What is happening to What is happening to polymer additivespolymer additives

Jitu VadodariaJitu Vadodaria

Jayvee Organics Endowment Lecture Jayvee Organics Endowment Lecture March 24, 2005March 24, 2005

AhmedabadAhmedabad

ContentsContents

Why additives - significanceWhy additives - significance Additives - typesAdditives - types Global scenarioGlobal scenario Indian scenarioIndian scenario Key issuesKey issues TrendsTrends Case studiesCase studies PVC compounding - some aspectsPVC compounding - some aspects

PVC/HDPE pipesPVC/HDPE pipes

50 years of service life50 years of service life PVC pipes - undergroundPVC pipes - underground HDPE pipes - outsideHDPE pipes - outside Heat stabilizer key for service life Heat stabilizer key for service life

of PVC pipesof PVC pipes Carbon black/UV stabilizer for Carbon black/UV stabilizer for

service life of HDPE pipesservice life of HDPE pipes

PVC windowsPVC windows

At least 15 years service life for At least 15 years service life for economyeconomy

No colour fadingNo colour fading No breakageNo breakage This is only possible due:This is only possible due:

* Acrylic/CPE impact modifier* Acrylic/CPE impact modifier

* Rutile titanium dioxide pigment* Rutile titanium dioxide pigment

PVC power cablePVC power cable

High temperature resistance due High temperature resistance due high tension power (85-105 C)high tension power (85-105 C)

Higher insulationHigher insulation Can only be achieved by:Can only be achieved by:

*Higher mol.wt. Phthalate *Higher mol.wt. Phthalate plasticizer (DIDP) or trimellitate plasticizer (DIDP) or trimellitate plasticizerplasticizer

* Calcined clay for insulation* Calcined clay for insulation

PE insulation cablePE insulation cable

PE in contact with copper breaks PE in contact with copper breaks downdown

This can be prevented by use ofThis can be prevented by use of

* Metal deactivator in addition to * Metal deactivator in addition to primary antioxidant systemprimary antioxidant system

PE halogen free flame PE halogen free flame retardant building wireretardant building wire High oxygen indexHigh oxygen index Low smoke densityLow smoke density

Only possible by use ofOnly possible by use of

* N-P based FR additive* N-P based FR additive

* Melamine compounds* Melamine compounds

Additives=Performance+Additives=Performance+property-preservation/retention property-preservation/retention

All these examples clearly show:All these examples clearly show:

* Performance* Performance * Property retention/preservation/protection * Property retention/preservation/protection

in severe service environment/conditionin severe service environment/condition

Polymer additives essential to providePolymer additives essential to provide

• PerformancePerformance• Property protectionProperty protection• Property preservation Property preservation

LLDPE thin filmLLDPE thin film

Shark skin surface - rough surfaceShark skin surface - rough surface Melt fractureMelt fracture Surface can be made smooth by Surface can be made smooth by

use ofuse of

* Polymer processing aid -* Polymer processing aid -

Fluro elastomer polymerFluro elastomer polymer

BOPP film for high BOPP film for high speed packagingspeed packaging High stiffnessHigh stiffness Easy machinabilityEasy machinability Faster packaging speedFaster packaging speed

High stiffness - Aromatic resinHigh stiffness - Aromatic resin Easy machinability - Slip additiveEasy machinability - Slip additive Faster packaging speed - Faster packaging speed -

TerpolymerTerpolymer

Plastic –wood Plastic –wood compositescomposites Wood flour dispersionWood flour dispersion Higher moisture of wood flourHigher moisture of wood flour Low flowLow flow Dispersion - Coupling agentDispersion - Coupling agent Moisture control - DesiccantMoisture control - Desiccant Flow - Processing aid/lubricantFlow - Processing aid/lubricant

PVC building thin wirePVC building thin wire

Economical production of highly Economical production of highly filled flame retardant formulationfilled flame retardant formulation

Faster extrusion speed for Faster extrusion speed for economyeconomy

This is achieved byThis is achieved by

* Use of processing aid* Use of processing aid

* Use of PE wax or montan acid * Use of PE wax or montan acid esterester

Polymer Polymer additive=Processabilitadditive=Processabilityy Processing aidProcessing aid

* Acrylics/ Fluro elastomer* Acrylics/ Fluro elastomer

* Slip additive - Erucamide/ * Slip additive - Erucamide/ OleamideOleamide

All these additives contribute to All these additives contribute to Processability of polymerProcessability of polymer

