2008 international lubricants and waxes meeting npra international lubricants and waxes meeting...
TRANSCRIPT
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2008 International Lubricants and Waxes Meeting
NPRA International Lubricants and Waxes Meeting
Session LW-08-106
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2008 International Lubricants and Waxes Meeting
Function and Performance of Hydrocarbon Waxes in Rigid PVC
• By: Thomas C. PedersenRheogistics LLC
Picayune, MS USA
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PVC
2008 International Lubricants and Waxes Meeting
• PVC resin is a free flowing, granular solid with a bulk density of 0.50 to 0.60 gm/ml.
• PVC resin contains 57% chlorine, 38% carbon, and 5% hydrogen.
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PVC Compound
2008 International Lubricants and Waxes Meeting
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PVC Compound
2008 International Lubricants and Waxes Meeting
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PVC Products
Vinyl Siding
Vinyl Siding
PVC Fence
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PVC Pipe
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PVC• Rigid PVC has great properties
– Typical 7000+ psi tensile strength– Excellent stiffness– Excellent impact strength– Good weatherability– Excellent cost performance
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Rigid PVC
• Most rigid PVC properties are affected in one way or another by the lubricant system.
• Getting things right is a constant balancing act.
• Customer quote: “Its always the wax,” VP of manufacturing of a leading building products manufacturer, 1980
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PVC Resin• PVC resin grains are approximately 100
microns in diameter. The large grains are composed of 2 to 10 micron sub-grains which in turn are composed of primary particles with a diameter of approximately 1 micron.
2008 International Lubricants and Waxes Meeting
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PVC Resin
2008 International Lubricants and Waxes Meeting
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PVC Processing
• The 1 micron PVC primary particles are thought to be the primary flow units during rigid PVC processing
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Processing Rigid PVC
• Rigid PVC products are formed by heating and compressing PVC compounds into desired shapes.
• The compound is compressed from a bulk density of approximately
0.50 gm/ml to a product density of approximately 1.40 gm/ml
• PVC is heated to ca. 400°F by mechanical shear and heat transfer.
• During processing, PVC is exposed to pressures of 2000 to 4000 psi.
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Processing Rigid PVC
• The function of lubricants in rigid PVC is to manage the fusion process while preventing the polymer from sticking to the processing equipment.
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PVC Lubrication
• Paraffin and hydrocarbon waxes are used in conjunction with calcium stearate as primary lubricants
• Ca(C18H35O2)2
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Behavior of Lubricants
• The calcium atom or polar end of calcium stearate is attracted to the machine and PVC resin surfaces
• Paraffin wax is thought to act as a slip agent between the exposed tails of calcium stearate
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Fusion Mechanism for Rigid PVC
• C – Compaction• D – Densification• F – Fusion• E – Elongation• Chemical/Plasticizing Effects
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Rigid PVC Fusion in Extrusion
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Fusion Characterization in the Lab
• Torque Rheometer– Fixed volume heated chamber– Work imparted into PVC compound by
mixing blades– Measure torque required to turn the blades
and melt temperature
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Torque Rheometer
2008 International Lubricants and Waxes Meeting
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Torque Rheometer Rotors
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Torque Rheometry Energy Balance
2008 International Lubricants and Waxes Meeting
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Extruder Energy Balance
2008 International Lubricants and Waxes Meeting
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Effects of Fusion Levels on Physical Properties
2008 International Lubricants and Waxes Meeting
• Tensile Properties– Increase with increasing fusion
• Impact Properties– Peak at an intermediate level of fusion
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Trial PVC Compound• PVC Resin 100 parts
• Stabilizer 0.50 phr
• Wax 1.30 phr
• Calcium Stearate 0.65 phr
• Oxidized PE Wax 0.15 phr
• Calcium Carbonate 5.00 phr
• Titanium Dioxide 0.50 phr2008 International Lubricants and Waxes Meeting
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100 grams of PVC Resin
Assume primary particles are spheres
Volume of a primary particle = 5.2x10-13 cm3
Weight of a primary particle = 7.3x10-13 gms
Number of primary particles per 100 grams of PVC resin = 1.4x1014
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1.3 grams of Paraffin Wax
Assume molecular weight of 450 gm/mole
# moles = 0.0029 moles
# wax molecules = 0.0029 * 6.023x1023
= 1.75x1021
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Wax Molecules Per PVC Primary Particle• 1.4x1014 PVC Primary Particles
• 1.75x1021 Paraffin Wax Molecules
• Estimated 10,000,000 to 15,000,000 Wax Molecules per PVC PP
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• PVC Resin 100 parts
• Stabilizer 0.50 phr
• Wax 1.30 phr
• Calcium Stearate 0.65 phr
• Oxidized PE Wax 0.15 phr
• Calcium Carbonate 5.00 phr
• Titanium Dioxide 0.50 phr2008 International Lubricants and Waxes Meeting
Trial PVC Compound
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Torque Rheometry - Classic Wax
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Torque Rheometry - C32
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Torque Rheometry – C26
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Torque Rheometry – C40
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Torque Rheometry – PE Wax
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Test Results
Wax Fusion Time Fusion Torque Fusion Temp Equil Torque Equil Temp
C26 166 sec 21.3 Nm 179°C None >195°C
C32 352 sec 15.2 Nm 183°C 13.0 Nm 188°C
C40 2,120 sec 10.1 Nm 184°C 12.4 Nm 188°C
Classic 318 sec 15.5 Nm 183°C 12.6 Nm 188°C
PE 182 sec 18.9 Nm 182°C None >195°C
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Conclusions
• The PVC Industry is a large application for paraffin and hydrocarbon waxes
• Waxes with carbon numbers of C30 to C36 work best as primary PVC lubricants in North America’s tin stabilized formulations
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Conclusions• The lubricant system is adjusted to tune
the formulation to the heating and shearing characteristics of the customer’s processing equipment.
• Changes in any material or any piece of equipment in a customer’s plant results in the need for a lubricant adjustment.
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Conclusions
• Understanding and managing lubricant performance in rigid PVC is complex
• “Its always the wax.” The PVC industry requires in-depth technical support and service.
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References
• T. C. Pedersen, “Process and Material Considerations in the Industrial Application of Lubricants in Rigid PVC Extrusion”, Journal of Vinyl Technology, 6, 104 (1984)
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References
• J. W. Summers, “Lubrication Mechanism in Poly (Vinyl Chloride) Compounds: Understanding the Three Distinct Roles of Lubricants” Antec 2006, Society of Plastics Engineers.
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References
• P. Benjamin, “The Influence of Processing on the Properties of PVC Pipe”, International Conference on PVC Processing, 6 & 7 April 1978, The Plastics and Rubber Institute.
2008 International Lubricants and Waxes Meeting