ASSI

GNMENT#4(
CPI
)

COMSATSUNI
VERSI
TYI
SLAMABD,
LAHORE
CAMPUS
(
CHEMI
CALENGI
NEERI
NGDEPARTMENT)
12/
26/
2020

CHEMI
CALPROCESSINDUSTRI
ES
CHE221
PLASTI
CINDUSTRY

MARYAM FATI
MA
SECTI
ONA
SEMESTER3
ASSIGNMENT#4
1
ASSI
GNMENT#4(
CPI
)

Tabl
eofCont
ent
s
Hi
stor
y: 3
I
ntr
oduct
ion: 3
RawMat
eri
al: 4
I
ndust
ri
alManuf
act
uri
ngMet
hods: 4
Addi
ti
onal
pol
ymer
izat
ion: 4
Condensat
ion-
eli
minat
ionpol
ymer
izat
ion: 4
Pol
ymer
izat
ionTechni
ques: 5
1. Bul
kpol
ymer
izat
ion: 5
2. Sol
uti
onPol
ymer
izat
ion: 5
3. Suspensi
onPol
ymer
izat
ion: 5
4. Emul
si
onpol
ymer
izat
ion: 5
Di
ff
erencebet
weenManuf
act
uri
ngpr
ocessesofpl
ast
ics 6
Pl
ast
icPr
ocessi
ngMet
hods: 6
I
nject
ionMoul
ding 6
Bl
owMoul
ding 7
Ther
mof
ormi
ng 7
Tr
ansf
erMoul
ding 7
React
ionI
nject
ionMoul
ding: 7
Compr
essi
onMol
ding: 7
Ext
rusi
on: 7

2
ASSI
GNMENT#4(
CPI
)

QUESTI ON:Plasti
ci samat er
ialconsisti
ngofwi derangeofsy nt
heti
corsemi -sy
ntheti
c
organi
ccompoundst hatar
emal leableandcanbemoul dedi nt
osoli
dobjects.Pl
ast
icsare
ty
picall
ypol y
mer s ofhigh molecularmass,butt heyof t
en contai
n othersubstances.
Diff
erenti
atebetweenthemanuf acturi
ngprocessesofplast
ics.

Hi
stor
y:
Oneoft hefi
rstex ampleswasi nventedbyAl exanderPar kesi n1855,whocoi nedt heter
m
Parkesine.Weknowi ttodayascel luloi
d.Pol y
v inylchlori
de( PVC)wasf i
rstpoli
shedbet ween
1838-1872.Ear lyplast
icsr eli
edonl ar
gecel lulosemol ecules,usuall
yf oundi nwoodpul p.
LeoH.Baekel and,aBel gianAmer icani nventor ,i
ntroducedanewcl assofl argemol ecul
es
when he t ookhi spatentBakel it
ei n 1909.Bakel itei sformed bya r eact i
on between
for
mal dehyde and phenol i
c materials athi gh temper atur
es;t he mat er
ialis hard,non-
abrasi
v e,andchemi cal
lyr esi
stant(at ypeknownast hermoset ti
ngpl asti
c).Thesuccessof
Bakeli
tegav egreatimpet ust otheplasticsindust r
y ,
tot hestudyoft heex tr
acti
onofcoalt ea
andot herhy drocarboncompounds,andt ot heoreticalunder st
andingoft hest r
uctureof
complexmol ecul es.

I
ntr
oduct
ion:
Pl
ast
icsar
eli
vi
ngthings,suchaswood,paper
,orwool.Therawmat er
ial
susedt
opr
oduce
pl
ast
icsar
enat
ural
pr oduct
ssuchascel
lul
ose,coal
,nat
ural
gas,sal
tand,cr
udeoi
l
.
Thewor d''plastic'
' i
sderi
vedfrom t
heGr eekword''pl
asti
kos''
,whi chmeansfitformolding.
Thisreferst othef ormati
onofmat eri
al,orpl
asti
cduringthepr ocess,whichall
owsi ttobe
dist
ri
buted,pr essed,orex t
ract
edfrom av ari
etyofmat er
ial
s-suchasf il
ms,f i
bers,pl
ates,
tubes,bottles,box es,andmuchmor e.Plasti
csisat er
m oftenusedt odescr ibeawi de
vari
etyofsy ntheti
corsemi -sy
ntheti
cmat eri
alsusedi nlar
geandgr owingframewor ksof
appli
cations.
Thiswor khasledt othesuccessfuluseofmol eculest opr oducesubstanceswi t
hspecif i
c
charact er
ist
icssuchasst r
engthorf lexi
bil
it
y.Strategieswer edev el
oped,oftenr equi
ri
ng
buil
di ngmat eri
alsandgener almachi ner
y,topr otectt hesepol ymer
s-t hatis,compl ex
mol eculesproducedbyt hecombi nat
ionofsimplest ructures.Linepol
ymer sprovi
dest r
ong
fi
ber s,polymersf or
m filmst hatareusef ulforpai nt
,andmanypol ymer sf or
m st r
ong
plastics.

