class-C reinforced foam composites Maximum strength observed in FA-C6 Tensile modulus increases by adding FA, same trend in flexural modulus C reinforced foam composites shows higher tensile and flexural strength due to its chemical composition. Calcium carbonate is the predominant filler used in PVC compounding higher calcium contents compared to class F may cause better interaction between the filler and the matrix. Reduced strength due to probability of agglomeration at higher filler loading 9/21/2018

Results and Analysis Viscoelastic and Thermal Characterization Objective #2 Results and Analysis Viscoelastic and Thermal Characterization TGA: Higher second decomposition temperature (SDT) in class-C reinforced composites Better bonding between FA-C and PVC matrix Storage modulus in DMA: Below Tg: Stiffness Increases with adding FA and depends on filler loading Above Tg: Higher increase rate in class-C reinforced composites Higher SDT C composites: more energy to break backbone indicating some bonding between the filler and the matrix. maximum SDT in FA-C6 : due to better bonding between FA-C and PVC matrix. Confirms mechanical properties   residual weight depends on filler loading not class of FA Storage modulus in DMA: Below Tg (stiffness): increases with adding FA, depends on filler loading Above Tg: increases more in class-C reinforced composites: better interaction btwn class-C FA and polymer Sample PDTa (̊C) SDTb (̊C ) %Residual weight at 800 ̊C FA0 277.02 428.76 9.31 FA-F6 270.02 444.73 19.48 FA-C6 275.05 446.68 18.76 FA-F40 265.23 438.25 37.13 FA-C40 271.21 438.18 40.72 9/21/2018

Results and Analysis Microstructural Characterization Objective #2 Results and Analysis Microstructural Characterization Uniform dispersion of FA within the PVC Foam matrix at lower loadings Aggregation and agglomeration at higher FA loading Presence of mechanically interlocked FA particles within the PVC matrix in all composites Higher debonding in the higher loaded composites Uniform dispersion of FA within the PVC Foam matrix at lower loadings Aggregation and agglomeration at higher FA loading Presence of mechanically interlocked FA particles within the PVC matrix in all composites Higher debonding in the higher loaded composites SEM micrograph of the PVC foam composites, a) FA-F6, b) FA-C6, c) FA-F40, and d) FA-C40 9/21/2018

Summary and Conclusion Objective #2 Summary and Conclusion Summary Better interaction between class-C FA and PVC matrix Good dispersion, distribution, and interaction in both classes Enhanced thermal and viscoelastic properties in class-C filled composites Conclusion Chemical composition of FA has remarkable effect on final properties of the prepared foam composites 9/21/2018

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