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POLYESTER TECHNOLOGY

POLYESTER TECHNOLOGY. SPEAKER: ZAINUL ABEDEEN AMIR ALI (SDM PRODUCT DEVELPEMENT, GATRON INDUSTRIES LTD.) VENUE: TEXTILE INSTITUTE OF PAKISTAN. DATE: 9 TH MAY, 2008. CONTENTS. HISTORY OF THE DEVELOPMENT OF POLYESTER FIBERS. WHAT IS POLYESTER? IMPORTANT POLYESTER. SPECIAL PET PRODUCTS.

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POLYESTER TECHNOLOGY

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  1. POLYESTER TECHNOLOGY • SPEAKER: ZAINUL ABEDEEN AMIR ALI (SDM PRODUCT DEVELPEMENT, GATRON INDUSTRIES LTD.) • VENUE: TEXTILE INSTITUTE OF PAKISTAN. • DATE: 9TH MAY, 2008

  2. CONTENTS • HISTORY OF THE DEVELOPMENT OF POLYESTER FIBERS. • WHAT IS POLYESTER? • IMPORTANT POLYESTER. • SPECIAL PET PRODUCTS. • SYNERGY & INTEGRATION. • INDUSTRY NEWS.

  3. 1. History of the development of Polyester Fibers • 1928-1932: Carothers laid the foundation for all processes used in the production of polyester, polymaide using polycondensation process. • The polycondensation of ethylene glycol and sebacic acid produced a melt from which filaments can be drawn by contact with a glass rod. • Early 1940s: the use of terephthalic acid for development of polyester fibers was implemented almost at the same time in Germany by Schlack at a branch of Agfa Wolfen and by Whinfield & Dickson in England in the laboratories of the Calico Printers Association. • Whinfield and Dickson preferred using a combination of terephthalic acid and ethylene glycol to produce polyester. Schlack used terephthalic acid and 1,4 butanediol.

  4. 1. History of the development of Polyester Fibers • The combination chosen by Whinfield and Dickson was the most favorable from the point of economy and application to textile usage and that is the reason it has succeeded over the combination used by Schlack. • 1947: Mass production started in United Kingdom by I.C.I. and in USA by Dupont after both companies acquired the patent rights from Calico Printers' Association Ltd. in Manchester. The I.C.I. marketed their polyester fiber as 'Terylene' while Dupont marketed their product as 'Dacron'. • All the procedures have one thing in common: • Preparation of the polymers; • Spinning of the polymers into filaments; and • Further processing of filaments into continuous filament or staple fibers.

  5. 2. WHAT IS POLYESTER? • Esterification is a reaction between Acid and Alcohol resulting in an Ester plus Water. • Polyester is a chain molecule formed by many basic ester molecules through condensation reaction. • Monomer (single) > Oligomer (some) > Polymer (many)

  6. 3. IMPORTANT POLYESTER 3.1 PET - Poly Ethylene Terephthalate • Raw materials: EG + PTA (Esterification process) or EG + DMT (Trans estrification process)

  7. 3. IMPORTANT POLYESTER • PET Characteristics: Because of higher melting (252 ~ 256 °C) & glass transition (about 80 °C) temperatures retains good mechanical properties up to 150 ~ 175 °C . Its chemical & solvent resistance is good. It has good fibre forming properties, has outstanding crease resistance and work recovery and low moisture absorption.

  8. PET APPLICATION: Fibre applications Filament yarn Industrial yarn Staple fibre Nonwoven spunbond Special fibre products Bottles & Containers Stretch blow molded bottles Extrusion blow molded bottles Biaxial Oriented films, BOPET Electronic media Photo technique Electrical insulation Packaging Cast films, A-PET Food trays ovenable, C-PET Engineering plastics 3. IMPORTANT POLYESTER

  9. 3.2 PBT - Poly Butylene Terephthalate Raw materials: BD + PTA PBT Characteristics: Its melting point is 232 °C. Its chief application is in field of industrial plastics. Lately, it has also been used to manufacture carpet yarns and textile fibres. Base resin is widely used in compounding. Has good chemical & heat resistance and outstanding electrical properties. It is easy to make flame retardant and master batches. PBT Applications: Electrical/electric connectors Smart network interface devices (SNID's) Power plugs and electrical components Switches and controls Circuit breaker enclosures Outdoor telecommunications enclosures Automotive under-hood components Electrical appliance components Fiber optic tubes Medical applications such as clamps, pump parts, plugs, etc. 3. IMPORTANT POLYESTER

  10. 3.3 PTT - Poly Tri-methylene Terephthalate Raw materials: PDO + PTA PTT Characteristics: It can be spun into both fibers and yarns. Stain resistance, wearability, colour fastness, softness and stretch are just some of its winning qualities. Its melting point is 233 °C. It is easy to dye below 100 °C. PTT Applications: It has extensive applications in carpeting, textiles and apparel, engineering thermoplastics, nonwovens, films and mono-filament. 3. IMPORTANT POLYESTER

  11. 4. SPECIAL PET PRODUCTS • A-PET: processed into amorphous, non-drawn cast films 150 to 1000 microns, are used to manufacture all types of rigid packaging, such as jars, meal trays & folded boxes, etc. • C-PET: a specially modified polyester obtained by adding crystallization accelerators, and is mainly used to manufacture ovenproof meal trays for ready-to-serve meals. • G-PET: these are highly modified polyesters, whereby the EG is replaced by other glycols, e.g., CHDM, are amorphous and uses ranging from A-PET to injection & extrusion blow moulding. Due to high modifier content are relatively expensive.

  12. 4. SPECIAL PET PRODUCTS • Bottle PET: are polyester feedstock for manufacturing bottles produced by stretch-blow moulding, melting temperature & crystallization rate are reduced by use of comonomers, e.g., IPA, DEG & CHDM. • Co-PET: is a generic term for all copolyesters which contain apart from PTA an additional acid e.g., IPA or an additional glycol e.g., CHDM. The majority of bottle polyesters, A-PET and G-PET are copolyesters. • BOPET: are biaxially oriented polyester films of 1 to 300 microns. Special anti-blocking additives are used to improve winding characteristics.

  13. AROMATIC PLANT PROPANE / BUTANE PARAXYLENE BENZENE METAXYLENE PTA PLANT ORTHOXYLENE EG PET PLANT BOTTLE CHIPS FILAMENT YARN STAPLE FIBRE TEXTILE CHIPS SYNERGY & INTEGRATION EXAMPLE OF A PETROCHEMICAL COMPLEX ACETIC ACID

  14. 6. INDUSTRY NEWS • In 2007 total global Polyester consumption was estimated at 44 million tons with an annual growth @ 7%. • Soaring Cotton prices will benefit Polyester Fiber consumption. • Reliance (India) with acquisition of Hualon has become the world’s largest textile polyester manufacturer. Global market share of 7 ~8% of total polyester production. • SABIC (Saudi Arabia) will become major global player of PET by 2011 with start up of 2nd plant.

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