Technology of PVC Compounding and Its Applications [PDF]

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TECHNOLOGY OF PVC COMPOUNDING AND ITS APPLICATIONS PVC RESINS MANUFACTURING & PROPERTIES •Introduction •Manufacture of PVCSuspension Polymerization Process •Clean Reactor TechnologyLarge Reactor Technology •VCM Containment •Mass Polymerization Process •Emulsion Polymerization Process •PVC Mass Polymerization •Comparative of PVC Produced using Different Processes •Copolymers, Chemical Modification & Blends/Alloys of PVC •Introduction •Reactivity Rations for VCM Copolymerizations •PVC Copolymers •Vinyl Acetate Copolymers •Recipe for VCM-VAC Copolymerization •Effect of VAC on Properties of PVC Copolymer •Copolymers with Olefins •Effect of Ethylene or Propylene on PVC properties •Copolymer with Vinyldene Chloride •Copolymers with Acrylates •Chemically Modified PVC •Introduction •Syndiotactic PVC •Effect of PVC Polymerization Temperature on Crystallinity •Chlorinated PVC •Comparative Properties of PVC & CPVC •PVC Grafts •Acrylic Graft •Properties of PVC Grafts •EVA grafted PVC •Cross linked PVC •Monomer for X-PVC Preparation

•PVC Blends & Alloys •PVC/NBR Blend •Properties of PVC/NBR Blends •Powered NBR •PVC/NBR •Dynamically Vulcanized PVC/NBR •Comparative Properties of PVC/NBR Blends and Thermoplastic Rubbers •Typical Properties of Elvaloy Resins •Comparative Properties of PVC/EVA Blends •PVC/ABS Alloy •Dynamic Thermal Stability of PVC/ABS Alloys •Comparative Properties of PVC Alloys •PVC/Acrylic & Miscellaneous Alloys •Properties of PVC/Acrylic Alloys •Properties of PVC/Gadds Alloys •Heat Deflection under Load for PVC Alloy •Effect of processing Temp. on Rheological properties of PVC/Gadds Alloy •Effect of PVC:Gadds Composition on Torque PROCESSING OF PVC •PVC Resins •Molecular Weight •Injection Moulding •Extrusion •Additives for Improving Processing •Heat Stabilizers •Processing Aids •Lubricants •Impact Modifiers •Compounding •Low Shear Horizontal Mixers (Ribbon Blenders) •Higher Shear Vertical Nonfluxing Mixers •Dry Blend Properties •Low Shear and High Shear Mixing in Horizontal, Jacketed Cylindrical Blenders •Hot Melt Compounding •Two Stage (Farrel) Continous High Intensity Fluxing Mixers

•Compounding Lines-Batch Type •Suggested K-Value of PVC Resins •Influence of Formulations on processing behavious •The Polymer •Relation of Polymer K-Values with Threshold Temperature •Lubricants •Heat Stabilizers •Processing Aids •Impact Modifiers •Plasticized PVC •Extrusion •PVC Compounds-Some Routes and Processing •Calendering •Injection Moulding •Unplasticized PVC •Typical Formulation of Rigid and Flexible PVC Films and Functions of various components there-in •General Types of Industrial PVC Compounding Operations •Equipments for Compounding of PVC •Calendar Products and their Products •Processing of Rigid PVC •Injection Moulding -Rigid PVC •Injection Blow Moulding (IBM) •A Typical Injection Moulding Screw Design for Rigid PVC Material •Three Station Horizontal Indexing Injection Blow Process •Biaxial Orientation •Conclusions •Typical High-Flow PVC Formulation •Blow Moulded Bottles and Containers •Reheat Stretch Blow •PET Vis-A-Vis PVC Stretched Bottles •PVC Heat Shrinkable Bands •Blow Moulding of PVC Bottles •Injection Blow Moulding •Orientation

•Cushioned Vinyl Flooring •Wide Choice of Different Substrates •Streen Coating System •Way ahead in Flexibility •Versatility in Coating •One Pass Production •Unique Process Improvements •Principle of Operation •Embossing problems a thing of the past •Double sided Coating of Openweave Fabrics •Single screen coating process •Screen to screen coating process •Principle of application •Recycling •Description of the Process •Compounding Internal Mixers •Internal Mixers •Schematic View of Compounding Operations •Unit Operations to Produce Glass Filled Polymers •Post Compounding Operations •Schematic of Banbury Mixer •Schematic of a Grnulator •Schematic of a strand pelletizer ADDITIVES FOR PVC •Introduction •Plasticizers •Plasticizer usage for PVC Compound •Typical Properties of Plasticizer •Physical Properties of Phthalate Plasticizers •Physical Properties of less common Phthalates •Properties of Specially Plasticizers •Physical Properties of Miscellaneous Plasticizers •Plasticizer Efficiency and Properties of Flexible PVC •Plasticizer Efficiency

