Plastic, Man-Made Fiber and Film Industries

A Written Report on Industrial Chemical Processes

Submitted to
Engr. Edwin Richard Ortiz
Xavier University- Ateneo de Cagayan

by
Dexby P. de Guzman
BSChE- 5
July 14, 2010
 Plastic Industries
Overview
A plastic is a material that contains a polymerized organic substance of large molecular
weight as an essential ingredient, is solid in its finished state, and at some stage in its
manufacture or its processing into finished articles can be shaped by flow. The plastic industries
have developed and grown then, since their discovery. Plastics can be used in various
applications because of their toughness, water resistance, excellent resistance to corrosion, ease
of fabrication, and remarkable color range.

History

The development of commercial phenolic resin in 1909 by Baekland was the start of the
synthetic plastic industry. His discovery stimulated the search for other plastics. The first plastic
of industrial significance was cellulose nitrate (Celluloid) and was discovered about the middle
of the nineteenth century. It was first used in 1869 by Hyatt who was searching for an ivory
substitute. New polymer materials were then introduced in later times.

Classification

They are divided into thermosetting, thermoplastic, oil soluble and, and protein products.
Thermosetting plastics are processed by heat curing to produce an infusible or insoluble product.
These plastics are formed by condensation polymerization. Condensation polymerization yields
polymers whose recurring units lack certain atoms present in the original monomer. The reaction
takes place by the combination of two or more units and the elimination of a small molecule such
as water, methanol, or hydrogen chloride. On the other hand, thermoplastics are processed by
heating to soften them and cooling to harden them. They are processed by addition
polymerization where a series of conversions produces a polymer having a recurring structural
unit identical with that of the monomer from which it is formed.

On the basis of derivation, they may also be grouped as natural resins, cellulose
derivatives, protein products, and synthetic resins.
Applications and Uses

Plastics are not interchangeable. Each one has its own individual properties and
characteristics that make it useful for certain applications. Shown in Table 1 are some common
resin types, their properties, and applications.

Table 1: Some Common Resin Types, Properties, and Applications

Resin Type Properties Applications

Polyesters Extreme versatility in processing; Construction, auto repair putty,
excellent heat, chemical and flame laminates, skis, fishing rods, boats
resistance, low cost; excellent and aircraft component, coatings,
mechanical and electric properties decorative fixtures, bottles
Polyurethanes Extreme versatility when combined Insulation, foam inner liners for
with other resins, good physical, clothing, rocket fuel binders,
chemical and electrical properties elastomers, adhesives
Polyethers Excellent corrosion resistance to Coatings, pump gears, water-meter
common acids, alkalies and salts; can parts, bearing surfaces, valves
be seam-welded and machined to fit
any type, shape, or size of structure
Epoxies Excellent chemical resistance, good Laminates, adhesives, flooring,
adhesion properties, strong and tough linings, propellers, surface
with low shrinkage during cure, coatings, filament-wound
excellent electrical properties, good structures (rocket cases)
heat resistance
Polyethylene Excellent chemical resistance, low Packaging films and sheets,
power factor, poor mechanical containers, wire cable insulation,
strength, outstanding moisture-vapor pipe, linings, coatings, molds, toys,
resistance, wide degree of flexibility housewares
Polypropylene Colorless and odorless, low density; Housewares, medical equipment
good heat resistance, “unbreakable”, (can be sterilized), appliances,
excellent surface hardness, excellent toys, electronic components,
chemical resistance, good electrical tubings and pipes, fibers and
properties filaments, coatings
Polyvinyl chloride Excellent physical properties, Pipe and tubing, pipe fittings,
 excellent chemical resistance, ease of adhesives, raincoats and baby
processing, relatively low cost, self pants, building panels, wastepaper
extinguishing, ability to be baskets, weather stripping, shoes
compounded with other resins
Acrylics Crystal clarity, outstanding Decorative and structural panels,
weatherability, fair chemical massive glazing domes,
resistance, good impact and tensile automotive lens systems,
strength, resistant to ultraviolet illuminated translucent floor tiles,
exposure windows, and canopies, signs,
coating, adhesives, elastomers
Polystyrene Low cost, ease of processing, Insulation, pipe, foams, cooling
excellent resistance to acids, alkalies, towers, thin-walled containers,
salts; softened by hydrocarbons; appliances, rubbers, automotive
excellent clarity; versatility instruments and panels
Cellulosics Outstanding toughness, high impact Textile and paper finishes,
strength, high dielectric strength, low thickening agents, magnetic tapes,
thermal conductivity, high surface packaging, pipe
luster
Polycarbonates High refractive index, excellent Replacement for metals, safety
chemical, electrical and thermal helmets, lenses, electrical
properties; dimensional stability; components, photographic film,
transparent; self-extinguishing; die casting, insulators
resistance to staining; good creep
resistance
Polyamides Tough, strong, and easily moldable; Unlubricated bearings, fibers,
light; abrasion-resistant; low gears, appliances, sutures, fishing
coefficient of friction, good chemical lines, tires, watch straps,
resistance; self extinguishing packaging, bottles
Raw Materials

The basic raw materials in the plastic production are mainly the monomers and the
chemical intermediates. The monomers include vinyl chloride, ethylene, propylene and similar
simple hydrocarbons. On the other hand, the chemical intermediates include phenol,
formaldehyde, hexamethylenetetramine, phthalic anhydride, methyl acrylate and methacrylate.
Other raw materials such as natural products (i.e. cellulose), plasticizers, fillers, and
reinforcements are also added to alter the properties of the plastic products.

