Polyester Manufacturing and Polystyrene.pptx

Chemical Process Technology
CHE-211
Asad U Khan (PhD)

• Esterification is a reaction between Acid and Alcohol resulting in an Ester
plus Water.
• Polyester is a chain molecule formed by many basic ester molecules through
condensation reaction.
• Monomer (single) > Oligomer (some) > Polymer (many)
What Is Polyester?

Polyester
Introduction
• Polyester is a category of polymers that contain the ester functional group in
every repeat unit of their main chain.
• As a specific material, it most commonly refers to a type called polyethylene
terephthalate (PET).
• Polyesters include naturally occurring chemicals, such as in plants and insects,
as well as synthetics such as polybutyrate.
• Natural polyesters and a few synthetic ones are biodegradable, but most
synthetic polyesters are not. Synthetic polyesters are used extensively in
clothing.

Polyester
Introduction
• Polyester fibers are sometimes spun together with natural fibers to produce a cloth with
blended properties.
• Cotton-polyester blends can be strong, wrinkle- and tear-resistant, and reduce shrinking.
Synthetic fibers using polyester have high water, wind, and environmental resistance
compared to plant-derived fibers.
• They are less fire-resistant and can melt when ignited
• Liquid crystalline polyesters are among the first industrially used liquid crystal polymers.
• They are used for their mechanical properties and heat-resistance.
• These traits are also important in their application as an abradable seal in jet engines.

• 1928-1932: Carothers laid the foundation for all processes used in the production
of polyester, polymaide using polycondensation process.
• The polycondensation of ethylene glycol and sebacic acid produced a melt from
which filaments can be drawn by contact with a glass rod.
• Early 1940s: the use of terephthalic acid for development of polyester fibers was
implemented almost at the same time in Germany by Schlack at a branch of Agfa
Wolfen and by Whinfield and Dickson in England in the laboratories of the Calico
Printers Association.
• Whinfield and Dickson preferred using a combination of terephthalic acid and
ethylene glycol to produce polyester. Schlack used terephthalic acid and 1,4
butanediol.
History of the development of Polyester Fibers

• The combination chosen by Whinfield and Dickson was the most favorable from
the point of economy and application to textile usage and that is the reason it has
succeeded over the combination used by Schlack.
• 1947: Mass production started in United Kingdom by I.C.I. and in USA by Dupont
after both companies acquired the patent rights from Calico Printers' Association Ltd.
in Manchester. The I.C.I. marketed their polyester fiber as 'Terylene' while Dupont
marketed their product as 'Dacron’.
All the procedures have one thing in common:
• Preparation of the polymers;
• Spinning of the polymers into filaments;
• Further processing of filaments into continuous filament or staple fibers.
History of the development of Polyester Fibers

Polymerisation
Esterification
Dimethyl Terephthalic Acid
(Trans-esterification)

Polymerisation
Esterification
Polybutylene Terephthalate

PET - Polyethylene Terephthalate
• Raw materials: EG + PTA (Esterification process) or EG + DMT (Trans estrification process)
Polyester Manufacturing

IMPORTANT POLYESTER
Production
• The polymer is made by heating teraphthalic acid with excess of ethylene glycol ( Both of
high priority) in an atmosphere of nitrogen initially at atmospheric pressure.
• A catalyst like hydrochloric acid speeds up the reaction.
• The resulting low molecular weight ethylene glycol teraphthalate is then heated at 280
°C for 30 minutes at atmospheric pressure and then for 10 hours under vacuum.
• The excess of ethylene glycol is distilled off, the ester can polymerise now to form a
product of high molecular weight.
• The resulting polymer is hard and almost white substance, melting at 256 °C and has a
molecular weight of 8000-10000.

