Polyolefins and their influence on single use technology

Engineering Conferences InternationalECI Digital ArchivesSingle-Use Technologies: Bridging Polymer Scienceto Biotechnology Applications Proceedings

Fall 10-19-2015

Polyolefins and their influence on single usetechnology for bioprocessingAmy PlanconSABIC Europe, amy.plancon@sabic.com

Marnik VaesSABIC Europe, marnik.vaes@sabic.com

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This Conference Proceeding is brought to you for free and open access by the Proceedings at ECI Digital Archives. It has been accepted for inclusion inSingle-Use Technologies: Bridging Polymer Science to Biotechnology Applications by an authorized administrator of ECI Digital Archives. For moreinformation, please contact franco@bepress.com.

Recommended CitationAmy Plancon and Marnik Vaes, "Polyolefins and their influence on single use technology for bioprocessing" in "Single-UseTechnologies: Bridging Polymer Science to Biotechnology Applications", Ekta Mahajan, Genentech, Inc., USA Gary Lye, UniversityCollege London, UK Eds, ECI Symposium Series, (2015). http://dc.engconfintl.org/biopoly/5

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSINGMarnik Vaes & Amy Plancon

Single-Use Technologies: Bridging Polymer Science to Biotechnology Applications18-21 October 2015Leesburg, Virginia USA

CONTENT

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING

No. 2

CONTENT

• INTRODUCTION: CHEMISTRY THAT MATTERS™

• POLYOLEFINSPOLYETHYLENE & POLYPROPYLENE

• KEY PROPERTIES PHYSICAL, MECHANICAL, CHEMICAL & ADDITIVES

• SUMMARYCHEMISTRY THAT MATTERS™ FOR SINGLE USE TECHNOLOGY

INTRODUCTION:CHEMISTRY THAT MATTERS™

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING

No. 4

SABIC IN NUMBERS

1976, our beginning39 years of growth

3rd largest global diversified chemical company* 116th largest public company in the world*

91 B$ total assets50 B$ annual revenue6.2 B$ net income

40,000 employees50 countries5 Strategic Business Units

64 world-class plants worldwide5 key geographies with innovation hubs150 new products each year10,640 global patent filings

* Forbes 2015

No. 5

PRODUCTION HAS MULTIPLIED BY 5 IN 20 YEARS

A high rate of growth…

Pro

duct

ion

(mill

ion

tons

)

…reaching 69.7M metric tons in 2014

Metals

5.869

Fertilizers

6.848

Chemicals

43.354

Polymers

11.673

Performance Chemicals

0.476

Innovative Plastics

1.505

0

10

20

30

40

50

60

70

80

1985 1990 1995 2000 2005 2010 2011 2012 2013 2014

22

13

28

47

6970.5

6

67 68.5 69.7

No. 6

COMPREHENSIVE HEALTHCARE SOLUTIONS

No. 7

WORKING TOGETHER: CHEMISTRY THAT MATTERS™

COST

BUILDING BRIDGES

SUSTAINABILITY & RECYCLING

NO-CHANGE

GUARANTEE

EXTRACTABLES

AND LEACHABLES

SABIC’S IN DEPTH

POLYMER

KNOWLEGE

PATIENTSAFETY

SECURITY OFSUPPLY

SUS PRODUCT

REQUIREMENTS

REGULATORY

Help our customers grow so as to help preserve and improve human life around the world

No. 8

GLOBAL POLYOLEFIN MARKET

98,33%150444

0,95%1459

0,72%1097

2556

Global Healthcare Polyolefin Demand, KT

Global Non-HC PO Global HC Non-medical Global HC Medical

99,50%1091,51

0,50%5,49

Polyolefins in SUS (KT, estimated)

Global HC EP/USP SUS

* Source: BCC Research 2013** SABIC Market Intelligence*** Estimated

HCMedical grade

HCNon-Medical grade

Medical grade

***

***

***

***Healthcare

Medical grade = EP and USP compliant materials

No. 9

Input• LDPE• HDPE• PP• Additives

Process• Injection

molding• Extrusion• Film (blown,

cast)• Printing• Filling• Sterilization

Output (SUS)• Mechanical

• Modulus• Impact• Rupture

• Chemical• Extractables

& leachables

Single U

se Technology

POLYOLEFINS & INFLUENCE ON SUT

CHEMISTRY THAT MATTERS™ for Single Use Technology

POLYOLEFINS:POLYETHYLENE & POLYPROPYLENE

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING

No. 11

FROM OIL TO OLEFINS

CrackersRefineryOil and Gas

EthylenePropylene

No. 12

POLYMERIZATION PROCESS

RadicalsHigh pressure

process

LDPE

Reaction through

Used technology

CatalystLow pressure

process

ULDPE, LLDPE, MDPE, HDPE

Ethylene (C2) C CH

H

H

H

No. 13

POLYETHYLENE (C2) STRUCTURE

LDPE: Branched HDPE: Linear LLDPE: Linear

Chemical structure

Molecular structure

LLDPE contains side chains by co-polymerization of e thylene with monomer (e.g. butane, hexane, etc)

No. 14

POLYPROPYLENE (C3) STRUCTURE

Homopolymer(no ethylene)

Random(<10% ethylene)

Impact Copolymer(>30% ethylene)

