The Polymer Study Tour 2003

An Industry Presentation by
David F Oxley

Worshipful Company
of Horners
davidoxley@onetel.net.uk
1

Why does the Horners Livery Company support the Polymer Study Tours ?

Horn was the first plastic for containers and transparent covers 2

Polymer Study Tours

The image of the scientist needs to be changed

The public is fascinated by science, but profoundly ignorant and therefore scared of it Men studying chemistry are swotty brainboxes Women are unattractive, non-feminine and scary Chemistry Connections is a book that highlights the role of chemistry in every day life with examples such as: What makes a no-tears shampoo What is the composition of an artificial hip

One of the aims of the Polymer Study Tour is to help you promote the knowledge of polymers and plastics and their importance to the quality of everyday life.
For further information see

ISBN 0 12 400860 7

Polymer Study Tours

Natural Gas Coal Nuclear Gas Separation

Petrochemical and related industries

Other Bulk Chemicals

Plastics

Energy Consumer Hydro Others Crude Oil Oil Refining

Olefins

Other end uses

Aromatics

Fibres

Plastics use only 4% of world crude oil, petrochemicals a further 4% 100 kg of oil products can provide a return journey from London to 4 Glasgow, 12 000 disposable PP syringes, or 3 000 carrier bags

Polymer Study Tours

The Plastics Producers

Original producers were the chemical companies that used clever chemistry to build a molecule with properties The next generation were the Chemical Companies with Oil refinery links Now the successful companies are the oil companies with chemical links The New generation will be the Oil and Gas companies with cheap feedstocks in the Middle East, Canada or Russia

The main sponsors of the PSTs are the raw material suppliers, but the support they give is limited as their profits drop and the companies are taken over by companies based outside the UK 5

Polymer Study Tours

Feedback to Sponsors

Each Teacher has a sponsor, either directly from a company or through the Horners Educational Fund Please send your sponsor a letter thanking them for their support and commenting on the course The sponsors want to know if the course was of benefit to you, was it enjoyable, how could it be improved, would you recommend it to a colleague Some sponsors like to follow up this dialogue and may invite you to take a small group of students round their facilities. Please do give your sponsor feedback, we lost a sponsor this year because none of the teachers they sponsored bothered to write with feedback
6

Polymer Study Tours

Polymer manufacture is chemistry in steel pipes

This relatively simple, low pressure process can be used for LLDPE, HDPE and PP with clever catalysts to tailor the polymer to end use For further information see
www.bpes.com
7

Polymer Study Tours

Polyethylene can come in many shapes

L Scientist: this means understanding catalysts and comonomers

Technologist: this means understanding the machinery to cope with the rheology and the physical properties of the film, pipe,sheet or moulding
8

Polymer Study Tours

Innovation leads to interpolymer competition

LLDPE replaces LDPE because it is sold at a lower price and has similar properties Processing machines need to be modified to use LLDPE effectively Customers need to be sold the idea of a new polymer The USA invented LLDPE and introduced it at lower prices than in Western Europe Western Europe has many old LDPE plants that can be run at cash cost, whereas new plants need to run at full replacement cost Eastern Europe cannot afford to reequip
9

Technologists need to understand what the scientists are developing

For further information see

www.chemsystems.com

Polymer Study Tours

Properties of molten polymer

Molten polymers have a non Newtonian viscosity, ie the faster you push them the lower the viscosity, ideal for high speed injection moulding of thin disposable containers This viscosity is measured by weighing the amount of polymer extruded from a standard hole under standard temperature and pressure conditions, as you will see later.