Manufacturing Processes

There are four general polymerization procedures: (1) bulk polymerization, (2) solution
polymerization, (3) suspension polymerization, and (4) emulsion polymerization.

1. Bulk polymerization is carried out in the liquid or vapor state. The monomers and
activator are mixed in a reactor and heated or cooled as needed.

2. Solution polymerization is used when the exothermic heat is too great to be controlled
in bulk polymerization. The monomer and initiator are dissolved in a nonreactive solvent
which serves to slow the reaction and thus moderate the heat given off.

3. Suspension polymerization is the process where the monomer is suspended in water by

agitation, and stabilizers (i.e. talc, fuller’s earth, and bentonite) are added to stabilize the
suspension and prevent polymer globules from adhering to each other.

4. Emulsion polymerization is similar to suspension polymerization but the monomer is

broken up into droplets that form aggregates called micelles. The monomer is on the
interior of the micelles, and the initiator is in the water. Soap or another emulsifying
agent is used to stabilize the micelles.

For the purpose of discussion, let us consider a very common plastic, polyethylene. It is
the first and the largest in production of polyolefin plastic. Two types of polyethylene are
available. High-density polyethylene (HDPE), produced by low-pressure methods, is used
mainly for blow-molded containers and injection-molded articles and pipe. Low-density
polyethylene (LDPE), produced by high-pressure methods, is used mainly for plastic films.

The process flow of low-density polyethylene (LDPE) is shown in Figure 1. It is a high-

pressure process that uses oxygen or peroxides for catalysts. This is the manufacturing process
being considered in the report. Process descriptions will be based on this technology.
 Figure 1: Process Flow Diagram for LDPE Production

Individual Process Descriptions

1. Demethanization and Deethanization – The feed for the process is a mixture of

methane, ethane, and ethylene. Since ethylene is the monomer to be used ethylene has to
be separated from methane and ethane. High purity ethylene is used (99.8%).

2. Compression of Ethylene and Catalyst - Ethylene and the catalyst (free-radical yielding
such as oxygen or peroxide) are compressed to operating pressure (150 MPa).

3. Solution Polymerization – In a tubular reactor maintained at 190°C, solution

polymerization occurs to convert ethylene to polyethylene. About 30% conversion is
achieved per pass.

4. High Pressure Separation – At this stage, the unconverted ethylene is removed and
recycled.
 5. Extrusion and Pelletizing – The polyethylene is extruded and pelletized.

6. Quench Cooling – This hardens the polyethylene pellets by addition of cold water.

7. Water Separation and Drying – These involve the removal of water from the pellets to
obtain the final product.

Engineering Plastics

They are high- strength high-performance materials that can be substituted for many
metal uses.

References:

1. Austin, G.T. Shreve’s Chemical Process Industries (5th Ed). New York: McGraw-Hill,
Inc., 1984.

2. Meyers, R. Handbook of Petrochemicals Production Processes. New York: The

McGraw-Hill Companies, Inc., 2005.

Man-Made Fiber and Film Industries

Overview

Fibers were originally of natural origin and were produced from wool, silk, cotton, flax,
and similar materials. The first man-made fibers were made by Swan in 1883 when he squirted a
solution of cellulose nitrate in acetic acid through holes. The first truly synthetic fiber was nylon
(a polyamide) introduced in 1940. Until the middle 1950’s, the principal synthetic fibers were
polyamides, polyesters, acrylics, and polyolefins. Thereon, research and developments have been
made to commercialize the production of other synthetic fibers.

Fibers have three important general properties: length, crimp and denier. According to
length, fibers can either be continuous filaments or short fibers. The curl or waviness placed in
synthetic fibers by chemical or mechanical action is called crimp. Lastly, denier is a measure of
the weight of fibers per unit length.

Classification

Man-made fibers are classified chemically by the method of spinning. Spinning

procedures are divided into melt, dry and wet. Melt spinning involves pumping molten polymer
through capillaries or spinnerets and the polymer streams that emerge are solidified by
quenching in cool air. In dry spinning, the polymer is dissolved in a suitable organic solvent. The
solution is forced through spinnerets and dry filaments are formed upon evaporation of the
solvent. Wet spinning involves spinning of a solution of polymer and coagulation of the fiber in
a chemical bath.

Synthetic Fibers and their Applications

1. Polyamides – Nylon 6.6 was the first all-synthetic fiber made commercially and opened
up the entire field. It is the product resulting from the polymerization of adipic acid and
hexamethylene diamine. They are used in home furnishings, especially carpets.

