What is happening to polymer additives Jitu Vadodaria Jitu Vadodaria Jayvee Organics Endowment Lecture March 24, 2005 Ahmedabad Ahmedabad

Contents Why additives - significance Why additives - significance Additives - types Additives - types Global scenario Global scenario Indian scenario Indian scenario Key issues Key issues Trends Trends Case studies Case studies PVC compounding - some aspects PVC compounding - some aspects

PVC/HDPE pipes 50 years of service life 50 years of service life PVC pipes - underground PVC pipes - underground HDPE pipes - outside HDPE pipes - outside Heat stabilizer key for service life of PVC pipes Heat stabilizer key for service life of PVC pipes Carbon black/UV stabilizer for service life of HDPE pipes Carbon black/UV stabilizer for service life of HDPE pipes

PVC windows At least 15 years service life for economy At least 15 years service life for economy No colour fading No colour fading No breakage No breakage This is only possible due: This is only possible due: * Acrylic/CPE impact modifier * Acrylic/CPE impact modifier * Rutile titanium dioxide pigment * Rutile titanium dioxide pigment

PVC power cable High temperature resistance due high tension power ( C) High temperature resistance due high tension power ( C) Higher insulation Higher insulation Can only be achieved by: Can only be achieved by: *Higher mol.wt. Phthalate plasticizer (DIDP) or trimellitate plasticizer *Higher mol.wt. Phthalate plasticizer (DIDP) or trimellitate plasticizer * Calcined clay for insulation

PE insulation cable PE in contact with copper breaks down PE in contact with copper breaks down This can be prevented by use of This can be prevented by use of * Metal deactivator in addition to primary antioxidant system

PE halogen free flame retardant building wire High oxygen index High oxygen index Low smoke density Low smoke density Only possible by use of Only possible by use of * N-P based FR additive * Melamine compounds

Additives=Performance+ property-preservation/retention All these examples clearly show: All these examples clearly show: * Performance * Performance * Property retention/preservation/protection in severe service environment/condition * Property retention/preservation/protection in severe service environment/condition Polymer additives essential to provide Performance Performance Property protection Property protection Property preservation Property preservation

LLDPE thin film Shark skin surface - rough surface Shark skin surface - rough surface Melt fracture Melt fracture Surface can be made smooth by use of Surface can be made smooth by use of * Polymer processing aid - * Polymer processing aid - Fluro elastomer polymer Fluro elastomer polymer

BOPP film for high speed packaging High stiffness High stiffness Easy machinability Easy machinability Faster packaging speed Faster packaging speed High stiffness - Aromatic resin High stiffness - Aromatic resin Easy machinability - Slip additive Easy machinability - Slip additive Faster packaging speed - Terpolymer Faster packaging speed - Terpolymer

Plastic –wood composites Wood flour dispersion Wood flour dispersion Higher moisture of wood flour Higher moisture of wood flour Low flow Low flow Dispersion - Coupling agent Dispersion - Coupling agent Moisture control - Desiccant Moisture control - Desiccant Flow - Processing aid/lubricant Flow - Processing aid/lubricant

PVC building thin wire Economical production of highly filled flame retardant formulation Economical production of highly filled flame retardant formulation Faster extrusion speed for economy Faster extrusion speed for economy This is achieved by This is achieved by * Use of processing aid * Use of processing aid * Use of PE wax or montan acid ester * Use of PE wax or montan acid ester

Polymer additive=Processability Processing aid Processing aid * Acrylics/ Fluro elastomer * Slip additive - Erucamide/ Oleamide * Slip additive - Erucamide/ Oleamide All these additives contribute to Processability of polymer

Polymer additive can spoil quality if care not taken properly Quality of additive quite difficult to convert into plastic properties Quality of additive quite difficult to convert into plastic properties Chemical quality alone can not justify its use in polymer Chemical quality alone can not justify its use in polymer Numerous suppliers Numerous suppliers Slow process of approval Slow process of approval Select standard additive product from leading suppliers and not go for cost saving Select standard additive product from leading suppliers and not go for cost saving Loss will be significantly high Loss will be significantly high

POLYMERADDITIVES PERFORMANCE PROPERTYRETENTIONPRESERVATIONPROCESSABILITY Functions of polymer additive

Additives classification Property modifier Plasticizer Plasticizer Impact modifier Impact modifier Blowing agent Blowing agent Coupling agent Coupling agent Nucleating agent Nucleating agent Organic peroxide Organic peroxide Reinforcing agent Reinforcing agent

Additive classification Property extender Flame retardant Flame retardant Heat stabilizer Heat stabilizer Antioxidant Antioxidant Light stabilizer Light stabilizer Antistatic agent Antistatic agent

Additive –classification Processing aid Lubricant Lubricant Mould release agent Mould release agent Anti block additive Anti block additive Slip additive Slip additive

Polymer additive demand estimates 2004 Polymer demand 170 MMT Polymer demand 170 MMT Additive demand 9 MMT Additive demand 9 MMT Additive percent 5 % Additive percent 5 % Additive cost 10 % Additive cost 10 % Additive costs only 10% of the polymer but plays a much bigger role Additive costs only 10% of the polymer but plays a much bigger role

Global polymer additive distribution by type (%) Plasticizer59 Plasticizer59 Flame retardant12 Flame retardant12 Impact modifier 8 Impact modifier 8 Heat Stabilizer 6 Heat Stabilizer 6 Lubricant 6 Lubricant 6 Antioxidant 3 Antioxidant 3 Peroxide 2 Peroxide 2 Light stabilizer 1 Light stabilizer 1 Others 3 Others 3 Total 100 Total 100

Additive usage distribution by polymer Polymer% Polymer% PVC65-70 PVC65-70 Polyolefin10 Polyolefin10 Styrenics 5 Styrenics 5 Other15-20 Other15-20

