Polyolefins, Polyethylene, Polypropylene & Polystyrene Video Lecture | Chemical Technology - Chemical Engineering

We are discussing the organic chemical technology
course, module 08 and that is about polymer
elastomer and synthetic, synthetic fiber that
is the we are having the 8 lecture in this.
Already I discussed in lecture 01 I talk about
the general introduction to the polymer elastomer
and synthetic fiber, what are the various
step of the polymer elastomer synthetic fiber.
And how the what are the driving force of
the development of these three important class
of the polymer, that is the plastic elastomer
and synthetic fiber.
And in that also we discussed the various
type of the reaction that is taken in the
place in the manufacture of the all the polymers,
within the elastomer, synthetic fiber all
the polymer as such. So, the and the different
type of the reaction different type of the
process that you are because those process
are also being used in the various, whether
you are manufacturing the poly olefins are
others polymers.
And so the this lecture that will be about
the polyolefin’s, polyethylene and polypropylene
and polystyrene because these are the three
important polymers specially the ethylene
and the propylene that has come in the large
number of the a large increase in the capacity.
That is in the with the coming of the petrochemicals
or the cracker plants naphtha cracker and
the gas cracker, and the with the availability
of the ethylene, and the propylene. And the
similarly, in case of the polystyrene they
have availability of the benzene for making
the ethyl benzene and ethyl benzene to styrene.
So, this will be the coverage of the lecture
introduction general about the polyolefins
and then you will be discussing about the
polyethylene. And polypropylene catalyst,
and development for the various step of the
catalyst, we are using in case of the polyolefin.
So, metallocene catalyst they have been actually
the change in the whole pattern of the making
of the polymers. In the polypropylene what
are the various step of the polypropylene
that you are making that will discuss. Process
technology for manufacturing of these two
in detail will be discussing, and then the
polystyrene so this will be the broad coverage
of the lecture.
So, polyolefin’s are high polymer produced
by polymerization of olefin, polyethylene
the various as I told you the various grade
of the polyethylenes are L D P E low density,
high density. Linear low density polyethylene
and the polypropylene also in the polypropylene
different grade of the polypropylenes are
there. So, these are the main polyolefins
that we are producing.
Polyolefin’s such as polyethylene and polypropylene
are commodity plastic found in application
in vary from house hold items such as, grocery
bags, containers, carpets, toys, appliances
to high technical product such as engineering
plastic, industrial pipes, automotive parts,
medical appliances such like in case of the
polypropylene. That is finding large application
in the medical appliances and even the prosthetic
in plant. Because now the we are having now
we are talking about the artificial part of
the body. So, from where, so we are using
different type of the polymers there, even
in case of the a large variety complex are
also available.
So, ethylene and propylene are the monomers
for the polyethylene and the poly and the
polypropylene because you see the these are
the two. As I told you the starting also the
ethylene and the propylene there availability
from the petrochemical complexes, that has
played an important role in the development
of these two major product.
In India the domestic polymer industry is
dominated by polyolefin’s main the polyethylene
and the propylene. And you see the in India
the so far the polyolefin are concern reliance,
haldia and the Gale these are the major and
now the I O C that is also coming, and the
O N G C after coming of the O N G C they will
also a major player in case of the, but at
the this stage the reliance then haldia and
the Gale these are the three major. But still
the major shares is of the Reliance so for
the polyethylene and polypropylene is concerned.
Polyethylene is the one of the most widely
used thermoplastic and its even increasing
demand is due to availability of monomer ethylene,
which I told you the from the naphtha and
the gas cracker. First polyethylene plant
that was based on the ethylene from molasses
that was the actually, they started the small
polyethylene plant with the based on the ethylene
from the molasses. And then it was the after
coming of the gas small cracker plant naphtha
cracker plant by union carbide in Bombay.
So therefore the smaller plant capacity that
was, but after that after coming of the I
P C L now reliance industry and then the reliance
industry. And then the reliance hazira project
in k l for. So, lot of the production path
changes in the production that has communication
of the polyethylene as well as the polypropelene.
