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FROM LITTLE MOLECULES TO BIG MOLECULES

September 28th, 2009 aryshi No comments

The behavior of polymers represents a continuation of the behavior of smaller
molecules at the limit of very high molecular weight. As a simple example,
consider the normal alkane hydrocarbon series
mononer

These compounds have the general structure
structure
where the number of —CH2— groups, n, is allowed to increase up to several
thousand. The progression of their state and properties is shown in Table 1.1.
At room temperature, the first four members of the series are gases.
n-Pentane boils at 36.1°C and is a low-viscosity liquid.As the molecular weight
of the series increases, the viscosity of the members increases. Although commercial
gasolines contain many branched-chain materials and aromatics as
well as straight-chain alkanes, the viscosity of gasoline is markedly lower than
that of kerosene, motor oil, and grease because of its lower average chain
length.
These latter materials are usually mixtures of several molecular species,
although they are easily separable and identifiable. This point is important.

Properties of the alkane/polyethylene series
Properties of the alkane/polyethylene series

because most polymers are also “mixtures”; that is, they have a molecular
weight distribution. In high polymers, however, it becomes difficult to separate
each of the molecular species, and people talk about molecular weight
averages.
Compositions of normal alkanes averaging more than about 20 to 25 carbon
atoms are crystalline at room temperature. These are simple solids known as
wax. It must be emphasized that at up to 50 carbon atoms the material is far
from being polymeric in the ordinary sense of the term.
The polymeric alkanes with no side groups that contain 1000 to 3000 carbon
atoms are known as polyethylenes. Polyethylene has the chemical structure

polyethylene_structure

which originates from the structure of the monomer ethylene, CH2=CH2.The
quantity n is the number of mers—or monomeric units in the chain. In some
places the structure is written
polyethylene structure

or polymethylene. (Then n’ = 2n.) The relationship of the latter structure to
the alkane series is clearer.While true alkanes have CH3— as end groups, most
polyethylenes have initiator residues.
Even at a chain length of thousands of carbons, the melting point of polyethylene
is still slightly molecular-weight-dependent, but most linear polyethylenes
have melting or fusion temperatures, Tf, near 140°C. The approach to
the theoretical asymptote of about 145°C at infinite molecular weight (1) is
illustrated schematically in Figure 1.1.
The greatest differences between polyethylene and wax lie in their mechanical
behavior, however. While wax is a brittle solid, polyethylene is a tough
plastic. Comparing resistance to break of a child’s birthday candle with a wash
bottle tip, both of about the same diameter, shows that the wash bottle tip can
be repeatedly bent whereas the candle breaks on the first deformation.

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CROSS-LINKING, PLASTICIZERS, AND FILLERS

September 24th, 2009 aryshi No comments

simple homopolymers, as made pure. Only a few of these are finally sold as “pure” polymers, such as polystyrene drinking cups and polyethylene films. Much more often, polymers are
sold with various additives. That the student may better recognize the polymers,
the most important additives are briefly discussed.
On heating, linear polymers flow and are termed thermoplastics.To prevent
flow, polymers are sometimes cross-linked (•):

cross-linked
THE MACROMOLECULAR HYPOTHESIS

The cross-linking of rubber with sulfur is called vulcanization. Cross-linking
bonds the chains together to form a network. The resulting product is called
a thermoset, because it does not flow on heating.
Plasticizers are small molecules added to soften a polymer by lowering
its glass transition temperature or reducing its crystallinity or melting temperature.
The most widely plasticized polymer is poly(vinyl chloride). The
distinctive odor of new “vinyl” shower curtains is caused by the plasticizer,
for example.
Fillers may be of two types, reinforcing and nonreinforcing. Common reinforcing
fillers are the silicas and carbon blacks.The latter are most widely used
in automotive tires to improve wear characteristics such as abrasion resistance.
Nonreinforcing fillers, such as calcium carbonate, may provide color or opacity
or may merely lower the price of the final product.