Polymersaresy nthesi
zedbyjoi
ningsmallmol
ecul
esintolar
geones.Butmostoft hese
monomer i
cmol eculesar
eperfectl
yst
ableastheyare,so chemist
shav edev i
sed t
wo
generalmethodst omakethem r
eactwi
theachot
her
,buil
dingupthebackbonechai
nast he
react
ionproceeds.
Pol
ymerPr
oduct
:
Thepr
ocessi
ngoft
hemaj
orpol
ymer
sint
oindust
ri
alandconsumerpr
oduct
sar
e:
1.Pl
ast
ic(
Ther
mopl
ast
icandTher
moset
ti
ngResi
ns)
.
2.El
ast
omer(
Nat
ural
andSy
nthet
icRubber
).
3.Man-
madeFi
ber
.
4.Adhesi
ve.

3
ASSI
GNMENT#4(
CPI
)

5.Sur
faceCoat
ing.

4
ASSI
GNMENT#4(
CPI
)

RawMat
eri
al:
 Monomer
s.

 Pl
ast
ici
zer
s.

 Nat
ural
Product
s(cr
udeoi
l
,coal
,cel
l
ulose)

 Rei
nfor
cement
s.

 Fi
l
ler
s

 Chemi
cal
Int
ermedi
ates.

I
ndust
ri
alManuf
act
uri
ngMet
hods:

Addi
ti
onal
pol
ymer
izat
ion:
Addi
ti
onofmonomermolecul
estotheacti
veedgesofagr owi
ngpolymer.Thi
sprocess,
si
mil
arto addi
ng l
i
nks t
o a chai
n,i
s cal
led chai
n-gr
ow pol
ymer
izati
on oraddit
ional
pol
ymeri
zat
ion.
Theaddi t
ionalpolymeri
zationr eact
ionisex ot
hermicitpr oducesheat.Heatpr oducti
oni s
rarel
yapr obl
em insmal l
-scalelaborat
oryresponse,butonal argei
ndust
rialscaleitcanbe
dangerous,becauseheatcausesani ncreaseinr eacti
onr ate,andrapidr eacti
onsal so
producemor eheat .Thispr acti
cecall
edaut oaccel er
ati
on,cancauset hepol ymerizati
on
reacti
ontoaccelerateatex plosiver
atesunlesseffecti
vethermaldegradationmechani sms
areincor
poratedintothereactionstr
ucture.

Condensat
ion-
eli
minat
ionpol
ymer
izat
ion:
Thisty
peofpol y
merizati
ont y
pical
lytakesplacebet weenmonomer scontaini
ngf unct
ional
groupthatreacti
nhighy iel
dtoform newf unct
ionali
ti
es.Chain-
growpolymerizat
ionismost
commonl yusedi nv
iny lmonomer s(i
.e.
,monomer scontai
ningcarbon-
carbonbondbonds)
andcertai
nt y
pesofcycl i
cmonomer s.
Condensationpolymer
izat
ionont heot herhandi sendothermi
c,thereacti
onrequi
resthe
i
ncorporati
onofheatfrom anex t
ernalsour ce.I
nthesecases,t
herespondentmustprov
ide
heattomai nt
ainaneff
ecti
vereacti
onr ate.Reactordesi
gnshouldalsoconsi
derther
emov al
orrecycli
ngofsolvent
sandcat al
ysts.Int hecaseofacondensationreacti
on,t
hereact
ors
mustpr ovi
defortheef
fect
iveremov alofproductsofaparti
cul
arty
pe.

