chemical engineering
DESCRIPTION
PEEK PMMA Kevlar PTFE PLA PC POM. Chemical Engineering . Cooper Union for the Advancement of Science and Art Summer Research Internship Program, Summer 2013 Professor Benjamin Davis . Polyether Ether Keton e. Rabia Akhtar and Ozzy Khan . History Markets. - PowerPoint PPT PresentationTRANSCRIPT
Chemical Engineering
Cooper Union for the Advancement of Science and Art
Summer Research Internship Program, Summer 2013
Professor Benjamin Davis
PEEKPMMA KEVLARPTFEPLAPCPOM
POLYETHER ETHER KETONE
Rabia Akhtar and Ozzy Khan
HISTORY MARKETS
Industrial: 39%Electronics: 24%Transport: 26%Medical: 11%
The percentage share of world consumption of Victrex PEEK by sector for the year 2012.
PROPERTIES AND USES
CHEMISTRY AND RAW MATERIALS
PEEK
Hydro-quinone
Arbutin
DFBP
DADM
Aniline
Nitrobenzene
Benzene
Petroleum
Nitric acid
Nitrogen Dioxide H2O
Formaldehyde
Methanol
CO2 H2
Sodium nitrate Hydrogen fluoride
SAFETY AND DISPOSAL
REACTOR DESIGN
Time: 41.7 days/batchBatch size: 3750 kg Spools per batch: 4,650 Spools per day: 100 Spool size: 250’ 1” PEEK electrical sleeving
Tank Size: 3,400 L Temperature: 90ºC
Polymethyl Methacrylate: PMMA
Saijah WilliamsMia Rodie
History and Markets• Discovered in 1877 by Fittig
and Paul
Uses and Properties
1972 Olympic Stadium- Munich, Germany
(pontiacgrandprix.net)
Edge-lighting.com
Headlights made of PMMA
Lighting Applications of PMMA LG LCD television
Polymer Chemistry• PMMA is made of methyl methacrylate. PMMA is most commonly polymerized
through free radical polymerization. • The application of PMMA traces back to the type of polymerization used.
Type of Polymerization Application
Bulk Plexiglas®
Solution Adhesives, paint resins
Suspension PMMA beads
Emulsion Paper coating agents, paper processing agents, textile binders
Raw Materials and Production Process
Hydrogen Cyanide
AcetoneMethyl formate
Methyl methacrylate
methyl a-hydroxyisobutyric
Methyl formate
a-hydroxyisobutyric
acid amide
Hydration of acetonecyanhydrin
Acetone
Prussic acid
Reactor Design
• Goal: 100 sheets of Plexiglas® per day• Amount of PMMA per year: 800 metric
tons• Amount of time per batch: 5.6 minutes
Equation 1
Variable Meaning
Ki, Kp, Kt Rate constants
p Polydispersity
[M] Concentration of monomer
[I] Concentration of initiator
Kevlar
By: Caroline Hunt & Isael Luperon
History and MarketCreated in 1964 by Stephanie KwolekProduced by DuPontFirst commercial use in 1971Mainly produced in USACosts : $12 - $27
Uses & PropertiesAdvantages:
Tensile strength Chemical resistanceStructural rigidityThermal resistanceLightweight
Disadvantages:Absorbs moisturePoor against
compression Poor against UV rays
4 5
6 7
32
Polymer Chemistry
1,4-phenylene-diamine(para-phenylenediamine)Terephthaloyl
Chloride HydrochloricAcid (byproduct)
Poly-para-phenyleneTerephtalamide (Kevlar)
Results of Reactor DesignGoal: 1,000 pairs of Kevlar gloves per dayTotal monomer: 835 molesTotal solvent: 278 molesTotal volume of tank: 150 Liters Time for one reaction: 9.7 seconds
By Sally Kramer
Properties, Uses, and Production of Polytetrafluoroethylene
Dr. Roy Plunkett
History, Discovery, Markets, Demand, Chemical Formula and PricesTeflonRoy Plunkett 1938 DuPont CompanyProduction rate of 900 tons per year in
1948 will grow to 240,000 tons per year by 2017
0123456789
10
2010
2011
PTFE Price as a Function of Time
Year
Pric
e pe
r po
und
($)
Figure 2
Polymer Chemistry, Raw Materials, and Production Process
CHCl3 + 2HF CHClF2 + 2HCl (1)
2CHClF2 F2C=CF2 + 2HCl (2)
Fluorspar, water, sulfur, air, natural gas
Ethics and SafetyCarcinogens and birth defects“Fracking” for natural gasDon’t leave an empty Teflon coated
pot or pan over an open flame!If your pan starts tolook like this, throw itaway!
Reactor Design for GasketsGoal: 10,000 Teflon gaskets per day, each
12.947gTen hours per batch, two batches per day24.399 kg
dimethylamine oxide dihydrate
8.714 kg glacial
acetic acid
87.14 kg TFE
26,142 kg water
64.725 kg PTFE
Producing Polylactic Acid By: Kevin Garcia and Janki Tailor
History/ Discovery/ Introduction
O Similar to petroleum based plastics but its biodegradable
O Lactic acid discovered in 1780 by Carl Wilhelm Scheele and PLA discovered in 1932 by Wallace Carothers.
O First official PLA production plant launched in Blaire, Nebraska.
Markets/ Demand/ PricesO Used in fibers, packaging,
and chemical products markets
O Archer Daniels Midland Company, Cargill Inc., and Ecochem
O 6.6 billion lbs. PLA produced annually$6 billion per year
O Global lactic acid production: 40,000 tons per year
Markets and Markets. http://www.marketsandmarkets.com/Market-Reports/polylacticacid-387.html (accessed July 9th, 2013), Global Lactic Acid & Polylactic Acid (PLA) Market by Raw Materials, Types, Applications, and Potential Opportunities (Forecast to 2016).
