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What is happening to polymer additives
Jitu Vadodaria Jayvee Organics Endowment Lecture March 24, 2005 Ahmedabad
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Contents Why additives - significance Additives - types
Global scenario Indian scenario Key issues Trends Case studies PVC compounding - some aspects
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PVC/HDPE pipes 50 years of service life PVC pipes - underground
HDPE pipes - outside Heat stabilizer key for service life of PVC pipes Carbon black/UV stabilizer for service life of HDPE pipes
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PVC windows At least 15 years service life for economy
No colour fading No breakage This is only possible due: * Acrylic/CPE impact modifier * Rutile titanium dioxide pigment
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PVC power cable High temperature resistance due high tension power ( C) Higher insulation Can only be achieved by: *Higher mol.wt. Phthalate plasticizer (DIDP) or trimellitate plasticizer * Calcined clay for insulation
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PE insulation cable PE in contact with copper breaks down
This can be prevented by use of * Metal deactivator in addition to primary antioxidant system
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PE halogen free flame retardant building wire
High oxygen index Low smoke density Only possible by use of * N-P based FR additive * Melamine compounds
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Additives=Performance+ property-preservation/retention
All these examples clearly show: * Performance * Property retention/preservation/protection in severe service environment/condition Polymer additives essential to provide Performance Property protection Property preservation
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LLDPE thin film Shark skin surface - rough surface Melt fracture
Surface can be made smooth by use of * Polymer processing aid - Fluro elastomer polymer
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BOPP film for high speed packaging
High stiffness Easy machinability Faster packaging speed High stiffness - Aromatic resin Easy machinability - Slip additive Faster packaging speed - Terpolymer
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Plastic –wood composites
Wood flour dispersion Higher moisture of wood flour Low flow Dispersion - Coupling agent Moisture control - Desiccant Flow - Processing aid/lubricant
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PVC building thin wire Economical production of highly filled flame retardant formulation Faster extrusion speed for economy This is achieved by * Use of processing aid * Use of PE wax or montan acid ester
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Polymer additive=Processability
Processing aid * Acrylics/ Fluro elastomer * Slip additive - Erucamide/ Oleamide All these additives contribute to Processability of polymer
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Polymer additive can spoil quality if care not taken properly
Quality of additive quite difficult to convert into plastic properties Chemical quality alone can not justify its use in polymer Numerous suppliers Slow process of approval Select standard additive product from leading suppliers and not go for cost saving Loss will be significantly high
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Functions of polymer additive
PERFORMANCE POLYMER ADDITIVES PROPERTY RETENTION PRESERVATION PROCESSABILITY
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Additives classification Property modifier
Plasticizer Impact modifier Blowing agent Coupling agent Nucleating agent Organic peroxide Reinforcing agent
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Additive classification Property extender
Flame retardant Heat stabilizer Antioxidant Light stabilizer Antistatic agent
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Additive –classification Processing aid
Lubricant Mould release agent Anti block additive Slip additive
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Polymer additive demand estimates 2004
Polymer demand 170 MMT Additive demand MMT Additive percent 5 % Additive cost % Additive costs only 10% of the polymer but plays a much bigger role
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Global polymer additive distribution by type (%)
Plasticizer 59 Flame retardant 12 Impact modifier 8 Heat Stabilizer 6 Lubricant 6 Antioxidant 3 Peroxide 2 Light stabilizer 1 Others Total
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Additive usage distribution by polymer
PVC Polyolefin 10 Styrenics 5 Other
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Additive usage by region
North America 2.5 Europe Asia 3 S. America 0.5 Middle East 0.5 Russia etc 0.5 Total 9 All in MMT
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Additive demand estimates India 2004 (KT)
Plasticizer Heat stabilizer Lubricant Antioxidant Flame retardant Impact mod/P. aid Others Total
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Polymer additive Key issues
Global market Vs local suppliers Market growing more in Asia but suppliers continue in Europe/USA Large no. of small suppliers in Asia Lower growth - survival of fittest leading to M&A Environmental pressures & new legislation
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Polymer additive Key issues
Plasticizer toxicity Elimination of heavy metal components Non halogenated flame retardants Lowering of dosage level for safety
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Recent trends Global majors developing niche products
Patents expiry leading to newer players M& A activities on an increase for survival Global majors setting up plants in fast growing Asia Higher awareness on environmental issues demanding more HSE research
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Recent trends PVC pipes moving from lead stabilizer to tin/ca - zn/organic Slow but sure phasing of lead from PVC cable sector Phasing out of halogenated flame retardants Shift from PVC to non vinyls for flame retardance
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New additive products/markets
Oxygen scavenger for packaging Wood composites Newer flame retardants Biodegradable additive Conductive additive Nano filler Newer additive for plasticulture
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Glass bead -an economic alternative of glass fiber
PP Moulded product of 0.5 KG weight Production requirement unit Production cost Rs 500/hour Raw material cost PP Rs. 60/KG Glass Fiber Rs. 70/KG Glass bead Rs. 60/KG
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Glass bead in PP- A case study
Cycle time/Defect rate PP second 5.2% PP+30% Glass fiber 65 second 5.2% PP+20% GF+10% GB 54 second 3.6% PP+20% Glass bead 46 second 1.2%
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PP moulded product A case study
Material Total units KG PP PP+30% GF PP+20%+10% PP+20% GB
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Cost benefit analysis PP glass bead Vs glass fiber moulded product
Material Process hour Total cost(Rs) PP PP+30% PP PP+20% Saving Saving Saving
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PVC compounding Some aspects
All PVC products contain % of PVC polymer PVC very dependent on additive/compounding More than 50% of PVC is mixed only up to dry blend powder form (rigid) Plasticized compounds in pellet form
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Key aspects of PVC compounding
Cooling of dry blend essential for efficient use of heat stabilizer Higher bulk density can only be developed by dry blending temp reaches 120C Moisture removal essential for better clarity or surface finish
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Critical compounding features - PVC
Cooler mixer essential for dry blend Internal mixer or continuous extruder often used Sequential addition of additive provides advantages Die face cutting system more suited to prevent moisture pick up Close system more preferred due environmental pollution
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Compounding of PVC is black art
PVC melt tends to stick to metal more than all other polymers Lubricant selection to be done on External Internal Internal-external Also multi lubricants with varying melting temp should be selected
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PVC is driven by additive systems & compounding
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 Additive indeed a great leveler in PVC products Learn additive in order to become expert in PVC compounding
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