•Dry Blending Time for Plasticizers •Effect of Plasticizers on Plastisol Gelation Temperature •Effect of Structure of Plasticizer on PVC Properties •Properties of Flexible PVC compounds at 50 PHR Phthalate Plasticizer Level •Physical Properties of Flexible PVC using specially plasticizers •Requirements for PVC Plasticizers •General Relationships between the structure of Plasticizers and their behaviour in PVC •Characteristics of the Major Types of Plasticizer •Polymeric Modifiers for PVC •Modifiers for Flow Improvement •Flow Promoter for PVC •Haake Rheogram for Rigid PVC Pipe Compound •Standard PVC Pipe Compound 2 PHR Modifier •Effect of Level of Flow Promoters on UPVC Rheological Properties •Effect of Low Molecular Weight Polymers •Typical Properties of Flow Promoters •Modifiers for Impact Enhancement •Mechanism of Impact Resistance •Effect of Modifier Quantity •Effect of EVA •Effect of Processing Time on Impact Strength •Systems with Honeycomb Network •Effect of Processing Conditions •Effect of Processing Conditions of UPVC •Effect of MBS/Acrylic Quantity on UPVC Impact Strength •Effect of Composition on Impact Resistance •Effect of Temperature of UPVC •Impact •Applications for Impact Modifiers •Heat Stabilizers for PVC •HCI Absorption •Elimination of Labile chlorine •Prevention of Autoxidation •Addition to polyene secuence •Carbenium ion elimination

•Lead Stabilizers •Structure of Lead Stabilizers •Tin Based Stabilizers •Structure of Tin stabilizers •Barium Cadmium Stabilizers •Stabilization by Barium and Cadmium Stabilizers •Calcium-Zinc Stabilizers •Non Metallic Stabilizers •Epoxy Based Stabilizers •Effect of Epoxy and Phosphite on PVC Static Thermal Stability •Organic Phosphites •Polyhydric Alcohols •Antioxidants •Light Stabilizers •Lubricants •Appearance and Melting Point of Lubricants •Calcium Carbonate •Physical Properties of CaCO3 Fillers •Clay & Talc •Silicas & Glass Fibres •Properties of Glass Fibre Reinforced PVC •Flame Retardant Agents •LOI for Various Plastics •Chlorinated Flame Retardants •Brominated Compounds Metal Oxides •Chemicals and Additives-A Review of Future Outlook •Colourants •Blowing Agents •Heat Stabilizers •Plasticizers •UV Stabilizers •Antimicrobials •Flame Retardants •Phosphate Ester Flame •Retardants/Plasticizers for Polyvinyl Chloride (PVC)

•Effect of Various Flame Retardants in Plasticized •Polyvinyl Chloride •Plasticized PVC with High Oxygen Index Use of Brominated Phosphate •Typical High emperature Wire Cable Polyvinyl Chloride Flame Retardant COMPOUNDING •Introduction •Mixing Theory •Limitations of Mixing Theory •Mixing Evaluation •Fillers •Common Fillers and their uses •Plasticizers •Colorants •Heat Stabilisers •Antioxidants •Ultraviolet Light Absorbers •Antistatic Agents •Flame Retardants •Blowing Agents •Lubricants •Methods of Compounding •Intensive Dry Mixers •Internal Intensive Batch Mixers •Continous Mixer •Two Roll Mills and Pelletisers •Underwater Pelletiser •Single Screw Extruders •Compounder Extruder •Twin Screw Extruder •Compounding Lines COMPOUNDING OF PVC •Selection & Characterization of PVC •Major Types of PVC Resins •Processing & Applications of PVC

