StyroChem

Expansion of Expandable
Polystyrene (EPS)
StyroChem

Expansion Basics
• Heat Is Applied
• Beads Expand
• Beads Cool
• Beads Age
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Expansion - Behind the Scenes

• Heat Is Applied
– Blowing agent(s)
vaporizes
(28oC iso-pentane, 35oC normal-
pentane, 49oC cyclo-pentane)
– Blowing agent(s)
permeate through the
polymer
(n-pentane<i-pentane<c-pentane)
StyroChem

Expansion - Behind the Scenes

• Beads Expand
– Polymer/blowing agent matrix reaches it’s glass
transition temperature (Tg)
(about 85oC, varies according to Mw & BA type)
– Polymer chains become fluid
– Internal pressure created by blowing agent
vaporization push apart [unfold] polymer chains,
creating cells
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Expansion - Behind the Scenes

StyroChem

Expansion - Behind the Scenes

• Beads Expand (cont.)
– Air & steam permeate
into the beads
– As expansion continues,
cell walls become thin
and subjection to high
heat can cause them to
break and rupture
StyroChem

Expansion - Behind the Scenes

• Beads Expand (cont.)
– Throughout expansion, blowing agent(s)
continue(s) to permeate out of the bead at an
increasing rate [depending on temperature and
thickness of cell walls]
(When permeation rate =/> vaporization rate, expansion ceases)
StyroChem Expansion of EPS
(Endotherms, Expansion Rate, & Pentane Loss)
7

A
B
5
C

Blowing agents
Endo <<  T >> Exo
vs. 40 Mesh Glass

4
begin to vaporize

% by Weight
1 ºC Polymer/blowing
agent matrix reaches
Cell walls begin to
its Tg 3
rupture
15X
Expansion 2
begins after
10X Loss of blowing
reaching Tg and
agent becomes
proceeds rapidly 1
5X more rapid as
temperature
increases
0
25 50 75 100 125 150
Temperature, ºC

Differential Thermal Analysis Change in Volume n-Pentane Loss

StyroChem

Primary Expansion Controls

• Temperature
• Time

Density

Time or Temperature
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Temperature Affects
• Greater the temperature
 Softer the polymer
 Increased expansion rate
• May result in uneven expansion due to inconsistent
– pentane content
– bead size
– cell structure
– raw material “carry over” [extreme cases]
 Increased permeation rate of blowing agent
StyroChem

Expansion verses Temperature

• <100oC
– Expansion can be sluggish due to stiff polymer
• >120oC
– Polymer is too soft, blowing agent loss is too rapid
• 110-120oC
– Most efficient use of blowing agent, but beads become sensitive
to shrinkage and heat
• 100-110oC
+ Best compromise
StyroChem

Steam Quality
• Key to Expansion
– Consistent utilities are crucial to achieve consistent
densities with consistent volatile content
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Secondary Expansion Controls

• Volume of Expander
• Molecular Weight
• Blowing Agent
• Bead Size
StyroChem

Expander Volume
Affects the total heat available to each bead
• Things that can change it
– Drop/charge weight
– Lumps in expander that don’t discharge
– Build up on walls or stir blades
StyroChem

Molecular Weight
• The lower the molecular weight,
 Increased expandability
 Increased heat sensitivity
 Increased permeation rate of blowing agent
 Increased shrinkage
 Increased collapse
 Structural strength
StyroChem

Blowing Agent
• Amount
– Higher percentages give greater expandability (to a
point)
– Too high a percentage causes rapid permeation
thus shrinkage, collapse and heat sensitivity
StyroChem

Blowing Agent
• Type
– The longer the blowing agent stays in the bead,
 Increased expandability
 Reduced shrinkage rate
 Increased prepuff life (from expansion to mold)
– Relative retention
n-pentane < i-pentane < c-pentane
StyroChem

Blowing Agent
• Degree of Distribution (has a direct affect on
cell size)
 Expandability
 Heat sensitivity
 Structural strength
 R-Factor (insulation properties)
 Permeation rate
StyroChem
Poor Distribution of Blowing Agent

Blowing Agent
Good Distribution of Blowing Agent
StyroChem

Bead Size
• The larger the bead, the easier it is to achieve
low densities
– Less surface area for blowing agent to permeate
out of
StyroChem

Expander Equipment
• Continuous
• Batch
– Wet
– Dry
StyroChem

Continuous Expanders
• Description
– Material is fed into the bottom of the expansion chamber
where it is subjected to steam under agitation, material
expands and as density decreases, material rises to the top
and out the exit chute.
• Rely on Time & Temperature
StyroChem

Continuous Expanders
• Main Controls
– Feed rate
– Steam pressure (temperature)
– Agitation rate
– Outlet height
– Fresh air introduction (temperature)
StyroChem