Uses/ Properties
RigidsThe Potential of Bio-Based Plastics. Steeman, A.
http://bestinpackaging.com/2009/11/30/the-potential-of-bio-based-plastics/ (accessed August 7, 2013).
Food ServicewareExcellent Packaging & Supply (EPS). http://www.packaging-
int.com/suppliers/excellent-packaging-supply-eps.html (accessed August 7, 2013).
Polymer ChemistryO Monomer: L-Lactide
(two lactic acids combined)
Lactic AcidIntech. Jamshidian et al.
http://www.intechopen.com/books/biodegradation-life-of-science/biodegradable-
polymers (accessed July 23, 2013).
L-LactideFuterro.
http://www.futerro.com/products_lactide.html(accessed August 7, 2013).
O Most methods for making PLA are not economically viable
O Methods to synthesis PLA:O Step Growth O Ring Open
Polymerization
Raw Materials/ Production/ Safety
O PLA is eco-friendly, and releases carbon dioxide and methane when it degrades
Corn Starch Fermentation
Lactic Acid PLA Step Growth
Lactide Ring-open Polymerization
Batch DesignO Task: To design a batch
reactor to make these cups
O Goal: Make 10,000 plastic cups/day
O Bulk Reaction
O Catalyst used for reaction: Tin Octoate
Fabri-Kal. http://www.fabri-kal.com/product/greenware-cold-drink-cups/ (accessed August 6, 2013)
Results for our Batch Reactor
OTime per batch: 200 hoursOBatches per year: 44 batches OCups produced per batch: 82,955 cupsOMass of monomer used per cup: 48.65 gOVolume of batch reactor: 3.16 cubic meters
Lactide
PLA
Polycarbonate (PC)
Paulina BabiakAnd
Fradah Gold
Uses and Properties
Polymer Chemistry
ABispheno
l-A
BPhosgen
e
CPolycarbonat
e
Phenyl Groups
Methyl Groups
Carbonate
and Safety
Raw MaterialsPolycarbonate (C16H14O3)
Bisphenol-A (C15H16O2 )
Phenol (C6H5O)
Coal Tar C14H18O4ClN5
Coal
Acetone (C3H6O)
Benzene (C6H6)
Petroleum (crude oil)
Propylene (C3H6)
Petroleum Coal Natural Gas
O2
Phosgene (COCl2)
CO
CO2 C
Cl2
$1.75/lb
$0.94/lb $0.74/lb
Phenol NaOH
Phosgene Acetone
Diphenylcarbonate
Bisphenol- A
NaCl
POLYCARBONATE
(Condenser)
Caustic soda
200 L 200ºC 153 min
Process Design for 10 Million CDs
Markets
Polycarbonate Life Cycle
BY O L I V I A KA Z I O R A N D R E E C A N J U A R E Z
POLYOXYMETHYLENE (POM)
INTRODUCTION
• General molecular structure:
H—(—O—CH2—)n—OH
• Discovered during the 1920’s by German chemist Staudinger
• Production began in the U.S. in 1959 when it was finally made thermally stable by chemical company DuPont
MARKETS
Table 2. Percentage share of world POM consumption by market sector, 1999-20025
1999 2000 2001 2002
Automotive 31.8% 31.8% 32.0% 31.8%
Electrical & Electronics 23.1% 23.3% 23.0% 23.0%
Consumer Products 20.4% 20.3% 20.6% 20.9%
Industrial 17.1% 16.9% 16.4% 16.2%
Others 7.5% 7.6% 8.0% 8.3%
Table 1. POM consumption by region, 1999-2002
1999 2000 2001 2002
Western Europe 28.8%
29.5%
29.6%
29.6%
North America 23.7%
23.5%
23.0%
23.0%
Japan 15.7%
13.8%
13.9%
13.1%
Remainder of Asia Pacific
31.8%
33.1%
33.5%
34.3%
Source: Platt, D. Engineering and High Performance Plastics Market Report; iSmithers Rapra Publishing, 2003; pp 43
PROPERTIES & USES
• Great mechanical strength, toughness, and resistance to impact electronic and engineering appliances Reduced wear and friction transfer device
• Resistance to moisture and shrink resistance paper
• Can modify toxicity of viruses medicines
Image Source: DuPont Chemical Company
POLYMER CHEMISTRY
formaldehyd
e
+ Distilled H2O
+ Heat Polymerizatio
n + Initiator
Filtration +
Finished Product
Source: Schweitzer, C. E., Macdonald, R. N. and Punderson, J. O. (1959), Thermally stable high molecular weight polyoxymethylenes. J. Appl. Polym. Sci., 1: 158–163.
SAFETY & PRODUCTION
• Injection molding is commonly used to produce POM plastic.
• Formaldehyde (toxic)
• Methanol (toxic)
• POM is generally non-toxic to living things.Sources: DuPont.
http://plastics.dupont.com/plastics/pdflit/americas/delrin/H76836.pdfCenters for Disease Control and Prevention. http://www.cdc.gov/niosh/docs/81-111/
REACTOR DESIGN
To make 1000 POM guitar picks per 15 seconds, you would need:
100 metric tons of POM per year
• Time to make one batch of POM: ~40 hours
• Volume of reactor: 532 liters • Moles of POM: 1445 moles per
literImage Source: Dunlop. http://www.jimdunlop.com/product/delrin
Acknowledgments