•PVC Resins Properties •Relation of PVC K-Value, Viscosity & Mole Wt. •Effect of Polymerization Temp on % Crystallinity •Syndiotactic Structure •PVC Morphology and PVC Characteristics •Effect of PVC Morphology on Extruder Output •Rheological Properties of PVC Dry Blends •Effect of PVC Resin Bulk Density on Rheological Properties •Effect on Processing RPM on Rheological Properties •Effect of Processing Temp. on Rheological Properties •Effect of Bulk Density on DOP Absorption •Introduction •Elements of Compounding •Methods of Compounding •Intensive Dry Mixers •Internal Intensive Batch Mixers •Contionuous Mixer •Two Roll Mills •Single Screw Extruders •Compounder Extruder •Twin Screw Extruder •What are some of them ? •Custom Compounding for Special Properties •General Guidelines for PVC Formulations for Common Product •Formulating Rigid PVC Compounds •PVC Pipe Formulations •PVC Conduit Pipe Formulations •Window Profile Formulations •Interior PVC Profile Formulations •PVC Siding Formulations •Cellular PVC Profile Formulations •Extruded PVC Sheet and Film (Single -Screw) •Calendered PVC Sheet and Film Formulations-Second Alternative •PVC Injection Moulded Pipe Fitting Formulations •High Flow PVC Injection Moulding Formulations

•Extrusion Blow Moulding Rigid PVC Containers •Crystal Clear Food Contact Bottles •Clear Bottles good on taint and odour •Blow Moulded Bottle Formulations •Blow Moulded PVC Bottle Formulations •CA-ZN Formulation (Mineral Water) •CA-ZN Epoxy Recipe for 1 Litre Bottle •PVC Bottle for Shampoo •Shoe Soles •Tests for Compound •Floor Coverings/Wall Coverings •Typical Light Stable Formulation •Carbon Black Properties •Comparison -Titanium Dioxide and Zinc Oxide •Portable Water Pipe (Extruded from Dry Blend) •General Purpose Vinyl Film by Calendering •Sheeting for Outdoor Upholstry COMPOUNDING OF PVC PASTES •Plastisols •Compounding Ingredients of Plastisols •PVC Polymers •Plasticisers •Stabilisers •Fillers •Colourants •Thickeners •Other Additives •Organosols •Compounding Ingredients •Preparation of Pastes •Gelation •Applications of PVC Pastes •Rotational Casting Formulation for Dolls and Play Balls •Compounding of PVC Latices •Latex Property Modifiers

•Latex Stabilisers •Surface active agent •Defoaming Agents •Thickeners •pH Modifiers and Buffers •Polymer End Properties Modifiers •Heat Stabilisers •Plasticisers •Fillers •Pigments •Antiblocking Agents •Coalescing Aids (Volatiles) •Handling and Processing •Mixing •Dipping •Coating •Spraying •Compounding of PVC Solution & Adhesives •Plasticizers •Stabilisers •Fillers •Pigments •Lubricants •Methods of Application of Solutions •Applications of Solutions Adhesives TESTING OF RESINS AND COMPOUNDS •Testing of PVC Resin •K-Value •Bulk Density •Plasticizer Absorption •Particle Size Distribution •Electrical Conductivity of Water Extract •Powder Flow •Sulfated Ash Content

•Fish Eye Count •Testing of PVC Compounds •Bulk Density •Shore Hardness •Tensile Strength/Elongation •Static heat Stability •Dynamic Heat Stability •Brabender/Haake Gelation & Degradation Time •Electrical Volume Resistivity •Volatile Loss •Ageing Test •Cold Bend Temp. Test •Testing of PVC End Products •Films/Sheets/Profiles •Tensile Stress at Yield •Test for Dimentional Change at 120o C •Rigid PVC Pipes for Potable Water Supplies •Dimensions of Pipes •Visual Appearance •Opacity •Short Term Hydraulic Test •Long Term Hydraulic Test •Reversion Test •Impact Strength at oC •Methylene Dichloride Test •Flexural Strength •Wires and Cables •Thermal Stability Test •Determination of PVC Cable insulation Degradation •Comparison of Techniques to Assess FVC Degradation •Problem Solving in PVC Compounding and Processing •Resin •Lubricants •The Role of Lubricant •In PVC Compounding

•Stabilizers •Additives •Material Characteristics and its effect of processing resins •Development of an Optimum Formulation •New Do's and Don'ts •Plasticizer Migration •High Purity Non-Stain Plasticizers for Floor and wall Coverings •Testing •Sample Preparation •Cure •Stain Specimen Conditioning •Stain •TGATensile Properties •Hardness •Results •Chemical Resistance •Rigid •Chemical Resistance of Vinyl Compounds: Percent Change in Weight SPECIALITY PLASTIC COMPOUNDS & MASTERBATCHES •Introduction •Product •Coloured Masterbatches •Additive Masterbatch/Speciality Compounds •Market •Suggested Capacity •Land & Building •Raw Materials •Utilities •Manufacturing Process •Plant & Machinery •Personnels •Estimated Cost of the Project •Suggested Means of Financing PVC COMPOUNDS •Introduction

