Manufacture and Processing of PVC

BOOK COVER......Page 1
TITLE......Page 3
COPYRIGHT......Page 4
FOREWORD......Page 5
PREFACE......Page 6
LIST OF CONTRIBUTORS......Page 7
CONTENTS......Page 8
INTRODUCTION......Page 12
1.1  MARKET FOR PVC AND PRINCIPAL MANUFACTURING PROCESSES......Page 15
1.2  KINETICS OF VINYL CHLORIDE POLYMERISATION......Page 16
1.3  OUTLINE OF SUSPENSION POLYMERISATION PROCESS......Page 20
1.4  THE POLYMERISATION PROCESS......Page 21
1.4.2  Role of the Protective Colloid......Page 23
1.4.3  Role of the Agitator......Page 25
1.4.4  Role of the Buffer......Page 26
1.4.5  Role of the Initiator......Page 27
1.4.7  Vinyl Chloride Quality......Page 30
1.5  COST OF MANUFACTURING SUSPENSION PVC......Page 31
1.6.1  Size of Plant......Page 33
1.6.2  Effect of Size on Heat Removal......Page 34
1.6.3.1  Reduction of Peak Heat Removal Rate......Page 35
1.6.3.4  Use of Condensers......Page 36
1.6.5  Autoclave Fouling......Page 37
1.6.5.2  Chemical Build-up Suppression......Page 38
1.6.6  Instrumentation and Safety Consideration......Page 40
REFERENCES......Page 41
2.1  INTRODUCTION......Page 42
2.2  DEVELOPMENT OF BULK POLYMERISATION OF VINYL CHLORIDE......Page 43
2.3  EVOLUTION OF ST GOBAIN TO RHONE-POULENC......Page 44
2.4.2  Development of the Two-Stage Process......Page 45
2.5  RHONE-POULENC TWO-STAGE BULK POLYMERISATION PROCESS......Page 46
2.5.2  The Influence of the First Stage Reactor (Pre-po)......Page 47
2.5.3  The influence of the Second Stage Reactor......Page 49
2.6  CONTROL OF PROPERTIES......Page 50
2.8  DEGASSING AND POWDER HANDLING......Page 51
2.9  MORPHOLOGY......Page 52
2.10  COPOLYMERS......Page 53
2.12  LATEST DEVELOPMENT IN THE TWO-STAGE PROCESS: VERTICAL AUTOCLAVES......Page 54
2.13  POLYMER QUALITY STATUS—BULK VERSUS SUSPENSION......Page 56
ACKNOWLEDGEMENTS......Page 57
REFERENCES......Page 58
3.1  INTRODUCTION......Page 59
3.3  APPLICATIONS OF PASTE/EMULSION POLYMERS......Page 60
3.4.1  Properties Required of Dried Product......Page 61
3.4.2.1  Batch Process......Page 62
3.4.3  VCM Removal......Page 67
3.4.4  Drying of Latex......Page 68
3.4.5  Milling of Polymer......Page 70
3.4.6  Powder Handling......Page 71
REFERENCES......Page 72
4.1  INTRODUCTION......Page 73
4.2  THEORY OF COPOLYMERISATION......Page 74
4.3  VINYL ACETATE COPOLYMERS......Page 75
4.4.1  Ethylene......Page 78
4.4.2  Propylene......Page 79
4.5  OTHER COPOLYMERS......Page 80
4.7.1  Butadiene Based Rubbers......Page 81
4.7.3  Ethylene/Vinyl Acetate Rubbers......Page 82
4.7.5  Acrylate Rubbers......Page 83
4.8.3  Chlorinated PVC......Page 84
REFERENCES......Page 85
5.1  VINYL CHLORIDE TOXICITY......Page 86
5.2  PROTECTION OF PVC PLANT OPERATORS......Page 87
5.3.1  Atmospheric Testing......Page 89
5.3.3  Vinyl Chloride in Solids and Liquids......Page 90
5.4.1  General......Page 91
5.4.2  Stripping of Suspension PVC......Page 93
5.4.3  Stripping of Emulsion PVC......Page 97
REFERENCES......Page 99
6.2.1  Treatment Prior to Drying......Page 101
6.2.2  Morphology......Page 102
6.2.3  Solids Separation and Dewatering......Page 103
6.2.4  Drier Types Used......Page 106
6.2.4.2  Direct Heat Driers......Page 107
6.2.4.3  Flash Driers......Page 108