Some of the driving forces other deriving
forces is the fast growth of the use of polyethylene,
or ease of the processing the polymers that
is the relative cost they resistance to chemical
and its flexibility. These are the some of
the major deriving force for the adaptability
of the polyethylene. So, as I told you we
are making the different grade of the polyethylene.
So, low density polyethylene branch produce
by high pressure.
So, L D P E medium density depending upon
the density this also 0.940. So, 0.920, 0.940,
0.94. So depending upon the density you can
differentiate whether it is the and even the
crystallinity that is also changing L P D
E melting point. Slight difference in the
melting point is also there and the linear
high density to ultra high density polymer
that we are also making in case of the…
So these are the abroad grade of the polyethylene
that you are making, this is the some of the
your application your findings in case of
the polyethylene packaging industry...
also we are having the packaging many of the
convictional glass that has been replaced
with the it may be the polyethylene it may
be the p e t, in case of the mineral water.
So, all those thing that is the for the containers
for packaging edible oil, processed food lubricants
detergents, chemical, pesticide, industrial
crates and the containers carrier bags house
wares, ropes and twines pipes of water supply
everywhere they are using in some other either
although the p v c is more. These are the
some of the so far the piping is concern I
was telling about the p v c, more p v c pipes
in the irrigation and the house hold and is
there.
So, these are the some of the major catalyst
development in the in case of the polyolefin
Ziegler, Ziegler Natta catalyst, Phillips
chrome, metallocene that has come in big way
in case of the manufacture of the polypropylene.
Polyolefins by Metallocene catalyst Metallocene
catalyst have created revolution in the Polyolefin
production, on account of their unprecedented
potential in tailoring the molecular structure.
It has resulted in various new application
of the polyolefin, this is the actually the
now the processes using these catalyst for
polypropylene they have lot of changes in
the quality of the product is there.
In Metallocene catalyst, each catalyst molecule
has same activity and accessibility to the
monomer, which first not there in other type
of the catalyst. So that is very important
Metallocene catalyst has inherent ability
to produce extremely uniform home homopolymer
and co-polymer of a very narrow molecular
weight distribution higher temp stability.
Very narrow molecular distribution means,
more uniformity is there so this is the advantage
why the metals and catalyst they have enter
in the manufacturing of the and the why the,
why it availability of the Metallocene catalyst
is there.
This is the just comparison, why the, what
are the advantage important characteristics
activity and its very high activity towards
mono co and the ter-polymerisation with the
very high turnover time. Then the produce
very high molecular weight, very sensitive
to the hydrogen and only trace amount is required
to control molecular. Highly stereospecific
in nature, comonomer is highly random and
the homogenous.
Can incorporate polar monomers, provide polymers
which are highly linear polymers exhibit low
heat temp. And then the polymers with low
haze low, high the hexane extractable mechanical
properties, tailoring of the products can
produce tailor made product. So, these are
the some of the characteristics of the metallocene
catalyst and the copolymers, and why we are
using more now the metallocene character based
process are there. Now, let us discuss about
the polyethylene. As I discuss these are the
some of the actually the broad classification
already, we discussed about the low density
high density and the accordingly the process
technology that has been also developed.
This is the molecular mass advantage, low
cost excellent dielectric properties moisture
resistance, very good chemical resistance,
availability in the food grade, process by
all thermoplastic methods. Several processes
has been commercialized for the manufacture
of polyethylene with varying density.
This is how the branch and the linear polyethylene
look like, polyethylene process actually.
As I told you there are various process licensor
and different type of the process that has
not develop for producing wide variety of
the polyethylene that is one of process.
Sherilene gas phase process very low density
polyethylene. So that is L L D P, V L D P
they are also called this process V L D P,
L L D P high density polyethylene and then
the Ziegler Natta, titanium based catalyst
that we are using. And basell is the your
process licensor borster p e biomodal and
unimodal L L D P Ziegler Natta catalyst. And
licensor the borealis A S.
