What%20is%20happening%20to%20polymer%20additives

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
AdditivesPerformanceproperty-preservation/re
tention

• 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 additiveProcessability

• 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 MA
• 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
• PP30 Glass fiber 65 second 5.2
• PP20 GF10 GB 54 second 3.6
• PP20 Glass bead 46 second 1.2

31
PP moulded productA case study

• Material Total units KG
• PP 1052 526
• PP30 GF 1052 526
• PP2010 1036 518
• PP20 GB 1012 506

32
Cost benefit analysisPP glass bead Vs glass
fiber moulded product

• Material Process hour Total cost(Rs)
• PP 17.52 40327
• PP30 18.99 42635
• PP2010 15.54 39886
• PP20 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