Polyester Yarn Manufacturing
Polyester Yarn Manufacturing Process - From Chips to Yarn

Unsaturated Polyesters
• Raw materials: EG/PG + Phatic Acid/Anhydride/Maleic Acid/Anhydride
Unsaturated Polyester Manufacturing

Unsaturated Polyesters
• Raw materials: EG/PG + Phatic Acid/Anhydride/Maleic Acid/Anhydride
Unsaturated Polyester/Epoxy Resin Manufacturing

• Raw materials: PET, EG/DEG + Maleic Acid/Anhydride
Unsaturated Polyester from PET
(Upcycling of PET)

• Raw materials: PET, EG/DEG + Maleic Acid/Anhydride

• Curing of Unsaturated
Polyester Resins

Fibre applications
• Filament yarn
• Industrial yarn
• Staple fibre
• Nonwoven spunbond
• Special fibre products
Bottles and Containers
• Stretch blow molded bottles
• Extrusion blow molded bottles
Pet Application:
Biaxial Oriented Films (BOPET)
• Electronic media Photo technique
• Electrical insulation
• Packaging
Cast films, A-PET
Food trays ovenable, C-PET
Engineering plastics
IMPORTANT POLYESTER

PET Characteristics:
• Because of higher melting (252 ~ 256 °C) and glass transition (about 80
°C) temperatures retains good mechanical properties up to 150 ~ 175 °C .
• Its chemical and solvent resistance is good.
• It has good fibre forming properties, has outstanding crease resistance
and work recovery and low moisture absorption.
IMPORTANT POLYESTER

PBT - Polybutylene Terephthalate:
Characteristics:
• Its melting point is 232 °C, and mainly used in industrial plastics. Also been used to
manufacture carpet yarns and textile fibres.
• The base resin is widely used in compounding as it has good chemical and heat
resistance and outstanding electrical properties.
• It is easy to make flame retardant and master batches.
IMPORTANT POLYESTER

PBT Applications:
• Electrical/electric connectors
• Smart Network Interface Devices (SNID’s)
• Power plugs and electrical components
• Switches and controls
• Circuit breaker enclosures
• Outdoor telecommunications enclosures
• Automotive under-hood components
• Electrical appliance components
• Fiber optic tubes Medical applications such as clamps, pump parts, plugs, etc.
IMPORTANT POLYESTER

PTT – Poly-tri-methylene Terephthalate
Raw materials: PDO (1,3-Propanedio)+ PTA
PTT Characteristics:
It can be spun into both fibers and yarns.
Its Stain and wearability resistance, colour fastness, softness and stretchable.
Its melting point is 233 °C and its easy to dye below 100 °C.
PTT Applications:
It has extensive applications is in carpeting, textiles and apparel, engineering
thermoplastics, nonwovens, films and mono-filament.
IMPORTANT POLYESTER

• A-PET: processed into amorphous, non-drawn cast films 150 to 1000 microns, are
used to manufacture all types of rigid packaging, such as jars, meal trays & folded
boxes, etc.
• C-PET: a specially modified polyester obtained by adding crystallization accelerators
and is mainly used to manufacture ovenproof meal trays for ready-to-serve meals.
• G-PET: these are highly modified polyesters, whereby the EG is replaced by other
glycols, e.g., CHDM (Cyclohexanedimethanol), are amorphous and uses ranging from
A-PET to injection and extrusion blow moulding. Due to high modifier content are
relatively expensive.
SPECIAL PET PRODUCTS

• Bottle PET: are polyester feedstock for manufacturing bottles produced by
stretch-blow moulding, melting temperature & crystallisation rate are
reduced by use of comonomers, e.g., IPA ( Isophthalic Acid), DEG & CHDM.
• Co-PET: is a generic term for all copolyesters which contain apart from PTA an
additional acid e.g., IPA or an additional glycol e.g., CHDM. The majority of
bottle polyesters, A-PET and G-PET are copolyesters.
• BOPET: are biaxially oriented polyester films of 1 to 300 microns. Special anti-
blocking additives are used to improve winding characteristics.
SPECIAL PET PRODUCTS

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