This is known as MFI, melt flow index, sometimes known as MFR , melt flow rate.
A high MFI polymer has small molecules and is thin and watery when molten so flows easily into thin moulds, but the resultant moulding tends to be brittle A low MFI polymer has big molecules and is highly viscous when molten so is difficult to force into thin cavities, but the resultant moulding tends to be tough 10

Processing technology relies on Polymer Study Tours the chemical structure of the polymer

Increasing stiffness / strength

Scientist: this means understanding the mechanism of polymerisation

Technologist: this means understanding the fluid flow of molten non-

Newtonian fluids and the mechanical properties of structures made 11 from non-isotropic materials

Polymer Study Tours

The polymerisation process affects the properties of the polymer

Increasing stiffness / strength Scientist: this means understanding the chemical engineering of polymerisation and the conditions affecting the polymer molecular structure Technologist: this means being able to specify the properties required for the application
12

Polymer Study Tours

Polymer processing is a science: each process has its needs

Injection moulding likes low viscosity shear thinning polymer for fast injection into thin sections Blow moulding likes thixotropic polymer so the parison doesnt thin too much Film, fibre and pipe extrusion likes Newtonian fluid to prevent melt fracture, but most polymers are not that way inclined Vacuum forming hates shear thinning as the corners get too thin Extrusion coating likes supramolecular polymer that flows well into the substrate paper or fabric

The technologist has to understand the polymer properties in order to design the optimum process conditions For further information see
Chemistry & Industry 20 May 2002
13

The UK Plastics Industry Polymer Study Tours contributes 18 billion to UK GDP The Structure of the Industry

Plastic Material Supplier

Additive Supplier

Designer

CONVERTER

Compounder

Customer

End Use Market For Plastics

Machinery Manufacturer

The power has moved from the raw material supplier to the designer/customer as the industry has matured
For further information see

www.bpf.co.uk

14

Polymer Study Tours The key facts Plastics in Europe

Raw Materials (APME) Workforce Turnover Investment Investment R&D R&D Number Million Euro Million Euro % turnover Million Euro % turnover 70,000 29,000 3,000 10.3 700 2.4 Processing (EuPC) 1,000,000 100,000 6,600 6.66 1400 1.4 Machinery (Eurom) 55,000 6,700 140 2.1 280 4.2 Total

1,125,000 135,700 9,740 7.2% 2380 1.8%

Scientist: The R&D spend by the polymer suppliers is changing from Blue sky to applications development and catalyst design to make more effective polymers. The R&D by the machinery makers is mostly in Germany and France. The Processing and Machinery sectors have very few chemistry graduates, but need lots of skilled engineers and material scientists Technologist: The raw material suppliers need Chem Eng and application engineers. The processing sector is very short of material technologists and systems technicians. The Machinery sector needs engineers and skilled technicians

For further information see

www.apme.org/europe

15

Polymer Study Tours

Plastic usage in the UK was 4 790 ktonnes in 2002

UK Consumption of Plastics by Type

OTHERS 22% UP Resin 2% PET/PBT 5% ABS/SAN 2% PA 1% EPS 1% PS 5%

L/LLDPE 19%

HDPE 11%

PVC 16%

PP 16%

This is a slight increase on 2001

For further information see Appendix tables and BPF website
16

Polymer Study Tours

UK Plastics Consumption (ktonnes) 1973-2007
6000

Plastics consumption by type (k tonnes)

2000 LDPE LLDPE HDPE PP PVC PS EPS POLYAMIDES ABS SAN PET PBT PC ACETALS PTFE ACRYLICS POLYESTER PHENOLICS AMINOS EPOXIDES PU OTHERS
519.7 381.7 527.6 750.2 746.5 242.9 56.2 45.7 87.0 8.9 245.0 10.8 39.2 17.7 3.3 38.5 82.3 81.0 176.6 33.5 178.8 399.9

2001
511.9 398.8 538.1 784.0 727.9 224.1 55.7 43.3 87.0 8.9 250.0 10.0 39.2 17.7 3.3 37.0 84.8 81.0 176.6 33.5 183.3 399.9

Change
-1.5% 4.5% 2.0% 4.5% -2.5% -7.8% -0.7% -5.3% 0.0% -0.4% 2.0% -7.5% 0.1% 0.0% 1.2% -4.0% 3.0% 0.0% 0.0% 0.1% 2.5% 0.0%

5500
5000

4790

4000

3000

2000

1000

19 73

19 76

19 79

19 82

19 85

19 88

19 91

19 94

19 97

20 00

20 03

Average growth rate above that of GDP Light weighting means less polymer for same application Polymer substitution affects growth rates Import of polymers from the Middle East affects suppliers

