Plastics and Polymers

September 23, 2011

Introduction:
A polymer is a substance composed of molecules which have long sequences of one or more species of
atoms or groups of atoms linked to each other by primary, usually covalent, bonds. Polymerization is the
process by which macromolecules (molecules composing the polymer) are formed by linking together
monomer molecules through chemical reactions. There are five polymer based industries such as
plastics, adhesives, coatings, fibers and rubbers.
Plastic is capable of being molded or capable of being deformed continuously and permanently in any
direction without rupture. Plastic in modern industry covers high-molecular-weight organic
compounds.

Natural rubber is an elastomer (an elastic hydrocarbon polymer) that was originally derived from latex.
The purified form of natural rubber is the chemical polyisoprene, which can also be produced
synthetically.

Plastics can be categorized as thermosets and thermoplastics. Thermoplastics, often referred as plastics,
are linear or branched polymers which can be melted upon the application of heat. On the other hand,
thermosets cannot be reshaped.

Applications/Uses:
The Benefits of Plastics
Plastic in Aeronautics
Plastics are used in the solid fuel boosters form rockets and in the ablative shields for
reentry of space shuttles. Plastic materials are also used in the making of helicopters
because they are rigid and durable, yet flexible enough to withstand the vibrations made
by helicopters.
Plastics in the Building and Construction Industry
They are also used for decorative elements and heavy-duty uses because they are so easy
to handle, are durable, and are attractive. Some decorative places plastics are commonly
found include bathroom units, plumbing fixtures, flooring, siding, panels, insulation,
windows, doors, gratings, glazing, and railings.
Within piping and valves, plastics are highly used because of their superior resistance to
corrosion.



Plastics and the Use of Electronics
Due to the thermal and insulating properties of plastic, it is ideal for use in house wiring. Small
appliances also take advantage of plastic. Plastic is durable, yet lightweight and attractive.
Therefore, it is great for making small appliances such as can openers, food processors,
microwave ovens, mixers, coffee makers, shavers, irons, and hair dryers.
Plastics and Packaging
Plastic is so versatile, it can be used for a variety of packaging purposes. If the product needs to
be well protected, the plastic can be rigid and tough. If, on the other hand, the packaging needs
to be convenient to carry, the plastic can be flexible. Or, a combination of the two can be
achieved.
Use of Plastic in Transportation
Plastic is a popular choice when making modes of transportation because it is tough, resistant to
corrosion, durable, lightweight, and easy to color. For these reasons, plastic is found in the
fenders, bumpers, trunk lids, housings for headlights and side view mirrors, grilles, hoods, doors,
and wheel covers.
Process Description:
Oil and natural gas are the major raw materials used to manufacture plastics. The plastics
production process often begins by treating components of crude oil or natural gas in a "cracking
process." This process results in the conversion of these components into hydrocarbon monomers such
as ethylene and propylene. Further processing leads to a wider range of monomers such as styrene,
vinyl chloride, ethylene glycol, terephthalic acid and many others. These monomers are then chemically
bonded into chains called polymers. The first step in plastic manufacturing is polymerization. The two
basic methods by which polymerization can occur are addition and condensation reactions. These can
occur in the gaseous, liquid and occasionally solid phase. Sometimes the polymer synthesis can take
place at the interface of two immiscible liquids in which the monomers are dissolved. The different
combinations of monomers yield plastics with a wide range of properties and characteristics.
Chemical additives can be used in the production of plastics to achieve certain characteristics. These
additives include antioxidants, ultraviolet stabilizers, plasticizers, lubricants, pigments, flame retardants
and antistatics.
There are several different processing methods used to make plastic products. There are four main
methods in which plastics are processed to form the products that consumers use, such as plastic film,
bottles, bags and other containers. Extrusion, injection molding, blow molding and rotational molding
are processes of producing plastics.
ExtrusionPlastic pellets or granules are first loaded into a hopper, then fed into an extruder, which is a
long heated chamber, through which it is moved by the action of a continuously revolving screw. The
plastic is melted by a combination of heat from the mechanical work done and by the hot sidewall
metal. At the end of the extruder, the molten plastic is forced out through a small opening or die to
shape the finished product. As the plastic product extrudes from the die, it is cooled by air or water.
Plastic films and bags are made by extrusion processing.
Blow moldingThis process is used to manufacture hollow plastic products and its principal advantage
is its ability to produce hollow shapes without having to join two or more separately injection molded
parts. This method is used to make items such as commercial drums and milk bottles. Another blow
molding technique is to injection mold an intermediate shape called a preform and then to heat the
preform and blow the heat-softened plastic into the final shape in a chilled mold. This is the process to
make carbonated soft drink bottles.

SYNTHESIS OF PET
TA is produced by the oxidation of p xylene which is obtained largely from petroleum.
Dimethyl terephtahalate is also obtained from p xylene by a stepwise process of oxidation and
esterification. From either of the starting materials, the preparation of the polymer is carried out in two
steps. In the first step, the monomer (bis 2 hydroxyethyl) terephthalate is produced. Conditioned TA
and ethylene glycol in the molar ration 1:1:5 are introduced into the reactor and heated up tpo 235C.
Water from the reaction is eliminated continuously. When dimethyl terephthalate and ethylene glycol
are used as starting materials (1:2:2 molar ratio), the transesterification is conducted in the presence of
catalysts such as Sb
2
O
3.
Methanol formed as by product is removed by means of distillation column.
The monomer in the first stage is condensed in the interchange reaction that occurs in the presence
of Sb
2
O
3
catalyst. The pressure is reduced down to 0.13 kPa in order to eliminate the ethylene glycol
liberated in the reaction and to increase the molecular weight. The molten polyester is either
transformed into fibers or extruded into ribbon form and then granulated at 30 - 45C and stored.


Process Flowchart:

Figure 1.1 Preparation of poly (ethylene terephthalate)

Reference:

D. Feldman and A. Barbalata, Synthetic Polymers
Fred Billmeyer, Textbook of Polymer Science, 3
rd
Edition
Ferdinand Rodriguez, Principles of Polymer Science, 4
th
Edition