Value-Added Polypropylene Using Fillers

Dr. R Rangaprasad Product Application & Research Centre,

Reliance Industries Limited

Polyolefins Compounding

• Introduction to polyolefins compounding • Plastic additives • Compounding machinery • Value – added Polypropylene • Filled & reinforced PP compounds • PP Engineering blends & alloys • PE compounds, blends & alloys • Additive masterbatches

Introduction

Fundamentals of Polymer Stabilization

• PP / PE sold commercially has some basic type of additives & process / property enhancers

• Compounding or melt mixing is the process of incorporating additives & modifiers into PP / PE for achieving uniformity on a scale appropriate to the quality of the product subsequently made from the polymer

Additives For Polymer Stabilization

• Acid neutralizers ( Neutralize acidic catalyst residues) • Antioxidants ( Processing & long term thermal stability) • Slip additives ( Control over COF in blown films) • Processing aids ( Facilitate processing) • Lubricants ( reduce metal –polymer melt contact ) • Antiblock ( Facilitate openability of blown and cast films) • UV stabilizers (Provide protection to polymer from UV light during use) • Nucleating agents (Accelerate crystallization of PP CP & facilitate lower

molding cycle times)

• Clarifiers ( Nucleators which impart glass – like functionality to polymers)

• Antistatic agents ( Prevent development of static charge & dust-pickup )

Value - Added PP

Filled & Reinforced PP compounds

Prepared when PP alone cannot fulfill requirements of end-use sectors

• Talc • Calcium Carbonate • Glass Fiber & glass hollow microspheres • Wollastonite • Mica • Barium Sulfate • Wood flour & other natural fibers( jute, flax, hemp )

Value - Added PP

Modification of PP with minerals, fillers & reinforcements

• Talc filled PP : Improved stiffness • Calcium Carbonate : Improved surface finish • Glass Fiber : Increased tensile strength • Wollastonite : Increased stiffness • Mica : Improved electrical properties • Barium Sulfate : Improved scratch & mar resistance

Value - Added PP Elastomer Modified - PP compounds

• EPDM modified PP • Polyolefin elastomer modified PP • Polyolefin plastomer Modified PP • Thermoplastic Elastomers & Vulcanizates

Noteworthy Applications • Automotive bumpers • Instrument panels • TPE & TPVs as replacement for thermoset rubber

Value - Added Polyolefins

Machinery for making compounds

• Single screw extruders • Twin screw compounders • Farrel Continuous Mixers • Banbury Mixers • Dispersion kneaders • Buss – co - kneaders

Flame Retardant PP compounds

Additives for imparting flame retardancy to PP

• Brominated systems • Chlorinated systems • Halogen Free systems • Melamine based systems • Magnesium hydroxide based • Aluminum Trihydrate based • Treated clays

Flame Retardant PP compounds

Important aspects of FR- PP Compounds

• Physical properties • Mechanical properties • Thermal properties • Electrical properties • Cost of final product

Flame Retardant PP compounds

Testing of FR- PP Compounds

• Limiting Oxygen Index LOI • UL 94 test protocol • Flame spread • Smoke density

PP Engineering Blends & Alloys

• PP/ PS blends & alloys • PP/ABS alloys • PP/HIPS alloys • PP/PMMA alloys • PP/PPO alloys

Demanding requirements from automotive & appliance

sectors for high gloss, scratch resistant PP to target replacement of ABS & HIPS

Thermoplastic Composites based on PP

• Wood filled PP composites • LFTs based on PP • Polyolefin – clay Nanocomposites

PE Compounds

• PE (black) compounded for pipes, pipe coating, ducting • Glass filled HDPE for telecom • Calcium carbonate filled HM HDPE for paper-like films • Specialty films for packaging electronic parts • Foamable & foamed PE compounds • Cross linkable & cross linked PE • PE / PS alloys for engineering applications • Degradable & compostable Polyethylenes