20 06

TOTAL

4673.0

4696.0

0.5%

For further information see

www.bpf.co.uk

17

Polymer Study Tours

UK Plastics market in 2002 totalled 4 790 Kt

Packaging consumes 1777 kt of plastics, about 17% of all packaging, still growing. Construction accounts for 1050 kt of which PVC is 450 kt Transport uses 350 kt, mainly for car components, about 10% of a new cars weight, still growing Medical uses are about 90 kt, mainly commodity plastics Electrical and electronic uses have declined as less phones are sold and they get smaller Agriculture was affected by F&M, and uses imported films so growth limited Furniture is mainly chairs and PU foam, subject to strict fire regulations

The 2002 processor survey found that 77% had growth, 13% had no change and 9% reported decline in volumes in 2002
For further information see

www.bpf.co.uk

18

Polymer Study Tours

The Key facts a summary

West European Plastics Consumption 1999

8000 7000 6000

K tonnes

5000 4000 3000 2000 1000 0

LD PE /L LD PE HD PE

PP

ky ds Am in Ph o en ol ic s Ep ox Po y ly es te r

PV C

PC

PO M

PA

PE T

S/ SA N PM M A

PS /E PS

Plastics Applications

AB

Non-Plastics Applications

Non-Plastics applications include : Fibre, Coatings, Adhesives

Ac ry l

Al

For further information see

www.apme.org/europe

Ot he rs

PU

ic

19

Polymer Study Tours

Plastics in Automotives
The original Smart Car used PC/PBT for the panels The new Roadster horizontal panels for boot and bonnet are too big so will use painted SMC for increased stiffness PC/PBT will still be used for the door panels and front and rear bumpers

Smart Roadster Coupe due out in 2003

For further information see

All the mouldings will be painted to match, even though the PC/PBT ones will be self coloured
20

European Plastics News March 2003

Polymer Study Tours

Plastics in BMW cars

BMW say that their plastics usage in the 3, 5 & 7 series cars will rise from 100 to 160Kg/car in 1984 to around 200 Kg/car by the time the ELV directive comes into full force in 2015. Then used cars will 21 have to be taken back free of charge and designed for recycling

Polymer Study Tours

Polymer prices are volatile

(/tonne)

Average Bulk Polymer Prices 1990 - 2003

900

800
/TONNE

700 600

500
400 300

Polymers used for this graph are:- HDPE,LLDPE,LDPE,PP,PS,PVC

Designing a product to a budget is fraught with difficulty, especially for the car industry with its three year planning cycle
For further information see
www.bpf.com
22

Polymer Study Tours

/Tonne 855

Commodity Plastics Prices Note the volatility has more to do with supply/demand than oil prices Supply in several polymers has been upset by plant shutdowns LDPE short as old plants shut and no new ones are built as LLDPE is supposed to take over, but hasnt yet

715

570

430

Source: Plastics & Rubber Weekly 23rd May 2003

For further information see

www.prw.com

23

Polymer Study Tours

The West European polyolefin price history

Note the imperfect correlation between ethylene price and polyethylene price. This results in the profit margin moving along the supply chain.

24

Polymer Study Tours

Medical device Technology opens up new markets Plastics parts for implants Sterile plastics packaging Disposable syringes, gloves and instruments Disposable sheets, diapers and gowns Disposable blood bags, colostomy bags Biopolymer sutures and nails Slow release polymers for drug encapsulation Tablet blister packs and bottles

The UK consumption of Plastics in Healthcare is estimated to have been 90 000 tonnes in 2002
For further information see

www.medicaldevicesonline.com

25

Polymer Study Tours

Plastics used by manufacturers of medical devices

For further information see

Plastics in Healthcare The biggest use is in none critical packaging using commodity polymers Such applications are very price sensitive The use of esoteric polymers requires extensive research for low tonnages, so prices have to be high There is interpolymer competition as the market matures and Health Trusts try to cut costs The processing industry uses special sterile moulding rooms
www.medicaldevicesonline.com
26