5
 ASSI
GNMENT#4(
CPI
)

Polymeri
zat
ion on i
ndustr
ialscal
eis done usi
ng f
ive basi
c met
hods:mass,sol
uti
on,
suspensi
on,emulsi
on,andgasphase.

Pol
ymer
izat
ionTechni
ques:
1.Addi
ti
onPol
ymer
izat
ion

 Bul
kPol
ymer
izat
ion

 Sol
uti
onPol
ymer
izat
ion

 Suspensi
onPol
ymer
izat
ion

 Emul
si
onPol
ymer
izat
ion
2.Condensat
ionPol
ymer
izat
ion

 Mel
tPol
ycondensat
ion

 Sol
uti
onPol
ycondensat
ion
Pol
ymer
izat
iononi
ndust
ri
alscal
eisdoneusi
ngf
ourbasi
cmet
hods:
Bul
k,Sol
uti
on,
Suspensi
on,
Emul
sion.

1.Bul
kpol
ymer
izat
ion:
Bulkpolymerizat
ioniscarr
iedoutwi t
houtanysol ventordispersantandi stheref
oremuch
easi
ertof orm.Itisusedformostgr owthst eppolymersandmanyt ypesofchai ngrowth
polymers.I
nt hecaseofchainreacti
onr eact
ions,whichareoft
enex aggerated,t
hechanging
temperatur
ecancauset her esponsetobemor eintenseanddifficulttocontrolwit
houtthe
eff
ecti
vecoilcoolingcoi
lsintheresponsev essel
.Manypol ymerizationsarealsodiff
icul
tto
mov eduetot hehighvi
scosit
yrati
oassoci at
edwi t
hhi gh-
densi
typol ymers.

2.Sol
uti
onPol
ymer
izat
ion:
The cont inuous reacti
on ofpol ymer i
zat
ion to solv
enti s an ef f
ecti
v e means ofheat
dissipati
on;inadditi
on,solut
ionsaremucheasi ertomov et hanmostpol y meri
zati
ons.Liquid
chemi calsshouldbecar eful
l
yselected,however,sothattheydonotr eceiveachaintransfer
reactionwi t
hthepol ymer.Becauseitcanbedi f
fi
culttoremov et hesolventfrom afini
shed
viscous pol ymer,t he polymeriz
ati
on sol ut
ion binds itself bett
er t o poly
mer s used
commer cial
lyinthef orm ofasol uti
on,suchascer t
ainty pesofadhesi vesandcoat ings.
Polymer i
zationofgasmonomer sisalsocarri
edoutwi ththeuseofsol vents,
suchasi nthe
productionofpolyethylene.

3.Suspensi
onPol
ymer
izat
ion:
Inpoly
mer i
zati
on, t
hemonomerdissolv
est heli
quid(
usuall
ywater)byvi
gorousl
ystir
ri
ngand
addingsolventssuchasmet hylcel
lul
ose.Amonomer -sol
ublestar
teri
saddedt oi ni
tiat
e
polymeri
zati
onofchai ngr
owth.Theheatr eacti
onreact
swel lwi
ththestrongvolume.The
polymerisobtainedint
hefor
m ofgranulesorbeads,whichcanbedriedandpackeddi r
ectl
y
forshi
pment .

4.Emul
sionpol
ymer
izat
ion:
Oneoft hemostusedmet hodst oproducev iny
lpolymer s,emulsi
onpolymeriz
ationinvol
ves
theformati
onofast abl
eemul sion(of t
encalledlatex)monomeri nwaterusi ngsoapor
deter
gentasanemul sifyi
ngagent .Loosesol v
ents,dissolvedinthewaterphase,mov eto
stabl
emonomerdr oplets(knownasmi cell
es)toini
ti
atepol ymeri
zati
on.Thepoly meri
zati
on
react
ionisnoti
nter
rupteduntil
alargesecondv ol
umeent er
stheinfl
amedmi cell
es,resul
ti
ng

6
ASSI
GNMENT#4(
CPI
)

i
nt heformat
ionofver
yhighmol
ecul
arwei
ght
s.Ther
eact
iont
emper
atur
eisef
fect
ivel
y
di
spersedint
hewat
erphase.

