Mahendra Bharaskar APAR Industries Limited Tomorrow’s Progress Today Tomorrow's Progress Today

Tomorrow's Progress Today Company Profile Apar Industries Limited, founded by Late Mr. Dharmsinh D. Desai in the year 1958 One of the best established companies in India operating in the diverse fields of electrical, metallurgical and chemical engineering. A 3000 crore diversified company offering value added products and services in Power Transmission Conductors and Petroleum Specialties. 53 years of existence, highly competitive & market leader in these fields Firmly committed to being a responsible corporate citizen with an abiding belief in human engineering. Focuses on innovative products, establishing state of art manufacturing facility of cross linked cables and wires and other products with Electron Beam Technology at G.I .D.C, Umergaon. Gujarat. Tomorrow's Progress Today

Tomorrow's Progress Today Introduction of Radation Definition of Radiation Processing The treatment of products and materials with radiation or ionizing energy to change their physical, chemical or biological characteristics, to increase their usefulness and value or to reduce their impact on the environment Ionizing Energy Sources Electrons from Particle Accelerators. X-Rays from Accelerated Electrons. Gamma Rays from Radioactive Nuclides. In absorbing materials, electrons, X-rays and gamma rays transfer their energies by ejecting atomic electrons, which can then ionize other atoms. These radiations produce similar effects. The choice of a radiation source depends on the practical aspects of the treatment process, such as absorbed dose, material thickness, processing rate, capital and operating costs Tomorrow's Progress Today

Tomorrow's Progress Today Introduction of Radiation Radiation processing was introduced 50 years ago. Many practical applications have been discovered. The most important commercial applications are: Modification of plastic and rubber materials. Sterilization of medical devices and consumer items. Pasteurization and preservation of foods. Reduction of environmental pollution. Tomorrow's Progress Today

Tomorrow's Progress Today Electron Beam Processing Electron beam (EB) processing has been demonstrated on a large commercial scale to be a very effective means of improving end-use properties of various polymers. It is a well established and economical method of precisely modifying the bulk and surface properties of polymer materials. Although many of the EB applications are in wide use, the combination of high energy and high power of new electron accelerators now enable economical application to larger and thicker products. EB radiation is a form of ionizing radiation, generally characterized by its fixed penetration range and its high dose rate. These electrons are generated in equipment called accelerators, which produce a beam that is either pulsed or continuous. EB is a process in which the products are exposed to a concentrated, highly charged stream of electrons. As a product passes in front of the electron beam, it absorbs energy from the electrons. The energy that is absorbed per unit mass of product or material is referred to as the absorbed dose. Tomorrow's Progress Today

Tomorrow's Progress Today Electron Beam Processing Polymeric materials with high molecular weights are good candidates for radiation processing. Inorganic compounds with low molecular weights are poor candidates for radiation processing. Dilute solutions are exceptions. Ionizing a small fraction of the solvent will affect most of the solute. High energy electron used under high temperature & nitrogen atmosphere Possible uses for electron irradiation include sterilization, degradation and to cross-link polymers. X-linking polymeric products to improve mechanical, thermal, chemical and other properties Material degradation often used in the recycling of materials, and Sterilization of medical and pharmaceutical goods. Electron energies typically varies from keV to MeV range, depending on the depth of penetration In polymers, an electron beam may be used for chain scission & cross linking. The result is a change in the properties of the polymer which is intended to extend the range of applications for the material. The effects of irradiation may also include changes in crystallinity as well as microstructure. Tomorrow's Progress Today

Tomorrow's Progress Today E-Beam Accelerator An Electron Gun is housed in a thick vessel where electrons are accelerated in an acceleration tube The Electrons are directed to a scanning device magnetically Similarly, depending on the dosage required, suitable under-beam handling systems are designed The products are passed under the beam thru set of under-beam equipments Fig(1) Tomorrow's Progress Today

GLOBAL DISTRIBUTION OF ACCELERATOR P R O D U C T S p W I E & A B L , F M H N K Y V 8 5 - 1 140 J 2 . > 4 350 INDIA

Tomorrow's Progress Today INDIAN SCENARIO 1. 2 MeV EB MACHINE - AT BARC FOR R&D 3 MeV EB MACHINES ADDED IN 2003 2.5MeV added in 2007 AND IN 2011 4. 1.5 MeV & 3 MeV – New Project of Apar Industries Limited Tomorrow's Progress Today