Polymer additive can Polymer additive can spoil quality if care not spoil quality if care not taken properly taken properly Quality of additive quite difficult to convert Quality of additive quite difficult to convert

into plastic propertiesinto plastic properties Chemical quality alone can not justify its Chemical quality alone can not justify its

use in polymeruse in polymer Numerous suppliers Numerous suppliers Slow process of approvalSlow process of approval Select standard additive product from Select standard additive product from

leading suppliers and not go for cost saving leading suppliers and not go for cost saving Loss will be significantly highLoss will be significantly high

POLYMERPOLYMERADDITIVESADDITIVES

PERFORMANCEPERFORMANCE

PROPERTYPROPERTY

RETENTIONRETENTION

PRESERVATIONPRESERVATION

PROCESSABILITYPROCESSABILITY

Functions of polymer additiveFunctions of polymer additive

Additives classificationAdditives classificationProperty modifierProperty modifier PlasticizerPlasticizer Impact modifierImpact modifier Blowing agentBlowing agent Coupling agentCoupling agent Nucleating agentNucleating agent Organic peroxideOrganic peroxide Reinforcing agentReinforcing agent

Additive classificationAdditive classificationProperty extenderProperty extender Flame retardantFlame retardant Heat stabilizerHeat stabilizer AntioxidantAntioxidant Light stabilizerLight stabilizer Antistatic agentAntistatic agent

Additive –classificationAdditive –classificationProcessing aidProcessing aid

LubricantLubricant Mould release agentMould release agent Anti block additiveAnti block additive Slip additiveSlip additive

Polymer additive Polymer additive demand estimatesdemand estimates20042004 Polymer demand 170 MMTPolymer demand 170 MMT Additive demand 9 MMTAdditive demand 9 MMT Additive percentAdditive percent 5 % 5 % Additive cost 10 %Additive cost 10 % Additive costs only 10% of the Additive costs only 10% of the

polymer but plays a much bigger polymer but plays a much bigger rolerole

Global polymer Global polymer additive distribution additive distribution by type (%)by type (%) PlasticizerPlasticizer 5959 Flame retardantFlame retardant 1212 Impact modifierImpact modifier 8 8 Heat StabilizerHeat Stabilizer 6 6 LubricantLubricant 6 6 AntioxidantAntioxidant 3 3 PeroxidePeroxide 2 2 Light stabilizerLight stabilizer 1 1 Others 3Others 3 Total 100Total 100

Additive usage Additive usage distribution by distribution by polymerpolymer PolymerPolymer %%

PVCPVC 65-7065-70

PolyolefinPolyolefin 1010

StyrenicsStyrenics 5 5

OtherOther 15-2015-20

Additive usage by Additive usage by regionregion North AmericaNorth America 2.52.5 EuropeEurope 2.52.5 AsiaAsia 33 S. AmericaS. America 0.50.5 Middle EastMiddle East 0.50.5 Russia etcRussia etc 0.50.5 TotalTotal 99All in MMTAll in MMT

Additive demand estimatesAdditive demand estimatesIndiaIndia20042004(KT)(KT)

PlasticizerPlasticizer 185185 Heat stabilizerHeat stabilizer 25 25 LubricantLubricant 18 18 Antioxidant Antioxidant 5 5 Flame retardant Flame retardant 4 4 Impact mod/P. aid Impact mod/P. aid 5 5 OthersOthers 8 8 TotalTotal 248 248

Polymer additivePolymer additiveKey issuesKey issues Global market Vs local suppliersGlobal market Vs local suppliers Market growing more in Asia but Market growing more in Asia but

suppliers continue in Europe/USAsuppliers continue in Europe/USA Large no. of small suppliers in AsiaLarge no. of small suppliers in Asia Lower growth - survival of fittest Lower growth - survival of fittest

leading to M&Aleading to M&A Environmental pressures & new Environmental pressures & new

legislationlegislation

Polymer additivePolymer additiveKey issuesKey issues Plasticizer toxicityPlasticizer toxicity Elimination of heavy metal Elimination of heavy metal

componentscomponents Non halogenated flame Non halogenated flame

retardantsretardants Lowering of dosage level for Lowering of dosage level for

safetysafety

Recent trendsRecent trends

Global majors developing niche Global majors developing niche productsproducts

Patents expiry leading to newer playersPatents expiry leading to newer players M& A activities on an increase for M& A activities on an increase for

survivalsurvival Global majors setting up plants in fast Global majors setting up plants in fast

growing Asiagrowing Asia Higher awareness on environmental Higher awareness on environmental

issues demanding more HSE researchissues demanding more HSE research

Recent trendsRecent trends

PVC pipes moving from lead PVC pipes moving from lead stabilizer to tin/ca - zn/organicstabilizer to tin/ca - zn/organic

Slow but sure phasing of lead Slow but sure phasing of lead from PVC cable sectorfrom PVC cable sector