6.2.4.4  Fluid Bed Driers......Page 110
6.3.1  Latex Filtration......Page 111
6.3.3  The Properties of the Final Product......Page 112
6.3.4.2  Drum Drying......Page 113
6.3.4.3  Spray Drying......Page 114
6.3.5  Product Morphology......Page 119
6.3.7  Grinding or Milling and Blending......Page 120
6.5  PVC DUST—POSSIBLE HAZARDS......Page 121
REFERENCES......Page 122
7.1  INTRODUCTION......Page 123
7.2  NOMENCLATURE......Page 124
7.3  CLASSIFICATION OF PVC MORPHOLOGY......Page 125
7.3.1  Macro-Morphology of Suspension Polymerised PVC......Page 126
7.4.1  On the Macro-scale......Page 130
7.4.1.1  Droplet Stabilisation......Page 131
7.4.1.2  Effect of Conversion......Page 133
7.4.2  Micro-scopic Scale......Page 134
7.4.3  Sub-microscopic Scale......Page 137
7.5  OVERALL MORPHOLOGY OF SUSPENSION PVC AND POLYMER PROPERTIES......Page 139
7.5.1  The Effect of Higher Polymerisation Temperatures on Morphology......Page 141
7.7  MORPHOLOGY OF GAS PHASE POLYMER......Page 142
7.8  SUMMARY......Page 144
REFERENCES......Page 146
8.2  PRE-MIXING WITH ADDITIVES......Page 149
8.3  EFFECT OF PROCESSING PARAMETERS......Page 151
8.4.1  Theoretical Aspects of Single- and Twin-screw Extrusion......Page 155
8.4.3  The Schloemann BT80 Extruder......Page 156
8.5  TWIN-SCREW EXTRUDER SAMPLING......Page 157
8.5.1.1  Changes to Grain Structure......Page 158
8.5.1.2  The Development and Subsequent Fading of Fluorescence......Page 160
8.6  SINGLE-SCREW EXTRUDER SAMPLING......Page 161
8.6.1.2  The Development of the Dual Structure......Page 162
8.8  BANBURY HIGH SHEAR INTERNAL MIXER......Page 164
8.7.1  Microscopical Examination of Samples Compounded to Different Temperatures between 100 and 200°C......Page 165
8.8.3  The Gelation Process in the Banbury Mixer......Page 169
8.8.4  Relationship of Morphology with the Flow Pressure Curve......Page 170
8.9  BRABENDER PLASTICORDER......Page 171
8.11  SUMMARY......Page 172
REFERENCES......Page 174
9.1  INTRODUCTION......Page 175
9.2.1  Compound Manufacture......Page 176
9.2.2  Powder Blend Manufacture......Page 177
9.3  EXTRUSION......Page 178
9.4  THE INFLUENCE OF PROCESSING ON PROPERTIES......Page 179
9.5.1.1  Grain Size and Morphology......Page 184
9.5.1.2  K-value......Page 185
9.5.1.3  Copolymerisation......Page 186
9.5.2  Lubricants......Page 188
9.5.2.1  The Influence of Lubricants on Gelation......Page 189
9.5.3  Heat Stabilisers......Page 190
9.5.4  Processing Aids......Page 191
9.5.5  Impact Modifiers......Page 193
9.5.6  Fillers......Page 194
REFERENCES......Page 195
10.2  FEEDSTOCK PREPARATION......Page 197
10.2.2  Compounding......Page 198
10.4  PARTICLE MORPHOLOGY AND MELT FLOW......Page 199
10.4.1  Melt Rheology and Melt Structure......Page 200
10.4.2  Product Properties......Page 201
10.5.1.2  Grain Morphology......Page 202
10.5.2  Plasticiser Type......Page 203
10.5.4  Other Ingredients......Page 206
10.6  THE PROCESSING OF PVC PASTES......Page 207
10.6.1.1  The Polymer......Page 208
10.6.1.2  The Plasticiser......Page 209
10.6.2  Fusion......Page 211
10.6.3.1  Spread Coating Processes......Page 212
10.6.3.2  Dipping......Page 213
REFERENCES......Page 214
INDEX......Page 215