Polyvinyl Chloride (PVC)Polyvinyl Chloride (PVC)

Manufacturing of Vinyl Chloride Manufacturing of Vinyl Chloride Monomer (VCM) Monomer (VCM)

PVC MorphologyPVC Morphology

Suspension and Mass 100-180Suspension and Mass 100-180µmµm

Emulsion 5-50µmEmulsion 5-50µm

Suspension polymerization of Suspension polymerization of PVCPVC

Typical primary and secondary protective Typical primary and secondary protective colloids used in suspension polymerization colloids used in suspension polymerization

of VCMof VCM

Effect of the degree of hydrolysis of Effect of the degree of hydrolysis of poly(vinyl acetate) on grain porositypoly(vinyl acetate) on grain porosity

Initiator for suspension and Initiator for suspension and mass polymerization of VCMmass polymerization of VCM

Diacyl peroxidesDiacyl peroxides PeroxydicarbonatesPeroxydicarbonates Alkyl PeroxyestersAlkyl Peroxyesters Azo initiatorsAzo initiators

Porosity in PVCPorosity in PVC

General properties of PVCGeneral properties of PVC

Properties of PVCProperties of PVC

Properties of PVCProperties of PVC

Grades of PVCGrades of PVC

Unmodified gradeUnmodified grade

Moulding gradeMoulding grade

Extrusion gradeExtrusion grade

Impact modified gradeImpact modified grade

Plasticised gradePlasticised grade

Flame retardant gradeFlame retardant grade

PVC Processing techniquesPVC Processing techniques

Injection mouldingInjection moulding ExtrusionExtrusion CalenderingCalendering Stretch blow mouldingStretch blow moulding Rotational mouldingRotational moulding CoatingCoating ThermoformingThermoforming

Manufacturers of PVCManufacturers of PVC

ApplicationsApplications

Agriculture: Drip irrigation Agriculture: Drip irrigation systems, pipe fittings, systems, pipe fittings, reservoir liners, irrigation reservoir liners, irrigation pipes & profiles, drainage pipes & profiles, drainage installations, horticulture & installations, horticulture & green house irrigation green house irrigation system and sprinkler system and sprinkler system fittings.system fittings.

HouseholdHousehold

Household: Household: Bottles, foams, Bottles, foams, leather cloth, leather cloth, novelties,calenders, office novelties,calenders, office files & folders, purses & files & folders, purses & wallets, book & diary covers, wallets, book & diary covers, pass book & pass port covers, pass book & pass port covers, tool kit covers, washing tool kit covers, washing machines, cameras, records & machines, cameras, records & radio, photo albums, caps, radio, photo albums, caps, coats, umbrella covers & coats, umbrella covers & handles, sport shoes & shoe handles, sport shoes & shoe soles, boxes for dry fruits, soles, boxes for dry fruits, gifts, audio & video, inflatable gifts, audio & video, inflatable toy animals and balls.toy animals and balls.

..

IndustrialIndustrial

Film, fittings, profiles, Film, fittings, profiles, printing inks, conveyor printing inks, conveyor belting, battery belting, battery seperators, storage seperators, storage tanks, work tanks, work gloves,printing plates, gloves,printing plates, screens, protective screens, protective coatings hammer heads coatings hammer heads and steel strip coatingsand steel strip coatings

MedicalMedical

Glucose bag, urine Glucose bag, urine bag, infusion set, bag, infusion set, tubings and catheter tubings and catheter tubes tubes

Medical products

Electrical/ElectronicsElectrical/Electronics

Cable insulation, pipes & Cable insulation, pipes & profiles, wire extrusions, profiles, wire extrusions, TV back, radio parts, TV back, radio parts, business machine parts, business machine parts, office equipments, wire & office equipments, wire & cable fittings, wire racks, cable fittings, wire racks, electrical parts, plating electrical parts, plating racks, tool handles an racks, tool handles an electrical insulation.electrical insulation.Cable insulation

BuildingBuilding

swimming pool liners, coated metal swimming pool liners, coated metal components, fencing, floor Covering, components, fencing, floor Covering, wall coverings, carpet backing, floor wall coverings, carpet backing, floor tiles, foil coatings, heat seal tiles, foil coatings, heat seal adhesives, coatings, toilet boxes, adhesives, coatings, toilet boxes, sofa sets, furniture covers, house sofa sets, furniture covers, house sidings, windows, doors, bathroom sidings, windows, doors, bathroom equipments and cabinets.equipments and cabinets.

AutomotiveAutomotive

Seat belts, head rests, arm rests, Seat belts, head rests, arm rests, spark plug covers, air filters, boat spark plug covers, air filters, boat bumpers, mats, mud flaps, bicycle bumpers, mats, mud flaps, bicycle seats, transmission covers, car, seats, transmission covers, car, scooter and cycle seat covers.scooter and cycle seat covers.