7
 ASSI
GNMENT#4(
CPI
)

Di
ff
erencebet
weenManuf
act
uri
ngpr
ocessesofpl
ast
ics

Addi
ti
onal/chai
npol
ymer
izat
ion Condensat
ion/st
eppol
ymer
izat
ion

 Themonomermusthav
eatl
eastonemul
ti
ple  Themonomermusthav eatleastt
woi
dent
ical
bonds. (or
)di
ff
erentf
unct
ional
groups.
Exampl
es:Et
hyl
ene:
CH2=CH2,
Acet
ylene. Exampl
e:Gl
ycol
,Ny
lon(
6,6)

 Monomersadd on t
o giv
ea pol
ymerand no  Monomerscondenset
ogiveapol
ymerandby
ot
herby
-pr
oducti
sformed. pr
oduct
ssuchasH2O,CH3OHar
eformed.

 Numberofmonomer i
cuni
tsdecr
easesst
eadi
l
y  Monomer
s di
sappear at t
he ear
ly st
age of
t
hroughoutt
her
eact
ion. r
eact
ion.

 Mol
ecularwei
ghtofthepolymerisanint
egr
al  Molecul
arweightoft
hepoly
merneednotbean
mul
ti
pleofmolecul
arwei
ghtofmonomer
. i
ntegral
mult
ipleofmonomer
.

 High mol
ecul
arwei
ghtpol
ymeri
sfor
med at
once.  Molecul
arweightofthepol
ymerr
isesst
eadi
l
y
t
hroughoutt
hereact
ion.

 Longerr
eacti
onti
mesgi vehi
gheryi
eldbuthav
e  Longerr
eact
ion t
imesar
e essent
ialt
o obt
ain
ali
tt
leef
fectonmolecul
arwei
ght. hi
ghmolecul
arwei
ght.

 Ther
mopl
ast
icsar
epr
oduced.  Ther
moset
ti
ngpl
ast
icsar
epr
oduced.
Exampl
e:Pol
yet
hyl
ene,
PVCet
c., Exampl
e:Bakel
i
te,
urea-
for
mal
dehy
de

 Homo-
chai
npol
ymeri
sobt
ained  Het
ero-
chai
npol
ymeri
sobt
ained.

Pl
ast
icPr
ocessi
ngMet
hods:
Ther
ear ev ar
iousmet
hodsusedtopr ocessplast
ic.Eachmet hodhasitsadvant
agesand
di
sadvantagesandisbestsui
tedforspecifi
cprograms.Thesemet hodsincl
udeinj
ecti
on,
bl
ow moul di
ng,mechani
calheating,transf
er moulding,reacti
on inj
ect
ion mouldi
ng,
compacti
onmoul di
ng,
andextr
acti
on.

I
nject
ionMoul
ding
Themainmethodusedtoprocessplast
ici
sinj
ect
ionmouldi
ng.Inthi
sprocess,t
heplast
ici
s
pl
acedonthehopper.Thehopperthenturnst
heplast
ici
ntoahoti nj
ect
ionunit
,whereiti
s
pl
acedi
nalongchamberwithanequal scr
ew.Her
e,iti
smoistenedwit
hal i
quidfor
m.
Themicr
ophonei
slocat
edattheendoftheroom.Liqui
dplastici
sforcedthr
oughapipei
nto
acol
d,seal
edmould.Themoul dpar
tsarekeptsealedwit
hat i
ght
eningsystem.Whenthe
pl
ast
ichascool
edandhardened,t
hehal
vesopen,andt hefi
nishedproducti
sr emov
edfr
om

8
ASSI
GNMENT#4(
CPI
)

t
henewspaper
s.
Thermosett
ingmaterial
sareusuall
ynotprocessedbyinj
ect
ionbecausetheywi
llbesof
t,
str
ong,andi mper
vious.Iftheyarepr
ocessedwi t
hamoul dingneedle,t
heyneedtobe
tr
ansport
edt or
oom temperatur
eimmedi
ately
,sotheydonotset.

Bl
owMoul
ding
Blowmoul dingi
susedwhenapl ast
icobj
ectt
obef or
medneedst ohav eahol e.Themol t
en
tubeismadebybl owingamouldusingcompressedair,
whichinhalesthetubeandf orcesit
i
ntot hecoldmould.Vari
ati
onsofblowmouldingincl
udeinject
ion,inj
ect
ion-str
etchi
ng,and
extr
usionblowmoulding.
Byinj
ecti
onblowmoul dusesaper f
or m,whi chistransport
edtot heblowmoul dandfi
l
led
wit
hcompr essedair.Asar esul
t,itisassoci atedwi t
ht heint
ernalstruct
ureofthebl
ow
mould.Withthef or
mationoft hei njecti
on-str
etchblow,t heplasti
ci sstret
chedbef
ore
const
ruct
ion.Othert
hanthat
,it
'sli
ket heinjecti
onprocess.

