PROCESSING ADDITIVES

Module 4
CHE1019 – Polymer Technology
Dr. Mohammed Rehaan Chandan
Asst. Prof. Chemical Engineering
Syllabus portion
• Fillers
• plasticizers
• Anti-oxidants
• colorants
• stabilizers; and
• other related additives.
Role of polymer additives
• Pristine polymeric materials often show poor properties
and would result in a commercial failure.
• The incorporation of additives makes polymer materials
suitable for multiple applications in the plastic market:
automotive, design, packaging, constructions, electronics,
telecommunication.
• Additivation of molecules or particles to the virgin polymer
can improve the properties of the bulk product as well as
its surface.
Additives…
• Polymers unsuitable for processing in
pure unmodified form.
• e.g.
• Polyolefins – Oxidative degradation due to
heat and pressure during processing
• PVC - Degradation at processing
temperature
ADDITIVES
• Any Substance that is added
generally in small concentration to
resins in order to :
• Alter their properties
• Facilitate processing
• Change the physical, chemical or
electrical properties of end products.
• Reduce the cost
Requirements of Additives
• Effectiveness in their function
• Stable under processing conditions
• Stable under service conditions
• Economic
• Compatibility with Polymer Matrix
-At molecular level
• Neither Volatile nor extrude to the surface
• Neither bleed nor bloom
• Must have low vapour pressure at high temperature
• Non Hazardous, non impart taste & odour
CLASSIFICATION
Assist Processing • Processing Stabilizer
• Lubricants - External
• Lubricants - Internal
Modify Bulk Mechanical • Plasticizer
Properties • Reinforcing filler
• Toughening Agents
Reduce Cost • Fillers
• Diluents & extenders
Surface Properties • Antistatic
Modifier • Anti Slip
• Anti wear
• Anti block
• Adhesion Promoters
Optical Properties • Nucleating Agents
Modifier • Colorants
Anti-Ageing • UV Absorbers
• Fungicides
Others • Blowing Agents
• Flame Retarders
Processing Stabilizers
• Prevent degradation which is caused by
• Heat
• Oxygen
• What Happens?
• Oxygen combines with Polymer under high
temp to form carbonyl compounds which leads
to yellow & brown discolouration.
Processing Stabilizers
• Primary Stabilizers – Antioxidants
• Secondary Stabilizers – Peroxide
decomposes
• Chelating Agents – Metal deactivators
• Special Stabilizers (Heat Stabilizers) –
for halogenated polymers
Antioxidants (Primary Stabilizers)
• They inhibit or retard the oxidative degradation of
materials at normal or elevated temperature during
processing, storage or service due to
• Heat
• Light
• Chemical Induction
• How it works?
• It interrupt the chain reaction by combining with the
free radicals forming a non reactive products

(Amount : 0.1 – 0.5%)

Effect of Oxidation
– Loss in Tensile Properties
– Discolouration i.e. yellowing,
– Increase in Brittleness
– Melt Flow Instability
– Change in appearance.
– Hardness increases.
– Loss of Gloss.
– loss of transparency.
– Cracking.
Secondary Stabilizer – Peroxide decomposes

• How it works?
Peroxides are reduced to alcohols & are
deactivated.
• EX:
Sulphur & Phosphorus Compounds such as
Sulphides, thioethers, tertiary phosphites &
phosphorates.
Chelating Agents – Metal Deactivators
• Prevent degradation by metal ions
(impurities in polymers – ziegler-natta
redox initiators, fillers, pigments etc.)
• Example:
• Organic Phosphines & Phosphites
• Higher Nitrogenated compounds –
Melamine, diamine etc
Heat Stabilizers
• Prevent Degradation
• Absorb & Neutralize HCl gas evolved
• Prevent Oxidation reactions
• Prevent Discolouration
• Displace active substituents with
stable substituents
Heat Stabilizers
• Lead
– Tri Basic Lead Sulphate (TBLS)
– Dibasic Lead Sulphate (DBLS)
– Basic Lead Carbonate
– Dibasic Lead Phosphite
• Organo-tin
– Dibutyltin meleates
– Dibutyltin bis mercaptides
• Cadmium / Barium /Zinc
– Cadmium/Barium laurates
– Cadmium/Barium/Zinc Complexes
Synergistic Stabilizer Systems
• The term Synergism is used to describe the
combined effect of two or more stabilizers,
which is greater than the sum of the effects
of the individual stabilizers used in
isolation.

Effect (A+B) > Effect A + Effect B

Lubricants or Flow Promoters
Functions :-
• To reduce friction between the material and the
processing equipment. (Adhesive forces)
• To reduce heat & wear between two surfaces either
between the polymer molecules (Cohesive forces) or
between the polymeric material and the equipment.
• Reduces thermal degradation of the polymer.
• Modifies flow characteristics.
• Homogenous the polymer melt with other polymer
additives.
• To prevent the plastic from sticking to the mould surface
during processing
Lubricants or Flow Promoters

• External Lubricants
• Internal Lubricants
External Lubricants
• Prevent friction between polymer melt & metal surface
• Prevent sticking to the metal parts
• They are usually high molecular compounds and have
non-polar groups.
• They have low compatibility with the polymer but have
high affinity for the metal surface.
• During processing they form a thin film between polymer
melt & metal surface.
• They improve surface finish & gloss.
• They help to reduce melt viscosity and give a high output
rate.
External Lubricants
• Metal Soaps
• Metal Stearates
• Zinc Stearates
• Calcium Stearates
• Magnesium Stearates
• Hydrocarbon waxes
• Stearic Acid & its calcium, lead, Ba, Cd
Salt, Hydro carbon & Esters
 CHE1019 FALL19-20
CAT - 1
Avg = 26
45

40

35
Marks out of 50

30

25

20

15

10

0
1 6 11 16 21 26 31 36 41 46 51 56
Student no.
Internal Lubricants
• Promotes Flow by reducing cohesive forces
between molecular interfaces within the resin
• They are usually low molecular weight
compounds, having polar groups.
• They function by reducing intra-molecular friction
before and during the melt formation of the
polymer by promoting flow and reducing melt
viscosity of the polymeric mass.
• They also enhance polymer properties like heat
stability, impact strength, colour & clarity.
Internal Lubricants
• Amine Waxes
• Ester Derivatives
• Glyceryl mono stearate
• Long chain esters
• Fatty Acids & Amides
• Ethylene bi stear amide
• Zinc Stearates
Selection of Lubricants
• Metal Soaps – Low Compatibility with polymer, so
used as external lubricants
• Long Chain Fatty Acids – Used as Internal
Lubricants for polar polymers.
• Long Chain di-alkyl esters – Medium
compatibility, so act as external & internal
lubricants.
• High Molecular weight paraffin wax – low
compatibility with polar polymer, so used as
external lubricants.