Innovene gas phase that is Ziegler Natta catalyst,
that we are using chromium or the Metallocene
catalyst that can be used licensor BP. High
pressure I C I process for L D P E Ziegler
low process for H D P E, Philips process linear
polyethylene licensor chevron Philips, exxon
mobil, L D P E home homopolymer and the ethyl
acetate copolymer.
Other process licensor C X process for H D
P E, M D PE low slurry process licensor is
the mitsui chemicals. Unipol process L L D
P, H D P E fluidized bed reactor as we are
using in this process. Then the hostalean
process H D P E using stirred tank, high activity
ziegler catalyst we are using here. Licensor
basell polyolefins then the lupotech T S or
the T M modular reactor process, this is the
L D P E homopolymer EVA copolymer licensor
is the your basell polyolefins. So, these
are the some of the commercial process that
is available for making of the different grade
of the polyethylene.
This is the again innovene process polymerization
in fluidized bed reactor using Ziegler Natta
catalyst. This is the temperature condition
and this is the product that you are getting.
Broster process uses slightly more detail
about that process that was not there only
I gave the various process. So, here in case
of the broster process usage gas phase low
pressure reactor, Ziegler Natta catalyst comonomer
hydrogen pre-polymerisation in the slurry
loop reactor and a fluidized bed reactor temperature
75 to 100 degree centigrade. Bimodal and unimodal
L L D P E and the medium density polyethylene.
High pressure free radicals process by exxon
chemicals. Polymerization occurs in autoclave
reactors or the tubular reactor and the L
L D P E linear low density polyethylene that
you are making by this process.
Speriline gas phase process, Montell technology
that we are having the polymerization in gas
phase reactor using the Ziegler Natta catalyst.
Here the linear low density polyethylene or
the high density polyethylene that is the
product that we are getting.
Philips low polyethylene low density polyethylene
process polymerization take not linear polyethylene
process. The polymerization takes place in
as isobutene slurry using very high activity
properierty catalyst in loop reactor. So,
this is the linear polyethylene.
So, unipol process the process produces low
density polyethylene and high density polyethylene
using low pressure in the gas phase. And this
is the fluidized bed reactor in the fluidized
bed reactor after the polymerization is completed,
then it will go to the cyclone the separation
of the catalyst that will take and the polyethylene,
that will be getting from here. And then it
is with the recycle unreacted part that will
be gas that will be recycle here. Here it
will be separation of the polyethylene that
will be there.
And dupont sclairtech process is a broad range
of the polyethylene with a density varying
from 0.919 to 0.9605 varying melt indexcan
can be produce. Various melt indexcan that
is the actually the this is the one of the
new process or the modified process where
the high varying melt indexcan can be made
by this process. The process can be divided
into three major area reaction area, recycle
recovery area, extrusion and finishing and
dowtherm vaporizer these are the some of the
units various steps are there.
This is the why sclairtech process that is
the butene here we are using the copolymers
cyclohexane solvent and ethylene monomer,
that is going to the polymerization reactor.
And then the ethylene butene cyclohexane again
that is the recycle and then the finishing
after the catalyst and here the co-catalyst
deactivator, additive and the polymer pellets
that you are getting in this process. Now,
let us these this was the various processes
that is available for making of the polyethylene.
Now we will be discussing about the polypropylene.
Polypropylene is a low density semi crystalline
stereo regular polymer, which exists in three
forms isotactic, syndiotactic and the atactic.
So, these are the three forms of the polypropylene
that prior to 1954 only cationic or the free
radical catalysts were known to promote the
polymerization of the propylene.
This is the actually if you see the, this
is the courtesy of the reliance industry this
is the because they are the main major manufacture
of the polypropylene. And so the you see the
as I told you the in case of the hospital
and there the conventional in the syringes
and the bottles glass was, that has completely
replaced the replaced by polypropylene syringes.
That is the 1.5 billion use now we are with
the coming of the polypropylene at a very
cheaper rate, now it is the disposable syringes
million of mask that we are using caps uses
in the hospitals.