Additive usage by region North America2.5 North America2.5 Europe2.5 Europe2.5 Asia3 Asia3 S. America0.5 S. America0.5 Middle East0.5 Middle East0.5 Russia etc0.5 Russia etc0.5 Total9 Total9 All in MMT

Additive demand estimates India 2004 (KT) Plasticizer 185 Plasticizer 185 Heat stabilizer 25 Heat stabilizer 25 Lubricant 18 Lubricant 18 Antioxidant 5 Antioxidant 5 Flame retardant 4 Flame retardant 4 Impact mod/P. aid 5 Impact mod/P. aid 5 Others 8 Others 8 Total 248 Total 248

Polymer additive Key issues Global market Vs local suppliers Global market Vs local suppliers Market growing more in Asia but suppliers continue in Europe/USA Market growing more in Asia but suppliers continue in Europe/USA Large no. of small suppliers in Asia Large no. of small suppliers in Asia Lower growth - survival of fittest leading to M&A Lower growth - survival of fittest leading to M&A Environmental pressures & new legislation Environmental pressures & new legislation

Polymer additive Key issues Plasticizer toxicity Plasticizer toxicity Elimination of heavy metal components Elimination of heavy metal components Non halogenated flame retardants Non halogenated flame retardants Lowering of dosage level for safety Lowering of dosage level for safety

Recent trends Global majors developing niche products Global majors developing niche products Patents expiry leading to newer players Patents expiry leading to newer players M& A activities on an increase for survival M& A activities on an increase for survival Global majors setting up plants in fast growing Asia Global majors setting up plants in fast growing Asia Higher awareness on environmental issues demanding more HSE research Higher awareness on environmental issues demanding more HSE research

Recent trends PVC pipes moving from lead stabilizer to tin/ca - zn/organic PVC pipes moving from lead stabilizer to tin/ca - zn/organic Slow but sure phasing of lead from PVC cable sector Slow but sure phasing of lead from PVC cable sector Phasing out of halogenated flame retardants Phasing out of halogenated flame retardants Shift from PVC to non vinyls for flame retardance Shift from PVC to non vinyls for flame retardance

New additive products/markets Oxygen scavenger for packaging Oxygen scavenger for packaging Wood composites Wood composites Newer flame retardants Newer flame retardants Biodegradable additive Biodegradable additive Conductive additive Conductive additive Nano filler Nano filler Newer additive for plasticulture Newer additive for plasticulture

Glass bead -an economic alternative of glass fiber PP Moulded product of 0.5 KG weight PP Moulded product of 0.5 KG weight Production requirement unit Production requirement unit Production cost Rs 500/hour Production cost Rs 500/hour Raw material cost Raw material cost PP Rs. 60/KG PP Rs. 60/KG Glass Fiber Rs. 70/KG Glass Fiber Rs. 70/KG Glass bead Rs. 60/KG Glass bead Rs. 60/KG

Glass bead in PP- A case study Cycle time/Defect rate Cycle time/Defect rate PP 60 second 5.2% PP 60 second 5.2% PP+30% Glass fiber 65 second 5.2% PP+30% Glass fiber 65 second 5.2% PP+20% GF+10% GB 54 second 3.6% PP+20% GF+10% GB 54 second 3.6% PP+20% Glass bead 46 second 1.2% PP+20% Glass bead 46 second 1.2%

PP moulded product A case study Material Total units KG Material Total units KG PP PP PP+30% GF PP+30% GF PP+20%+10% PP+20%+10% PP+20% GB PP+20% GB

Cost benefit analysis PP glass bead Vs glass fiber moulded product Material Process hour Total cost(Rs) Material Process hour Total cost(Rs) PP PP PP+30% PP+30% PP PP PP+20% PP+20% Saving Saving Saving Saving Saving Saving

PVC compounding Some aspects All PVC products contain % of PVC polymer All PVC products contain % of PVC polymer PVC very dependent on additive/compounding PVC very dependent on additive/compounding More than 50% of PVC is mixed only up to dry blend powder form (rigid) More than 50% of PVC is mixed only up to dry blend powder form (rigid) Plasticized compounds in pellet form Plasticized compounds in pellet form

Key aspects of PVC compounding Cooling of dry blend essential for efficient use of heat stabilizer Cooling of dry blend essential for efficient use of heat stabilizer Higher bulk density can only be developed by dry blending temp reaches 120C Higher bulk density can only be developed by dry blending temp reaches 120C Moisture removal essential for better clarity or surface finish Moisture removal essential for better clarity or surface finish

Critical compounding features - PVC Cooler mixer essential for dry blend Cooler mixer essential for dry blend Internal mixer or continuous extruder often used Internal mixer or continuous extruder often used Sequential addition of additive provides advantages Sequential addition of additive provides advantages Die face cutting system more suited to prevent moisture pick up Die face cutting system more suited to prevent moisture pick up Close system more preferred due environmental pollution Close system more preferred due environmental pollution

Compounding of PVC is black art PVC melt tends to stick to metal more than all other polymers PVC melt tends to stick to metal more than all other polymers Lubricant selection to be done on Lubricant selection to be done on External External Internal Internal Internal-external Internal-external Also multi lubricants with varying melting temp should be selected Also multi lubricants with varying melting temp should be selected

PVC is driven by additive systems & compounding Same PVC products can be produced with different approaches of additives Same PVC products can be produced with different approaches of additives Experience a key requirement for successful PVC compounding/products at optimum cost and quality Experience a key requirement for successful PVC compounding/products at optimum cost and quality Additive indeed a great leveler in PVC products Additive indeed a great leveler in PVC products Learn additive in order to become expert in PVC compounding Learn additive in order to become expert in PVC compounding