•Product •Market •Suggest Capacity •Land & Building •Raw Materials •Utilities •Manufacturing Process •For Rigid Pipes •For Bottle Blowing •For Blown Film •For Flexible Hose Pipes •For Mineral Water Bottle •Plant & Machinery •Personnels •Estimated Cost of the Project •Suggested Means of Financing XLPE CABLE COMPOUND, JELLY FILLED TELECOMMUNICATION CABLE COMPOUND & SHEATING COMPOUND •Introduction •Product •XLPE Compound •MDPE Compound •FRLS Compounds •Land & Building •Raw Materials •Utilities •Manufacturing Process •XLPE Compound •MDPE Compound FRLS & Low Halogen •Compounds •Plant & Machinery •Personnels •Estimated cost of Project •Suggested Means of Financing

PLASTIC GRANULES FROM FRESH RESIN •Manufacturing process of LDPE Granules from LDPE Resin •Plastic Filler Granules (PP) •PVC Granules •Process of Manufacture •Plant Economics •Fixed Capital •Raw Materials •Total Working Capital •Total Capital Investment •Turn Over/Annum PLASTIC GRANULES •Process of Manufacture •Concentration of Blending •Removal of Colour to obtain Transparent Granules by Activated Carbon Treatment •Filteration •Distillation •Cooling and Dehumidifying •Granulation •Weighing, Filling and Packing •Plant Economics •Fixed Capital •Raw Materials •Total Working Capital •Total Capital Investment •Turn Over/Annum APPLICATIONS OF PVC •Review of Major Applications •Rigid PVC Pipes •Advantages of Rigid PVC Pipes •Graphical Sketch of a Twin Screw Extruder •Applications •Chemical Resistance •Resistance of PVC Pipes to Common Chemicals under use Conditions

•Composition Energy Saving of PVC Pipes •Weathering •Summary of the Testing Results •Flow through Rigid PVC Pipes •Flow or Friction Losses •Surge and Water Hammer •Economics of Rigid PVC Pipes •Water Flow Velocity •Start up •Schematic of a large tube die •some Common Problems and Solutions of Pipe Extrusion •Industrial Profiles •Various Forms •Major Applications •Cellular PVC Profiles, Boards and Pipes •Introduction •Technology of Structural Foam extrusion •Foaming •Foaming Processors •Free Foaming Process •Inward Foaming Process •Machine and Die Technology •Extruders •Dies •Chemical Blowing agents •Processing aids •PVC grades •Properties of Cellular UPVC Pipes •Physical Properties of Cellular UPVC Pipe •Physical Properties of Cellular UPVC Board and Profile •Manufacturing of PVC Sheets •Calendering •Extrusion of PVC Sheets •Extrusion Blowing of PVC Sheets •Calandrette Process

•Further Processing of Sheets by Forming •Requirements of PVC Sheets •Roller Film Calender •Calenders •Blister Packaging •Vacuum Formed Products •Skin Packaging •Problems and Suggested Remedies in Sheet Extrusion •Calendered Film-Typical Problems •Thickness Variation •Film Curling or Side Bending •Flatness Defects •Blister Packaging •Calendering of Rigid PVC Compounds •Advantages of Calendering Process •Blister Packaging Components •Heat Seal Coatings •Selection of Paperboard •Blister Packing Vs Skin Packaging •Blister Packaging Machinery •Advantages of Blister Packs •Blister Packaging Constraints •Blister Packaging in Pharmaceutical Industry •some Typical Applications of PVC Sheets •Typical Blister Packaging Applications •End Use Applications Chart •Non Packaging Applications •Tropicalised Blister Pack-ANew Concept •Rigid PVC Free Foam Boards •Areas of Application Overseas •Advertising •Building Sector •Electrical Industry •Miscellaneous •Typical Values of PVC