These are all actually the polypropylene fibers
are also that is being used divers are the
rise in the senior citizen population, health
awareness and enhance more disposable, India
and the medical destination polypropylene
usage 30 kilo tons per annum. So good growth
in the health care industry and these are
the some of the this the syringe and the bottles
glucose bottles earlier that is to be the
glass. So, you see the even the this day mask
another thing that is also we are using the...
Similarly you see the other application of
the rigid packing, this is also one of the
here the driver growth driver for the polypropylene
are the increase consumption, and the growth
India organize retail good processing, horticulture
dairy sector, increasing health safety concern
disposable single serve packaging formats.
So, polypropylene that is 250 kilo tons new
application are also there glass replacement,
multiwall containers are the growth drivers.
So, these are the some of the containers made
of the polypropylene.
Phosphoric acid because that was the earlier
in the catalyst phosphoric problem. The phosphoric
acid gave oily products later BF 3, alumina
silica H2So4, hydrofluoric acid aluminum halides
were used as catalyst in polymerizing polypropylene,
polymerizing the propylene. But the Ziegler
Natta catalyst that was the mostly widely
used catalyst.
There are structure in the polypropylene the
ratio of the various structure depends upon
the catalyst, and the operating condition
used. So, already I told you the isotactic
or stereo or the regular and the different
type of the actually the configuration are
there.
The atactic there is another the second and
the third is the syndiotactic.
Ethylene propylene co polymers are also there
using Ziegler Natta catalyst ethylene and
propylene can be copolymerized to yield elastomers.
Technologies used by various produces are
different, but involve the following steps.
Polymerization of polypropylene by continuous
process, copolymerization of ethylene and
the propylene with the first polymers using
the same catalyst in the second step.
So, this is the polypropylene process that
we are using the propylene that is going to
the polymerization, then the resin degassing
pelletizing and then the products. So, this
is the simplest actually the one of the process,
where you are using the that you can made
how the we are making the polypropylene pallets.
This is the unipol process where we are using
the your fluidize reactor propylene, that
is going to the polymerization reactor. And
then the here we are having the reactor one
and reactor two, defencing reactor and then
finally, the polypropylene resin that we are
getting in the final stage. So, this is the
process unipol process where we are using
the fluidized bed reactor, this was I was
telling about the why the three structure
they are very important in case of the polypropylene.
That is the isotactic stereo regular boiling
n-heptane insoluble highly crystalline high
temperature. The atactic stereo irregularity
generally soluble in boiling n-heptane low
melting temp. Here in case of the syndiotactic
that is stereo regularity different that isotactic
very low degree of crystallinity not much
in the practical use.
These are the summary of the processes in
case of the polypropylene, that is available
that the borstar polypropylene process licensor
borealis, and the produced by bulk polymerisation
loop reactor followed by the final gas phase
reactor. So two step process that is the spheripol
process montell technology, homopolymer and
random copolymer polymerisation takes place
in liquid propylene in a loop reactor. Heterophasic
impact co polymerisation is done by adding
a gas in the gas phase reactor.
Then the novolen process that the polymerisation
is conducted in one or two gas phase reactors
connected in series. Union carbide gas that
gas phase unipol process a wide range of polypropylene
is made in gas phase fluidized bed reactor,
using proprietary catalyst. Then the sperizone
process technology that is new proprietary
gaseous technology based on the multizone
circulating system that is there.
This process spheripol process this process
can produce a broad range of propylene polymers
including the homopolymer, polypropylene random
copolymer terpolymer. Teropolymer means the
two this monomer additional monomer that may
be there. Heterophasic impact specialty impact
as well as high stiffness copolymer, in this
process homopolymer and the copolymer polymerization
takes place in liquid propylene with loop
reactor. Heterophasic impact copolymerization
is achieved by adding as gas phase reactor.