Definition of Masterbatch

A masterbatch is a concentrate of additive /

modifier / filler , usually at high loading levels, prepared by melt mixing in a suitable carrier polymer & other proprietary techniques for easy let- down & dispersion of the ingredient into the host polymer to achieve a set of target properties

Type of Masterbatches

• Additive MBs( UV, LTHA,Slip, Antiblock etc) • Combination MBs • Pigment & Color MBs • Elastomer concentrates • Filler MBs( For furniture, antifibrillation MB for raffia

tape applications)

Foray Into New Product Innovations

• Nanocomposites based on Polyolefins - Automotive &

Barrier packaging • “Active Packaging” films from LLDPE • Cross linked and crosslinkable LLDPE - Roto, Blow &

Pipe sectors • Wood filled PP for profiles and sheets • Long glass fiber PP composites • Biodegradable polyolefins ! • TPEs & TPVs based on polyolefins

Technologies Under Development At PARC

Engineered Products

From

RIL - PARC

Technology Development Programme

Through R & D Efforts

For The

Year 2000 A.D. & Beyond

Technology Development Programme

Objective

• Every programme conceived has a business opportunity for RIL polymers : PE, PP and PVC

• Idea is to develop business for a customer through knowledge developed in-house or through collaborative efforts with customer as technical partner

• All programmes are supported by processing and analytical facilities at PARC

Technology Development Programme

Overview of Projects

• Materials Development

– Collaboration with processors and end-users

• Machinery Development – Collaboration with machine manufacturers and

processors & end-users

Our

Accomplishments

Polypropylene Developments

SEM of glass fibre / PP

T.S. : 350 kg/cm2 T.S. : 810 kg/cm2 High value addition business 360 MTPa

With Coupling Agent Without Coupling Agent

High Strength Glass Reinforced Repol PP for Auto & Appliance Applications

Polypropylene Developments

Flame Retardant Repol PP for Battery Box Applications

Polypropylene Developments

Flame Retardant Repol PP for Energy Meter Box

Flame Retardant Repol PP for Street Light Looping Box

Polypropylene Developments

Thermoformed Door Liner From Blend of Repol C015EG & Repol H020EG With Modifiers

Filled PP Vs HIPS

Polypropylene Developments

Parkhi based on 30% Glass Filled PP

Polypropylene Developments

High Gloss PP Compound for Mixer Body

Polypropylene Developments

20% Talc Filled PP Copolymer for Washing Machine Tub

Polypropylene Developments

Wood Filled Repol PP for Door Liner

Polyethylene Developments

Mulch Film For Groundnut Cultivation Based On

Reclair O19010

Polyethylene Developments

7 micron mulch film based on Reclair LLDPE was successfully developed for groundnut cultivation

Carrying langoors from field Banana loading in Trucks

Unloading at Savda Station Loading in wagons at Savda

Bananas in contact with walls of wagon Bananas opened after 46 hours of packing

Perfor mance

of Active

Packaging Films - A

Picture Essay

1 2

3 4

5 6

Trials on Banana Packaging

Results after 2 days on unloading

Greenhouse Films

Greenhouse Films

PE- Foamed Products

• In-house trials have given

encouraging results

- Consistent & uniform cell structure

- Increase in rigidity

- Good insulation

Crosslinked Products (PE) Crosslinked Products (PE)

• For tractor / Off-road vehicles fuel tank

• For recreation boat hulls

• For reactive / corrosive chemical tanks

Polyethylene Developments

Flame Retardant Reclair LLDPE

While Burning After Removal of Flame

Polyethylene Developments

Elastomer Modified Reclair LLDPE R35042 based Rotomoulded Bumper for India’s First Electric Car “Reva”

Conclusion

• PP blends , alloys & reinforced compounds are fast replacing expensive ETPs in most applications.

• Additive masterbatches based on PE are finding niche applications in preparation of films for agricultural & packaging sectors.