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What is happening to polymer additives

What is happening to polymer additives. Jitu Vadodaria Jayvee Organics Endowment Lecture March 24, 2005 Ahmedabad. Contents. Why additives - significance Additives - types Global scenario Indian scenario Key issues Trends Case studies

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What is happening to polymer additives

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

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

  3. 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

  4. 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

  5. PVC power cable • High temperature resistance due high tension power (85-105 C) • Higher insulation • Can only be achieved by: *Higher mol.wt. Phthalate plasticizer (DIDP) or trimellitate plasticizer * Calcined clay for insulation

  6. 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

  7. 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

  8. 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

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

  10. 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

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

  12. 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

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

  14. 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

  15. Functions of polymer additive PERFORMANCE POLYMER ADDITIVES PROPERTY RETENTION PRESERVATION PROCESSABILITY

  16. Additives classificationProperty modifier • Plasticizer • Impact modifier • Blowing agent • Coupling agent • Nucleating agent • Organic peroxide • Reinforcing agent

  17. Additive classificationProperty extender • Flame retardant • Heat stabilizer • Antioxidant • Light stabilizer • Antistatic agent

  18. Additive –classificationProcessing aid • Lubricant • Mould release agent • Anti block additive • Slip additive

  19. Polymer additive demand estimates2004 • Polymer demand 170 MMT • Additive demand 9 MMT • Additive percent 5 % • Additive cost 10 % • Additive costs only 10% of the polymer but plays a much bigger role

  20. 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 3 • Total 100

  21. Additive usage distribution by polymer • Polymer % PVC 65-70 Polyolefin 10 Styrenics 5 Other 15-20

  22. Additive usage by region • North America 2.5 • Europe 2.5 • Asia 3 • S. America 0.5 • Middle East 0.5 • Russia etc 0.5 • Total 9 All in MMT

  23. Additive demand estimatesIndia2004(KT) • Plasticizer 185 • Heat stabilizer 25 • Lubricant 18 • Antioxidant 5 • Flame retardant 4 • Impact mod/P. aid 5 • Others 8 • Total 248

  24. Polymer additiveKey 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

  25. Polymer additiveKey issues • Plasticizer toxicity • Elimination of heavy metal components • Non halogenated flame retardants • Lowering of dosage level for safety

  26. 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

  27. 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

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

  29. Glass bead -an economic alternative of glass fiber • PP Moulded product of 0.5 KG weight • Production requirement - 1000 unit • Production cost Rs 500/hour • Raw material cost • PP Rs. 60/KG • Glass Fiber Rs. 70/KG • Glass bead Rs. 60/KG

  30. Glass bead in PP- A case study • Cycle time/Defect rate • PP 60 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%

  31. PP moulded productA case study • Material Total units KG • PP 1052 526 • PP+30% GF 1052 526 • PP+20%+10% 1036 518 • PP+20% GB 1012 506

  32. Cost benefit analysisPP glass bead Vs glass fiber moulded product • Material Process hour Total cost(Rs) • PP 17.52 40327 • PP+30% 18.99 42635 • PP+20+10 15.54 39886 • PP+20% 12.93 36826 • Saving 4.59 3501 • Saving 6.06 5809 • Saving 2.61 3060

  33. PVC compoundingSome aspects • All PVC products contain 30-95 % 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

  34. 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

  35. 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

  36. 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

  37. 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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