Ther
mof
ormi
ng
Thermofor
mingusesapl ast
icsheet
,whi chismadeofmoul dthroughairormechani
cal
equi
pment.Theairpressureusedcanbeal mostzeropsi,orsev
eralhundr
edpsi
.At14psi,
equalt
oatmosphericpressure,t
hepressureiscreat
edbyr emovi
ngthespacebet
weenthe
mouldandthesheet.Thisi
sknownasv acuum const
ruct
ion.

Tr
ansf
erMoul
ding
Transfermouldingisoftenusedonlyinthemanuf actureofthermosett
ingplast
ics.I
tisl
ike
compr essi
on formati
on because the plasti
cist r
eated to an i
mper meable posi
ti
on by
pressureandheat .Unlikecomposi t
emoul di
ng,howev er
,transf
erri
ngmoul dinginvol
ves
heati
ngt heplasti
ctothepoi ntofplasti
cit
ybeforebeingappliedtotheskin.Themoul dis
thenforcedtoclosewithanelectr
icplug.
Transfermouldingwasi nit
ial
lyconstr
uctedtoshapecompl exproduct
s,suchast hosewith
manyembedded met al
s orsmal lholes deep.Thisis because pressure compressi
on
sometimesdi srupt
st hestructur
eofmet ali
nser
tsandhol esfortheset ypesofproducts.
Withthetransferstr
ucture,ontheotherhand,water
-r
epel
lentplast
iceasil
yf l
owsaroundthe
metalpartswithoutcausingthem tochangeposit
ion.

React
ionI
nject
ionMoul
ding:
Formul ati
onoft her eactioni nj
ection,orRIM,isoneoft henewmet hodsusedintheplasti
cs
i
ndust ry.I
tdiff
er sfrom liquiddi spersionint
hatt heli
quidcomponent saremixedi naroom
atal owt emper atureof75t o140degr eesFahrenhei
tonl ybefor
ebei ngpl
acedinacl osed
moul d.Her e,ast ranger eacti
onoccur s.Asar esul
t,RIMr equir
esl essener
gyt hanother
i
njectionmoul dingsy stems.Rei nforcedRIM,orR- RI
M,i nvol
vesinserti
ngmateri
alssuchas
crushedorcar vedf ibreint oacomponentt oincr
easedur abil
i
ty.

Compr
essi
onMol
ding:
Compr essionmoul di
ngisav er
ycommonpr ocessusedwi ththermoset t
ingmaterial
sandi s
usuallynotusedf orthermoplast i
cs.Throught hisprocess,t heequi pmentisputi nt
oi ts
desiredshapewi t
ht hehel pofpr essureandheat .Plasticmoul dingpowderandot her
mat eri
alsareaddedt ot hemixt uretof orm specialproperti
esort ost r
engt
hent hefinal
product.Whent hemoul di ssealedandheat ed,t
hemat erialundergoesachemi calr
eaction
thatmakesi tmor estable.Thetemper at
ure,theamountofpr essure,andt hel
engthoftime
spentbet weenprocessesdependont hedesiredresul
t.

9
ASSI
GNMENT#4(
CPI
)

Ext
rusi
on:
Theex trusionpr ocessi softenusedt omakepr oductssuchasf i
l
m,cont i
nuoussheet s,
tubes,pr ofi
le shapes,r ods,fabric coveri
ngs,threads,cor ds,and cor ds.Like i
njecti
on
moul di
ng, dryplasti
citemsarepl acedinahopperandpl acedi nahightemper atur
eroom.At
theendoft heroom, theequipmenti sforcedtomakeasmal lholeordi eintheshapeoft he
fi
nishedpr oducty ouwant .Asthepl asti
ccomesoutoft hetrash,i
tisplacedonaconv ey
or
beltwher eitcancool .Sometimesbl ower sareusedt oassistinthi
spr ocess,ortheproduct
canbei mmer sedinwat ertohelpitcooldown.

10