Applications of Radiation Processing Modifying Polymeric Materials Curing Monomers and Oligomers Grafting Monomers onto Polymers Crosslinking Polymers Degrading Polymers Biological Applications Sterilizing Medical Products Disinfecting Consumer Products Pasteurizing and Preserving Foods Environmental Applications Reducing Acid Rain Treating Waste Materials Solid State Applications Modifying Semiconductors Coloring Gemstones Tomorrow's Progress Today

Applications of Radiation Processing Materials Suitable for Grafting A variety polymeric materials Polyethylene, Polypropylene Polyvinyl Chloride, Fluoropolymers Cellulose, Wool Property Improvements by Grafting Addition of hydrophilic surfaces on hydrophobic polymers to make perm selective membranes. Fuel cell and battery separator films. Improvement of surface adhesion properties. Biocompatible materials for medical applications. Tomorrow's Progress Today

Applications of Radiation Processing Typical Materials for Crosslinking Polyethylene Polyvinylchloride Polyvinylidenefluoride Ethylene-propylene rubber Ethylene vinylacetate Polyacrylates Products Improved by Crosslinking Plastic Products in Finished Form Heat Shrinkable Tubing and Film Electrical Wire and Cable Jackets Tires for Automobiles and Trucks Plastic Foam Padding for Automobiles Bulk Plastic Materials Tomorrow's Progress Today

Tomorrow's Progress Today Improve Material Properties through X-linking Improved Heat Resistance Improved Pressures(Stress Rupture)Resistance at elevated temperatures. Improved environmental stress crack resistance Mechanical properties such as tensile strength Scratch resistance Reliable and efficient use of energy. Performance at temperatures, often increase in the melting temperature Resistance to chemicals with lower solubility in organic solvent Gas permeation reduction Improved low temperature strength Tomorrow's Progress Today

Tomorrow's Progress Today Commercial Examples Typical Polymer(s) Property Improved Due to E- Beam Processing Foam PE Improved cell structure, mechanical properties and appearance Gaskets, Seals PE, EVA,(TPE) Improved heat properties, chemical resistance and resistance to compression Heat Shrinkable Tubes / Films PVC, PE, PVDF “Memory” Imparted, chemical resistance Medical Devices PP Sterilization Molded parts( Electronic Components) PA Solder Iron Resistance Molded parts(Automotive ) Improved heat deflection & operating temperature PEX- Crosslinked flexible pipe Increased heat distortion temperature, operating temp & dimensional stability Recycling of Ram Materials PTFE Micronized Powders used in Inks, Lubricants and Coatings Rubber Various Cold Vulcanization Wire & Cable Insulation PVC, PE High temperature properties, chemical resistance, tensile strength, “low smoke/zero halogen”(PE) Tomorrow's Progress Today

COMPARISON OF HDPE, PP(H) & X-LINKED HDPE Sr.No. Properties HDPE PP(H) X-LINKED HDPE 1. Continuous use 90 °C 120 °C 2. Melting Temperature at 170 to 180 °C Melts easily Melts Does not melt 3. Oil Resistance at 150 °C for 24 Hrs. Not Good (Melts & Dissolves) Not Good Very Good 4. High Temperature ageing resistance (150 °C / 7 days) Brittle Good 5. Hot Set Test at 200 °C for 15 Minutes Fail Pass 6. ASTM Oil Swelling at 150 °C fir 24 Hrs. Swelling very high > 40% Swelling very high > 50% Swelling very less < 10% Tomorrow's Progress Today

Application of Crosslinked Nylon 6

Automotive connectors, where higher temperature performance is required, are one application where crosslinkable nylon 6 compounds can exhibit cost-performance advantages over high-performance engineering thermoplastics.

Experimental setup for a simple test of nylon crosslinking (above) Experimental setup for a simple test of nylon crosslinking (above). The 350 C soldering iron with a 1-kg load immediately penetrates the non-crosslinked nylon sample (below) but does not penetrate the crosslinked sample (bottom) after 30 sec.

Non Crosslink Crosslink By Electron Beam