Polymer Study Tours

PAI PPSU PEEK FP LCP PPS PET PC MPPO SMA PMMA ABS PP PBT POM PA 6/6.6 PA 4.6

Polymer properties at a price

Ultra high performance engineering plastics up to 40 000 per tonne

PES
PSU

High performance engineering plastics, up to 5000 per tonne

Mid range engineering plastics, up to 1800 per tonne

GPPS/HIPS PVC SAN

LLDPE
LDPE

HDPE

Commodity plastics, up to 700 per tonne

For US prices see www.plasticsnews.com 27

Amorphous
Low distortion, viscous melts

Semi-Crystalline
Higher distortion, easy flow melts

Polymer Study Tours

Design to astonish your customers Understand the customers needs Lateral thinking in design Use the properties of materials to develop a solution Use rapid prototyping to help the customer approve the concept Use the technology of fabrication to provide a cost effective product Think sustainability

The design and technology student of the future needs to understand both the science and properties of materials
Alan Griffiths and John McLoughlin will cover design in more detail later
28

Polymer Study Tours

Making polymers do what they were good at not doing

Early modifications focussed on making polymers stiffer or tougher. Then came flame retardants and lubricants Now we have improved electrical and heat conductivity with carbon black or steel fibres Light and sound emitting polymers are coming We can even make commodity polymers biodisintegrate or special biopolymers that the body can absorb

The scientists will develop a polymer to meet a need, the technologists define that need, and learn to process the new polymer 29

Polymer Study Tours

Why Not Polypropylene for everything ?

The basic Homopolymer can be copolymerised, modified with additives to make it tougher, stiffer, more transparent, flame retardant, but -: It is still brittle at low temp and notch sensitive It still melts at 167 oC Partially crystalline so distorts on moulding Feels oily and is difficult to paint or print on

The improved performance envelope of PP is why it has replaced other materials such as wood, metal, glass and more expensive plastics such as ABS and its growth has outstripped GDP and that of other plastics30 For further information see www.basell.com

Polymer Study Tours

How to choose the material: Key properties required

How transparent How stiff How tough How chemically resistant How heat resistant How water resistant How scratch resistant How UV light resistant How flame resistant How feely friendly texture How biocompatible How environmentally acceptable must the choice be

The scientist can design a plastic to meet the needs at a price The technologist has to work out how to make the product at a price The industrialist has to accept a compromise. There are 39 000 options on the Campus.com website

31

Polymer Study Tours

Plastics processing cost is rate dependent

Low tool costs favour initial production, even if labour costs are high High tool costs are justified as the production rate rises High raw material costs can be justified initially, but the move to mass production means a switch to cheaper polymers Freight costs of finished goods affects import competition, thus blow mouldings less vulnerable than film on the reel from low labour cost regions Scientist: Know the chemistry of each process Technologist: Fit the process to the market demand and be aware that the process affects properties of the design 32 For further information see www.pras.com

Polymer Study Tours The dippy egg spoon material selection ranking. (5 good, 0 poor)
?????
staining breaks bending slips hygiene feel safety

A
B

0
3

5
2

4
4

3
5

5
2

2
1

2
2

C
D E F

4
4 5 4

1
3 5 3

3
2 5 3

2
2 4 4

3
4 2 4

2
2 4 5

3
4 3 5

Scientist: understand the environment in which the material will be used

and the properties needed to be successful in the market

materials, everything is a compromise. The market selects the winner

Technologist: be aware of the interplay between properties of

Health warning: This analysis ignores the most important property PRICE, which is derived from material cost and fabrication technique
33

Polymer Study Tours

Recycling is a serious issue for the plastics industry

Politically motivated legislation uses more resources, creates non-tariff trade barriers, and often fails to address the real problem Source reduction means thinner films, bottles and lighter weight mouldings. Less energy is used Re-use means returnable boxes and refillable bottles longer life additives, better design Recycling means expensive separation of post consumer waste that may consume more energy than using new plastic. Controlled incineration with heat recovery is an environmentally responsible option
34

Scientist: develop more effective

polymers by clever chemistry

less and measure the energy cost Much more on the environment and recycling from John Sale later