Phasing out of halogenated flame Phasing out of halogenated flame retardantsretardants

Shift from PVC to non vinyls for Shift from PVC to non vinyls for flame retardanceflame retardance

New additive New additive products/marketsproducts/markets Oxygen scavenger for packagingOxygen scavenger for packaging Wood compositesWood composites Newer flame retardantsNewer flame retardants Biodegradable additiveBiodegradable additive Conductive additiveConductive additive Nano fillerNano filler Newer additive for plasticultureNewer additive for plasticulture

Glass bead -an Glass bead -an economic alternative economic alternative of glass fiberof glass fiber PP Moulded product of 0.5 KG weightPP Moulded product of 0.5 KG weight Production requirement - 1000 unitProduction requirement - 1000 unit Production cost Rs 500/hourProduction cost Rs 500/hour Raw material costRaw material cost PP Rs. 60/KGPP Rs. 60/KG Glass Fiber Rs. 70/KGGlass Fiber Rs. 70/KG Glass bead Rs. 60/KGGlass bead Rs. 60/KG

Glass bead in PP- A Glass bead in PP- A case studycase study Cycle time/Defect rateCycle time/Defect rate PP 60 second 5.2%PP 60 second 5.2% PP+30% Glass fiber 65 second PP+30% Glass fiber 65 second

5.2%5.2% PP+20% GF+10% GB 54 second PP+20% GF+10% GB 54 second

3.6%3.6% PP+20% Glass bead 46 second PP+20% Glass bead 46 second

1.2%1.2%

PP moulded productPP moulded productA case studyA case study Material Total units KGMaterial Total units KG PP 1052 526PP 1052 526 PP+30% GF 1052 526PP+30% GF 1052 526 PP+20%+10% 1036 518PP+20%+10% 1036 518 PP+20% GB 1012 506PP+20% GB 1012 506

Cost benefit analysisCost benefit analysisPP glass bead Vs glass PP glass bead Vs glass fiber moulded productfiber moulded product Material Process hour Total cost(Rs)Material Process hour Total cost(Rs) PP 17.52PP 17.52 4032740327 PP+30% 18.99PP+30% 18.99 4263542635 PP+20+10 15.54 39886PP+20+10 15.54 39886 PP+20% 12.93 36826PP+20% 12.93 36826 Saving 4.59 3501Saving 4.59 3501 Saving 6.06Saving 6.06 5809 5809 SavingSaving 2.61 2.61 3060 3060

PVC compoundingPVC compoundingSome aspectsSome aspects All PVC products contain 30-95 % of All PVC products contain 30-95 % of

PVC polymerPVC polymer PVC very dependent on PVC very dependent on

additive/compoundingadditive/compounding More than 50% of PVC is mixed only More than 50% of PVC is mixed only

up to dry blend powder form (rigid)up to dry blend powder form (rigid) Plasticized compounds in pellet formPlasticized compounds in pellet form

Key aspects of PVC Key aspects of PVC compoundingcompounding Cooling of dry blend essential for Cooling of dry blend essential for

efficient use of heat stabilizerefficient use of heat stabilizer Higher bulk density can only be Higher bulk density can only be

developed by dry blending temp developed by dry blending temp reaches 120Creaches 120C

Moisture removal essential for Moisture removal essential for better clarity or surface finishbetter clarity or surface finish

Critical compounding Critical compounding features - PVCfeatures - PVC Cooler mixer essential for dry blendCooler mixer essential for dry blend Internal mixer or continuous extruder Internal mixer or continuous extruder

often usedoften used Sequential addition of additive provides Sequential addition of additive provides

advantagesadvantages Die face cutting system more suited to Die face cutting system more suited to

prevent moisture pick up prevent moisture pick up Close system more preferred due Close system more preferred due

environmental pollutionenvironmental pollution

Compounding of PVC is Compounding of PVC is black artblack art PVC melt tends to stick to metal PVC melt tends to stick to metal

more than all other polymersmore than all other polymers Lubricant selection to be done on Lubricant selection to be done on ExternalExternal Internal Internal Internal-externalInternal-external Also multi lubricants with varying Also multi lubricants with varying

melting temp should be selectedmelting temp should be selected

PVC is driven by PVC is driven by additive systems & additive systems & compoundingcompounding Same PVC products can be produced Same PVC products can be produced

with different approaches of additiveswith different approaches of additives Experience a key requirement for Experience a key requirement for

successful PVC compounding/products successful PVC compounding/products at optimum cost and qualityat optimum cost and quality

Additive indeed a great leveler in PVC Additive indeed a great leveler in PVC productsproducts

Learn additive in order to become Learn additive in order to become expert in PVC compounding expert in PVC compounding