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The Value in Recycled Polyamides
Polyfunc)onal Chain Extenders
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Overview
• Background - Industry, Materials, Technical Objectives
• Technical Data - Rheological Analysis - Mechanical Analysis
• Conclusion & Recommendation - Discussion, Product Comparisons
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Background - Industry Objectives
• “Developing market-based solutions for the recycling and reuse of post-consumer carpet” – Carpet America Recovery Effort slogan
• Voluntary initiative by industry/government to prevent burdening landfills
• Plan to achieve 40% landfill diversion by 2012
• 2002 diversion goal, 178 million pounds (3.8%) • 1.3 billion pounds diverted since 2002, 92% of which has gone into
other value added products • Estimated 5 billion pounds landfilled, annually • 5 billion pounds can support the NA injection molding market
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Background – Materials, Availability
*Courtesy of Phantom Plastics
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Background - Value-Added Process
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Background - Limiting Factor
Specifications
Mechanical Properties
Molecular Weight
Recycled Nylon
1
1
Virgin Fiber Grade
2
2
Injection Molding
3
3
Specifications
Mechanical Properties
Molecular Weight
Recycled Nylon
Low
Low
Virgin Fiber Grade
Med
Med
Injection Molding
High
High
Degradation
Added Value
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Technical Objectives
• Objective #1: Improve the mechanical properties of reprocessed recycled nylon derived from carpet using a functional additive
• Objective #2: Impart value added properties to recycled nylon that stay within a low cost model
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Theory - Recycled Nylon
Low Mw High Mw
FA
FA FA
FA FA FA
2. Melt Processing
1. Dry Blending
5. Chain Extended
3. Homogenizing
4. Reaction
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Materials
• Yan et al. documented the importance of diffusion of reactive species • Hargreaves et al. described the reaction between amino group and anhydride
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Materials
Model Formulation • 98 to 99% r-PA (N66, >95% purity) • 1 to 2% Chain Extender*
* LPBD were prepared on a porous silica at 70% active
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Results
• Grafted MA yielded more chain extension reactions • Low viscosity LBPD likely integrated more efficiently • Mobility of low Mw SMA led to shorter induction times
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Optimization Results
• Low shear viscosity attributed to increased branched structure • Increased long chain branching or MWD • Reactivity of graft versus in-chain anhydride
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Results
• SMA improved mechanical properties more than LPBD • Homogenization an important factor in additive selection • Chain extended r-PA has properties encroaching on virgin PA
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Results
• Thermal characteristic improved with low/high Tg additive • Extent of branching suggested by improvement in HDT • SMA more efficient at restoring properties of r-PA
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Conclusion
• Significant improvements in r-PA using low molecular weight anhydride functional additives
• Anhydride grafted LPBD gave the greatest extent of
reaction as shown by increased melt characteristics
• Low molecular weight additives were deemed more beneficial due to increased mobility in the melt
• Homogenizing the melt involved balance of reactivity and mobility
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• Leading global supplier of hydrocarbon resins, diene-based resins, and specialty monomers - Wingtack® and Norsolene® (C5 & C9 tackifiers)
- Poly bd®, KrasolTM and Ricon® (low molecular weight liquid
polybutadiene resins)
- SMA® (styrene-maleic anhydride copolymer resins) - DymalinkTM (metal centered monomers)
• Annual sales over $350 million and has more than 340 employees worldwide
• Company’s more than 250 products are manufactured at 9 sites in 4 countries
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Upstream Downstream Chemicals
Focus • Oil & gas exploration • Production • Gas & power • Alternative energy
• Trading & shipping • Refining & marketing • Commodity & specialty fluids
• Base chemicals • Industrial & consumer market specialty chemicals
Sales (billion) $24.6 $163.4 $23.2
Employees 17,192 32,631 41,658
Total, a partner in your challenges
Cray Valley HSC A Division of Total SA
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Rubb
er
• Performance additives
• Tire & hose applications
• Co-curing agents Ad
hesiv
es
• Pressure sensitive
• Reactive adhesives
• Insulated Glass Sealants G
row
th M
arke
ts • Printed
circuit boards
• Pigment Dispersants
• Mineral Dispersants
Cray Valley HSC Focus Markets
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Cray Valley HSC Global Presence
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• For additional information about Cray Valley, its products or its work in Hydrocarbon Specialty Chemicals,
visit www.CVPolymerAdditives.com