Technologist: create more from

Polymer Study Tours

Rate of decomposition depends on the conditions of use and disposal Anaerobic conditions of land fill prevent decomposition anyway Inhibits the recycling loop Only delays the return of the C atom to CO2 and may contaminate the ground water or produce methane, a worse greenhouse gas than CO2 Requires thicker films for given strength, so adds to the cost True biodegradable polymers are expensive, most are starch filled commodity polymers that bio disintegrate not decompose

Is Biodegradable packaging the answer to litter ? NO

Scientist: Scope for decomposition kinetics to develop useful products

Technologist: Does Life Cycle Analysis prove biodegradable plastics are viable

The answer to litter is education, not restriction of supply or tax

35

Polymer Study Tours

Conclusion: Plastics are GOOD

They protect us and our food from heat, cold, rain, germs, impact, and theft

They enhance our life with colour, sound, safety and convenience
Responsible use of plastics is environmentally responsible The Plastics industry in this country is still growing, is moving upmarket in D&T and offers an exciting future for Young People in both science and technology
Polychicken made from recycled plastics bags. Bought on a roundabout in South Africa by Horner Colin Richards

We hope this polymer Study Tour will increase your knowledge, give you ideas for teaching both science and technology and be fun 36

Polymer Study Tours

Epilogue

The world has moved on since Horn was used for glazing lanterns. Plastics have a bright future Plastics are complex structures made from highly purified simple units, put together by clever chemists and manipulated by skilled technologists. Plastics are valuable materials that can afford to bid for petrochemical feedstocks, but the sources may relocate to the Middle East and Canada. The UK plastics industry represents 12% of the European industry and is still growing at above GDP growth rates. It needs more skilled scientists and technologists to help develop the industry to compete in the world The relocation of manufacturing industry to the Far East and Eastern Europe reduces the potential market for UK processed plastics, but the design and specification is still UK based

We hope this PST will help you to encourage more young people to consider 37 a science or technology based career

Polymer Study Tours

The Worshipful Company of Horners

1284 Guild of Horn Workers recorded in City records 1376 Horners Guild send two members to Court of Common Council to rule City of London 1476 Leather Bottle makers merge with the Horners 1638 King Charles 1 grants Royal Charter, for a fee! 1943 Horners Company associates with the Plastics Industry, its main competitor The Company now supports the Lord Mayor in promoting the City of London, supports the ancient craft of Horner and Bottle Maker and the development of plastics and scientific education.

For further information see

www.horners.org.uk

38

Three Unipol Reactors

LLDPE/HDPE Unipol Plant Buddeynosk Russian Federation

39

Polymer Study Tours

Phenol Formaldehyde (PF) dark Colour

Identification of Plastics 1 Melamine Formaldehyde Urea Formaldehyde (UF) (MF) none some light Scuff resistance

Start

sharp knife

Cut with

Flakes, chips Coherent slivers

THERMOSET THERMOPLASTIC

Drop on hard surface

Metallic ring GPPS, HIPS SAN, ABS, PC PVC, Polyamide (PA), Polyacetal (POM), PET Cellulosics

Dull sound

Drop in water sinks

Surface finish
High gloss

floats
polyolefins

Scratch Some scratch

HDPE

Low gloss Low density 40 Polyethylene LDPE

Little scratch
Polypropylene PP

Polymer Study Tours

PTFE

Urea or Melamine Polycarbonate Phenol Formaldehyde Formaldehyde PVC

Identification of Plastics 2
Cellulose Acetate Polyamide (Nylon)

Smell

none

fishy none

phenol

phenol yellow

acrid yellow smoky

vinegar sparks

burning hair blue

Flame colour

Chars

THERMOSET

Self-extinguishing When removed

Start
Flame colour Smell

Gentle Heat

Burns

Melts

THERMOPLASTIC

Continues to burn When removed

Pale blue fruity

Blue, white tip

Blue, yellow tip marigolds + acrid Sweet ester

yellow smoky

marigolds + rubbery + acrid marigolds + rubbery

ABS

formaldehyde

waxy

diesel

Polymethyl Polypropylene methacrylate Toughened Crystal (PP) Styrene 41 (PMMA) Polyethylene Polyacetal Acrylonitrile Polystyrene Polystyrene (HIPS) (LDPE,HDPE) (POM) (SAN) (GPPS) (PET)

marigolds