Batch Expanders
• Description
– A pre-weighed quantity of material is dropped (or
charged) into the expansion chamber where either
the expander walls are jacketed with steam (dry)
&/or steam is injected into the chamber (wet). An
agitator keeps material moving. Vacuum, purge or
water inject may be used to stop the expansion.
• Rely on time, temperature &/or volume
StyroChem

Batch Expanders
• Main Controls
– Steam pressure (temperature)
– Volume or height
– Time
– Charge weight
– Vacuum or purge time
– Water inject
StyroChem

Density Check
• Consistency is the Key
• Procedure
– Prepuff is overfilled into a known volume (pre-
tared) container. The container is vibrated or
tapped (vibration is more consistent). A straight
edge is used to strike the top level with the canister.
The canister is reweighed and the density
calculated.
StyroChem

Expansion - Behind the Scenes

• Beads Age, a.k.a. Maturing or Stabilizing
– Internal moisture [from condensed steam]
permeates out of the bead
– Air permeates into the bead until internal and
external pressures equal
– Blowing agent(s) continue(s) to permeate out of
the bead
(n-pentane>i-pentane>c-pentane)
StyroChem

Why Age Prepuff?

• Foam becomes more resilient after it’s
stabilized
– Internal vacuum makes beads susceptible to deformation
• Reduces blowing agent levels
– Too high a blowing agent level leads to excessive cool
times and heat sensitivity during molding
• Dry prepuff
– Improves ease of transportation
StyroChem

Volatile Content on Aging

% Volatiles - X185 RX3859

7.00%

6.00%

5.00%
% by V olum e

4.00%

3.00%

R2 = 0.8749

2.00%

1.00%

0.00%
0:00 2:24 4:48 7:12 9:36 12:00 14:24 16:48 19:12 21:36 0:00
Time from Expansion

% Volatiles Poly. (% Volatiles)

StyroChem

Aging
• Key
– A consistent environment is important to provide
prepuff to mold with a consistent volatile content
StyroChem

Aging Time Controls

• Environment
 Air flow Time
 Temperature Time
  Density Time
  Bead Size Time
  Blowing Agent Type(boiling point &
molecular complexity) Time
  Polymer Mw Time
StyroChem

Expansion - Troubleshooting
• High Density
– Insufficient steam pressure/temperature
• check traps, valves, accumulator pressure
• steam flow restricted
Note: by monitoring both steam pressure and steam temperature, you’ll know your
steam quality.

– Insufficient steam times

– Too high a throughput through expander
(continuous) gives raw material carry-over
– Wet material
StyroChem

Expansion - Troubleshooting
• High Density (continued)
– Collapsed or over expanded prepuff
– Low blowing agent content in raw EPS
– Additive problem (block and shape EPS grades)
– Increased drop weight
– Electric eye level too low
StyroChem

Expansion - Troubleshooting
• Low Density
– High steam pressure/temperature
– Longer steam times
– Reduced drop/charge weight
– Wet material
– Over dried material
– High blowing agent content
– Surface additives (block & shape grade EPS)
– Electric eye level too high
StyroChem

Expansion - Troubleshooting
• Density Fluctuations
– Inconsistent steam pressure/temperature
– Inconsistent steam time
– Erratic drop/charge weights
– Inconsistent measuring techniques
– Inconsistent blowing agent content
– High static (affects electric eye)
StyroChem

Expansion - Troubleshooting
• Density Fluctuations (continued)
– Purge valve sticking
– Vacuum problems
– Inconsistent water inject volume
– Poor additive distribution (block & shape grade
EPS)
StyroChem

Expansion - Troubleshooting
• Wet Prepuff
– Common on expander start up
– Wet steam
– Purge valve or vacuum not working
– Poor air flow through fluid bed dryer
– Too much material in the fluid bed dryer
StyroChem

Expansion - Troubleshooting
• Bead Collapse
– Over-expanded
• Excessive steam pressure/temperature
• Excessive steam time
– Too high an expansion rate
– Thermal shock after expansion
– Blades too close to walls or bottom of expansion
chamber
– Wrong additive package (block and shape grade
EPS)
StyroChem

Expansion - Troubleshooting
• Lumping
– Too much moisture (condensate)
– Inadequate stirring
– Excessive steam pressure/temperature
– Anti-lumping agent level too low
– Hot spots in expander
– Excessive steam time
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Expansion - Troubleshooting
• Irregular Prepuff (size/appearance)
– Poor or irregular steam flow
– Hot spots in expander
– Insufficient time in expander
– Contamination of prepuff in raw EPS (double
pass)
– Irregular raw EPS