2. Polyesters – The common polyester fibers are polymers of the ester formed from
dimethyl terephthalate and ethylene glycol.

3. Acrylics and Modacrylics – polyacrylonitrile is the major component of several

industrial textile fibers.

4. Vinyls and Vinylidines

 A. Saran is the copolymer of vinyl chloride and and vinylidene chloride. It is resistant to
mildew, bacterial and insect attack. Automobile seat covers and home upholstery are
its prime applications.

B. Vinyon is the trade name of copolymers of 90% vinyl chloride and 10% vinyl acetate.

Resistance to acids and alkalies, sunlight, and aging makes Vinyon useful in heat-
sealing fabrics and clothing.

5. Spandex – a generic name to a manufacture fiber in which the fiber-forming substance is

a long chain synthetic polymer comprising at least 85% of segmented polyurethane. It is
used in foundation garments, hose, swimwear and other elastic products.

6. Polyolefins – fibers are usually made of polyethylene or polypropylene. They excel in

special cases, such as ropes, laundy nets, carpets, blankets and backing for tuffed carpets,
but are difficult to dye and their melting point is low.

7. Fluorocarbons – Teflon is polytetrafluoroethylene and as fiber or film is nonflammable

and highly resistant to oxidation and the action of chemicals, including strong acids,
alkalies and oxidizing agents. It is widely used in pump packings and shaft bearings.

8. Glass Fibers – are used for electrical insulation in motors and generators, structural
reinforcement of plastics, fire-proof wall coverings and tire cords.

Multicomponent fibers

Multicomponent fibers have been prepared which possess superior properties to either
component if spun alone. They correspond to better dyeability, permanent crimp, or silklike feel,
etc.

Cellulosic fibers

1. Rayon and Cellulose Acetate – are primarily used in women’s apparel, draperies,
upholstery, and blends with wool in carpet and rugs.
 2. Carbon fibers – are used for reinforcing plastics which can be used for sporting goods
and engineering plastics.

Finishing and Dyeing of Textiles

Dyeing, bleaching, printing, and special finishing (such as for crease recovery,
dimensional stability, resistance to microbial attack and ultraviolet light) involve unit operations
such as filtering, heating, cooling, evaporation and mixing. The modification of fibers and
fabrics by special treatments to change their properties and improve their usefulness is
increasing.

Films

Films are made from different polymers such as polyesters, polyvinyl chloride, etc.

3 Common Types of Processing:

1. Slit-die process – produces flat sheets by extruding the molten polymer through a slit-die
into a quenching water bath or onto a chilled roller.

2. Blow-extrusion Process – produces tubular film by using air pressure to force the molten
polymer around a mandrel.

3. Calendering – preparation of film is produced by feeding a plastic mix of polymer,

stabilizer, and plasticizers between two heated roll where it is squeezed into a film.

Process Flow Diagrams

For discussion, the manufacturing of nylon yarns will be tackled. Figure 2 is the flow
diagram of the manufacturing process.
 Figure 2: Process Flow Diagram of Nylon Yarn Manufacturing

Raw Materials

The raw materials for fiber production are just the same as in plastics production and will
depend on the type of material the fiber is made up of. For the production of nylon yarn,
however, the raw materials cited are adipic acid and hexamethylene diamine (“hexa”). Utilities
such as steam and water will also be used.

Individual Process Description

1. Nylon Salt Formation – The reaction between equimolar proportions of the two raw
materials produces nylon salt solution. Acetic acid is added to the (“hexa”) to to stabilize
chain length.

2. Evaporation – The water produced from the reaction is evaporated in an evaporator and
a jacketed autoclave. In the jacketed autoclave, pure nitrogen at 175-345 kPa forces the
material downward. TiO2 dispersion is also added in the

3. Casting Wheel – Each 900-kg batch is extruded as rapidly as possible. A ribbon of

polymer about 30 cm wide and 6 mm thick flows on the 1.8-m cat drum. Water sprays on
 the inside cools and harden the underside of the ribbon, the outer is cooled by air and
water.

4. Blender and Hopper – The ribbons are cut into small chips or flakes, blended and
emptied to hoppers.

5. Melt Spinning – A typical spinning unit is composed of a metal vessel surrounded by a

Dowtherm vapor heated jacket which keeps the temperature of the vessel above melting
temperature (263°C). As the nylon flake enters the vessel, it strikes a grid, where it melts
and flows through to the melt chamber below. The molten polymer passes through the
portholes in this chamber to gear spinning pump. They deliver it to a sand filter, which is
followed by screens and a spinneret plate. The filaments are solidified by air and passed
in a bundle through steam-humidifying chamber.

6. Cold Drawing – After lubrication on a finish roll, the yarn is stretched or drawn to the
desired degree.

7. Bobbin – The nylon yarn passes through a bobbin system and is shipped to various
manufacturers for processing.

Reference

1. Austin, G.T. Shreve’s Chemical Process Industries (5th Ed). New York: McGraw-Hill,
Inc., 1984.