.. Marine: Marine: Ships, life jackets, life vests, deep Ships, life jackets, life vests, deep

sea diving equipment and boat partssea diving equipment and boat parts Miscellaneous'. Miscellaneous'. Air bags, hand bags and Air bags, hand bags and

shopping bags, refrigerator components, shopping bags, refrigerator components, furniture, wheels, golf bags, swim fins, table furniture, wheels, golf bags, swim fins, table cloths, closet accessories, shower curtains, cloths, closet accessories, shower curtains, garden hose, baby pants, rain wear, garden hose, baby pants, rain wear, disposal stoppers, bottle cap liners, traffic disposal stoppers, bottle cap liners, traffic safety covers, athletic padding, life safety covers, athletic padding, life preservers apparel fabrics, roll coating, fire preservers apparel fabrics, roll coating, fire ring mains, brushes & brooms, floor ring mains, brushes & brooms, floor coverings, files & folders, yarn for lawn coverings, files & folders, yarn for lawn furniture and animal ear tags furniture and animal ear tags

PlasticizersPlasticizers

Most widely used are C4–C12 esters such as phthalates, adipates,azelates, sebacates, trimellitates, and phosphates.

Chlorinated paraffins are used as secondary plasticizers.

A good plasticizer should have low volatility, low color value, neutral reaction,

resistance to hydrolysis, insolubility in water, flame resistance, and nontoxicity.

Influence of plasticizers on Influence of plasticizers on final product propertiesfinal product properties

Influence of Plasticizers on Influence of Plasticizers on Plastisol PropertiesPlastisol Properties

RheologyRheology

Effect of shear rate on the PVC plastisolviscosity (DOP/PVC = 100/50 at T = 25OC

Factors affecting the rhelology Factors affecting the rhelology of PVC plastisolof PVC plastisol

Polymer/plasticizer mixing ratio Type of plasticizer and its interaction with polymer Particle size and their distribution of primary particles Structure, shape, porosity, and surface of the secondary particles Surfactants, added during polymerization or in the paste Molecular mass and molecular mass distribution Paste-making conditions such as mixing

temperature, time, and intensity

Changes in Morphology and mechanical Changes in Morphology and mechanical properties of PVC plastisol during gelation properties of PVC plastisol during gelation

and fusionand fusion

Fikentscher K-value

Molecular weight characteristic Molecular weight characteristic of PVCof PVC

Grades NomenclatureGrades Nomenclature

SK 68/173 Suspension grade PVC SK 68/173 Suspension grade PVC with K value 68 and viscosity no 173with K value 68 and viscosity no 173

VY 110/57 PVC with K value 57 and VY 110/57 PVC with K value 57 and viscosity no 110viscosity no 110

K valueK value

PVC with K = 66–68 can be processed in rigid

formulations to give pipes,conduit, sheet, and window profiles

K = 65–71 in flexible formulations for flexible sheet, flooring, wallpapers, cable coverings, hoses, tubing, and medical products

low K-values (55–60) in formulations for injection molding of pipe and conduit fittings, integral electrical plugs, and blow molding of bottles and other containers.

Compounding ingredientsCompounding ingredients

Polymer Stabilisers Plasticisers Extenders Lubricants Fillers Pigments Polymeric processing aids Impact modifiers

Factors affecting the choice of Factors affecting the choice of StabilizerStabilizer

The grade of polymer used. The nature of other ingredients present. The cost of stabilizer required to give adequate stabilization for the processing

and anticipated service life of the compound The clarity required of the compound. Toxicity. The effect on lubrication, printing, heat sealing and plate-out.

Heat stabilizers for PVCHeat stabilizers for PVC

Lead compoundsLead compounds

basic lead carbonate (white lead) Low cost

Disadv decomposes at higher temp giving porous product

tribasic lead sulphate : better electrical insulation properties

dibasic lead phthalate,Lead silicate, dibasic lead stearate

Metallic soaps or saltsMetallic soaps or salts

Metal stearates, ricinoleates, palmitates and octoates

cadmium-barium systems strontium/zinc Calcium/zinc

Organo-tin compounds

Dibutyltin maleate dibutyltin di-iso-octylthioglycollate,

Requirements of plasticizersRequirements of plasticizers

It should have a molecular weight of at least 300.

It should have a similar solubility parameter to that of the polymer.

If the polymer has any tendency to crystallise, it should be capable of some

It should not be a crystalline solid at the ambient temperature unless it is

specific interaction with the polymer. capable of specific interaction with the

polymer.

Common plasticizers for Common plasticizers for PVCPVC

Extenders

Chlorinated paraffin waxes. Chlorinated liquid paraffinic fractions. Oil extracts. If too little is used sticking problems occur;

if too much the compound may develop haze and greasiness, printing and heat sealing may be difficult and gelation and fusion of the compound may be slowed down

Lubricants

Calcium stearate Dibasic lead stearate Stearic acid Normal lead stearate

Internal lubricants

improve the flow of the melt, reasonably compatible with the polymer do not retard gelation, cause haze or cause greasiness wax derivatives, particularly from

montan wax, glyceryl esters, particularly glyceryl monostearate, and long chain esters such as cetyl palmitate.

General purpose insulation General purpose insulation compoundcompound

Transperant Calendering Transperant Calendering compoundcompound