•Integral Foam Sheets •PVC Integral Foam Sheets Applications •Characteristics •Advantages •Fabrication •Major Applications •Expanded PVC for Replacement of Wood •Free Foaming •Surface Treatment •Fabrication of PVC Sheets •Matchining •Rigid •Flexible •Cutting •Rigid •Flexible •Drilling •Punching and Blanking •Planning •Routing and Milling •Screwing and Tapping •Grinding and Sanding •Engraving •Adhesive Bonding •PVC to Other Materials •PVC to itself •Printing and Metallising •Laminating and Plastification of Printed Master •Welding •Ultrasonic Welding •High Frequency and Radio Frequency Welding •Shaping of PVC •Cold •Hot •Three Dimensional Shaping

•Simple Forming •Injection Moulding-Rigid PVC •Injection Blow Moulding (IBM) •Biaxial Orientation •High Flow Injection Moulding Applications •Conclusions •Typical High Flow PVC Formulation •Blow Moulded Bottles and Containers •Reheat Stretch Blow •Pet vis-a-vis PVC Stretched Bottles •PVC Heat Shrinkable Bands •Blow Moulding of PVC Bottles •Injection Blow Moulding •Orientation •Cushioned Vinyl Flooring •Wide Choice of Different Substrates •Prodution of Cushio Vinyl Flooring Using glass fibre •Production using asbestos mat •Rotary screen printing system for cushion vinyl flooring •Screen Coating System •Way ahead in FlexibilityVersatility in coating •The screen coating system: Advantages •One Pass Production •Unique Process Improvements •Principle of Operation •Embossing problems a thing of the past •Double sided Coating of Open weave Fabrics •Single Screen Coating process •Screen to screen coating process •Principle of application •PVC in Medical Applications •Typical Medical Grade PVC Compound for Extrusion •Moulding of PVC Footwear •Compounding •Moulding

•Machines •Moulds •PVC Uppers •Processing •Coatings •Sectional View of a coating Machine •Various types of spreader •Rotational casting and slush moulding •Dipping •Injection Moulding •Extrusion •Graphical Sketch of a twin screw extruder •Screw Temperature Control •Application Principle •Friction free Applications •Clear, simple operation •Two sided coating of openweaving fabrics •Tarpaulin Coating Line •PVC Coated Tarpaulines •Properties of Vinylidene Chloride Copolymer Films •Properties of VDC copolymer Films made •From Aqueous Latices and from Solutions •Lamination Methods •Direct lamination in cleander of two PVC Sheets •Lamination in calender of several sheets •Independent Lamination and Embossing •Laminating and Embssing Plant •Lamination and embossing of three PVC or PVC/ABS sheets •Embossing of wall paper coated with vinyl film •Roller Melt Process •Description of the Process •Application Carrier Materials •The Roller Melt Process is suitable for Recycling •Processable Raw Materials •Advantages of the Process

•Process of Plasticised PVC •Processing of PVC Pastes •Dipping Process •Slush or Rotational Moulding •Blown Films •Moulding of PVC Footwear •Moulding •Flexible (Soft Plasticized) PVC Film RECYCLING OF PVC •Plastics Waste Management Hierarchy •Coding as an aid to separation •Recycling of Short Life PVC Products •Bottles •Separation by Hydrocyclones •New Products from Recycled PVC Bottles •Prospects for Chemical Recycling of PVC •Tecoplast Bottle Plant •Service Life of PVC Products •Recyclable Vinyl •PVC Bottles, Jars and Containers •Design Considerations •Physical Properties •Marketing Consideration •Safe and Recycleable •Lower Mold Costs SUPPLIERS OF RAW MATERIALS PRESENT MANUFACTURERS SUPPLIERS OF PLANT & MACHINERIES Engineers India Research Institute (EIRI) is a renowned name in the industrial world for offering technical and financial consultancy services. EIRI services are: •Detailed Feasibility Reports •New Project Identification

•Project Feasibility and Market Study •Identification of Lucrative Industrial Project Opportunities •Preparation of Project Profiles / Pre-Investment and Detailed Feasibility Studies, •Market Surveys / Studies, Market Survey Cum Detailed Techno-Economic Feasibility Reports •Project Reports in CD Roms •Identification of Plant /Process/Machinery and Equipment, Industrial General Guidance for setting up new industrial projects. Our most up-to-date and Technologically Advanced Industrial Project Reports, categorized with respect to Financial Outlays and Sector – wise Classification are immensely useful for : •Existing Small or Medium Scale Industrialists facing competition from large houses •Young Entrepreneurs dreaming to start their own industrial enterprise •Young Graduates and Professionals wishing to begin their career •Industrialists interested in Debottlenecking their capacities & New Product – Lines