Chemical structure

Molecular structure

KEY PROPERTIES: PHYSICALMECHANICALCHEMICAL & ADDITIVES

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING

No. 16

• Polymers have a distribution of chain lengths

• Production technology allows some tailoring of MWD:

• Narrow distribution for film grades

• Broader distribution for injection molding grades

• Melt Flow Index (MFI) is inversely proportional to MW

PHYSICAL PROPERTIES: MOLECULAR WEIGHT DISTRIBUTION (MWD)

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

2,0 3,0 4,0 5,0 6,0 7,0 8,0

LLDPE (C4)

LDPE (Autoclave)

LDPE (Tubular)

Chain lengths range from very short… …to very long

No. 17

PHYSICAL PROPERTIES: DENSITY & CRYSTALLINITY

Plastomers/rubbers ULDPE HDPELDPE/LLDPE

860 970940920890

75%50%40%30%10% 20%

Density (kg/m 3)

Crystallinity

Chain regularity

LDPE has Long Chain Branches and Short Chain Branch es

No. 18

MECHANICAL PROPERTIES

Tensile Modulus • Resistance of materials to tensile force.

Flex Modulus• Resistance of materials to flexural force

Izod Impact• Resistance of materials to impact at

several temperatures

No. 19

MECHANICAL PROPERTIES: IMPACT STRENGTH

Impact strength is influenced by melt index and den sity

No. 20

CHEMICAL PROPERTIES: TYPES OF ADDITIVES

Modifiers

• Impact Modifiers• Nucleating

agents/clarifiers• Organic

Peroxides• Plasticizers

Property Extenders

• Antioxidants• Antistatic agents• Heat stabilizers• Light stabilizers

Processing Aids

• Anti-blocking agents

• Lubricants/mold release

• Slip agents

Additives are used to improve processing of polymer s and to enhance their properties

Improves film toughness

• Inhibits gels• Increases

gamma stability

• Facilitates bag opening

• Minimizes blocking

No. 21

Energy

Metal Ions

CHEMICAL PROPERTIES: OXIDATION & POLYMER DEGRADATION

• Mechanical stress

• Heat• Light

• Catalytical residue

• Impurities • Co-additives

PeracidsPeroxides

Alcohols Ketones

AcidsAldehydes

AUTO-OXIDATION

No. 22

CHEMICAL PROPERTIES: OXIDATION & ANTIOXIDANTS

Polymerization

Extrusion

StorageInjection molding

Irradiation

Why do we use antioxidants?

Auto-oxidation ALWAYS takes place

No. 23

CHEMICAL PROPERTIES: DEGRADATION CHEMISTRY

Various Oxidation Products

Chain Scission Property deterioration

Chain scission produces small chains that degrade m echanical properties

No. 24

CHEMICAL PROPERTIES: ANTIOXIDANTS & DEGRADATION

Primary (Phenolic)

Secondary (Phosphite)

Antioxidants are used in most polymer resins to pre vent oxidative degradation

Oxidative degradation can lead to gels and black sp ecs in PE film

No. 25

CHEMICAL PROPERTIES: EXTRACTABLES & LEACHABLES

Solvent BP GC-MSUPLC-HRMS(+ & - APCI)

Headspace

Ethanol 78 °C ➼ ➼

DCM 40 °C ➼ ➼

Hexane 69 °C ➼ ➼

Water pH 2, 7, 9 100 °C ➼ ➼

Neat “150 °C” ➼

Degradation products can impact E&L

CHEMISTRY THAT MATTERS™: ensure “what comes out” will work in SUT

SUMMARY:CHEMISTRY THAT MATTERS™ FOR SINGLE USE TECHNOLOGY

POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING

No. 27

PROCESS• Sterilization (gamma), etc.• Extrusion• Injection molding

END APPLICATION• Properties (chemical/ E&L,

mechanical)

POLYMER• Additives• Physical properties

CHEMISTRY THAT MATTERS™ FOR SUT

WORKING TOGETHER TO FIND SMART NEW SOLUTIONS

No. 28

No. 29

THANK YOU

No. 30

LEGAL DISCLAIMER

The products and services of SABIC are sold and rendered subject to SABIC’s standard terms & conditions of sale (GTCS), which are available free of charge upon request, by post or digital. Standard terms & conditions other than the GTCS are dismissed and do not apply. Although any information or recommendation contained herein is given in good faith, SABIC makes no warranty or guarantee, express or implied, (i) that the results or specifications described herein will be obtained under end-use conditions, or (ii) as to the effectiveness or safety of any design incorporating SABIC’s products, services or recommendations.

This presentation or document does not contain any calculation, estimate or other warranty or representation that customers and third parties may rely on. Customers and third parties are responsible for making their own determination as to the suitability of SABIC’s products, services or recommendations for the customers’ particular intended use through appropriate end-use testing and analysis, and compliance with applicable laws and regulations.

Except as provided in SABIC’S GTCS, SABIC shall not be responsible for any loss or damage resulting from any use of its information, products or services described herein and SABIC assumes no liability whatsoever in this respects.

Nothing in any document or oral statement shall be deemed to alter or waive any provision of SABIC’s GTCS or this Disclaimer, unless it is specifically agreed to in a writing signed by SABIC.

No statement by SABIC concerning a possible use of any SABIC product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of SABIC or as a recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right.