This is the process which you are having the
two stages a reactor here, the finishing the
for this is called the impact reactor. And
the finally, we will be getting the your polypropylene
then the process. Now let us this was about
the polypropylene manufacture and as I told
you the polypropylene that was the actually,
the automobile sector, that has come in a
big way and the huge amount of the polypropylene
that we are using in the automobile sector
where the we are making the pumper other material
of the polypropylene. That is after certainly
after the processing that polypropylene that
we are using. So, another important this polystyrene
is a important thermoplastic when styrene
is copolymers different type of the combination
of the styrene with the acrylonitrile butadiene
is there.
So, when styrene is copolymerized with the
acrylonitrile the polymer is styrene acrylonitrile
san resin has a higher tensile strength, then
the polystyrene. Next is the acrylonitrile
because in case of the combination of the
polystyrene acrylonitrile butadiene styrene
polymer has special mechanical properties,
and find application as the engineering plastic.
Styrene as I discussed in the while discussing
the petrochemicals, we discuss the manufacture
of styrene that was the from the ethyl benzene
dehydrogenation of the ethyl benzene, which
is made by the alkylation of the benzene.
So, the benzene and the ethylene that was
the two major raw for the styrene and so with
the development at the petrochemical industry.
Now, we have been able to make the polystyrene
at the cheaper rate and polystyrene that is
fine wide application in the industry.
So styrene co polymerized with the acrylonitrile
resulting in the acrylonitrile resulting the
san polymers is characterized with the high
tensile strength then the polystyrene. So,
this is the reason because this special, specialized
plastic we are using this styrene acrylonitrile
plastic that we are using. Another important
styrene co copolymer that which I told that
the acrylonitrile butadiene ABS plastic which
is find use in the engineering plastic, and
is characterized with the special mechanical
properties. Even you are having the polymer
metal composite also.
So, ABS they are also being used in case of
the your some of the composite in the automobile
sector also. That is the important in case
of the when we are acrylonitrile and butadienes
are also there when we are polymerizing the
styrene acrylonitrile butadiene.
We are discussing the various polystyrene
process technologies and one of the processes
is nova's polystyrene process, polystyrene
technology. The process produces a complete
range of general purpose crystal and the impact
resistant polystyrene, this is based on the
bulk continuous polymerization technique.
This is the polystyrene process technology
by UOP, this process is based on continuous
bulk polymerization to produce a wide range
of general purpose, polystyrene because we
are having the different gate of the one is
the general purposed polystyrene and at the
high impact polystyrene and the expendable
also. But here we are making this two type
of the general purpose and the high impact
polystyrene and styrene niclo nitrate resin.
A typical plant included feed preparation
reactor section, devolatilisation section,
monomer recovery section, water removal product
pelletizing, and the bulk resin handling.
Another quality of the your this polystyrene
that is the high impact polystyrene. So, high
impact polystyrene process, this is the process
licensor is heaviest global BP, chemical.
The process produces wide range of general
purpose and high impact polystyrene via bulk
polymerization process. So, another great
of the polystyrene that is the expandable
polystyrene EPS which called it the EPS expandable
polystyrene. So, this is the process technology
where BP, chemical NABABB lumus global, here
in this process you are making the expandable
polystyrene.
The process produces regular and the flame
retardant grade EPS it is batch suspension
process followed by continuous dewatering,
drying and size classification. So, this was
the about the various grade of the polystyrene,
we discuss in this lecture about the polyolefin,
polyethylene and the polypropylene, and the
various process technology. And as I told
you the major driver the for this development
of the polymer industry, that has been the
availability of the raw material especial
ethylene, propylene, benzene from the petro-chemical
complexes.
And so far the in the near future polyolefin
they are going to be play a very important
role, and with the coming of the metals and
the catalyst definitely the polypropylene
that will be use for more specialize purpose
also. In the next lecture, will be lecture
three will be discussing about the polyvinyl
chloride and some other polymers also, which
are finding wide application.
Same thing has been in case of the polyvinyl
chloride also where the petrochemical complex
specially, the naphtha cracker they have played
an important role in the manufacture of the
polyvinyl chloride. And the cost reduction
because they are p v c as I told you the while
in beginning also that was the acetylene root
from the acetylene to that was produce from
the calcium carbide. So, in the next lecture
we discussing about the p v c.