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ADVANCED POLYMER PROCESSING – INJECTION MOLDING

August 8th, 2009 aryshi No comments

injection molding

The main parts in Injection molding machine are:

  1. INJECTION UNIT
  2. CLAMPING UNIT
  3. MOLD SYSTEM
  4. CONTROL SYSTEM
  5. HYDRAULIC SYSTEM

I. INJECTION UNIT

Parts which are belonging to injection unit are:

  • Screw
  • Check valve
  • Cylinder (barrel)
  • Heating Zones
  • Nozzle

Tasks of the injection units are:

  • Feeding of materials
  • Transport of material
  • Melting and plastification of granulates
  • Homogenization of melted material
  • Injection of melted material
  • Compacting of injected material

Screw

  • Task of screw:
  • Feeding of granule
  • Transport of material
  • Plastification of granule
  • Homogenization of melted material

Construction of a standard screw:

  • Material of screw: nitride steel
  • Roughness of screw surface Rt < 1 um
  • L/D ratio -20
  • 3 zones (feeding-, compression- and metering zone)

Check valve:
Function of check valve: to prevent the melting materials in front of barrel go back into feeding zone during injection

check valve

Heating zone

  • Melting of plastic material
  • Control of mass temperature
  • Max. temperature < 500 C
  • 4 heating zones ( 3 cylinder zones, 1 nozzle zone)

Nozzle
Type of nozzle:

  • Open nozzle
  • Shut-off nozzle (needle shut off nozzle, moved by spring, moved by hydraulic, slide shut off nozzle)

II   CLAMPING UNIT

Task of clamping unit:

  • Fixing and guiding the mold
  • Keeping the clamping force
  • Ejecting the molded part

III MOLD SYSTEM

Mold system consist of:

  • Runner system
  • Cavity (forming the molded part)
  • Cooling system
  • Demolding of part for complex geometry
  • Ejector system

Runner system
Types of runner system are:

  • Cold runner: Bar sprue, pin gate, film gate
  • Hot runner
  • Insulating runner

Cavity
Task of cavity are:

  • Forms geometry of plastic part
  • Responsible for surface quality
  • Equalizes the material shrinkage

Cooling systems
The significant parameter for cooling system are:

  • Cooling channel (geometry and location)
  • Cooling media
  • Cooling time
  • Cooling rate

Ejector systems
Ejector system consists of:

  • Ejector pin
  • Ejector plates
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Diagrams for Understanding Chemical Processes

July 4th, 2009 aryshi No comments

The chemical process industry (CPI) is involved in the production of a wide variety of products, including polymers, that improve the quality of our lives and generate income for the companies and their stockholders.

In general, chemical processes are complex, and chemical engineers in industry encounter a variety of chemical process flow diagrams. These processes often involve substances of high chemical reactivity, high toxicity, and high corrosivity operating at high pressures and temperatures. These characteristics can lead to a variety of potentially serious consequences, including explosions, environmental damage, and threats to people’s health. It is essential that errors or omissions resulting from missed communication between persons and/or groups involved in the design and operation do not occur when dealing with chemical processes. Visual information is the clearest way to present material and is least likely to be misinterpreted. For these reasons, it is essential that chemical engineers be able to formulate appropriate process diagrams and be skilled in analyzing and interpreting diagrams prepared by others.

The most effective way of communicating information about a process is through the use of flow diagrams.

We concentrate on three diagrams that are important to chemical engineers: block flow, process flow, and piping and instrumentation diagrams. Of these three diagrams, we will find that the most useful to chemical engineers is the PFD.

BLOCK FLOW DIAGRAMS (BFDs)

This diagram is a series of blocks connected with input and output flow streams. It includes operating conditions (temperature and pressure) and other important information such as conversion and recovery, given in the problem statement. It does not provide details regarding what was involved within the blocks, but concentrated on the main flow of streams through the process.

The block flow diagram can take one of two forms. First, a block flow diagram may be drawn for a single process. Alternatively, a block flow diagram may be drawn for a complete chemical complex involving many different chemical processes.

An example of a block flow process diagram is shown in Figure, and the process illustrated is described below.

Reaction:C 7H8 + H2 -> C6H6 + C H4

Toluene and hydrogen are converted in a reactor to produce benzene and methane. The reaction does not go to completion, and excess toluene is required. The noncondensable gases are separated and discharged. The benzene product and the unreacted toluene are then separated by distillation. The toluene is then recycled back to the reactor and the benzene removed in the product stream.

Such a diagram is very useful for “getting a feel” for the process. Block flow process diagrams often form the starting point for developing a PFD. They are also very helpful in conceptualizing new processes and explaining the main features of the process without getting bogged down in the details.

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Polymerisation

June 8th, 2009 aryshi No comments

The [chemical] process by which [one or more] monomer(s) becomes a polymer

monomer

end-group

dimer

oligomer

polymer

Addition Polymerisation

a polymer chain grows by addition of monomer to a reactive end-group

addition_drw

oligomer_addition

polymer_addition

Condensation polymerisation

A polymer chain grows step-wise by reaction that  involve the elimination of a small molecule

condensattion

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Categories: Polymerisation Tags: , ,