Cooper Union for the Advancement of Science and Art Summer Research Internship Program Summer 2013 Professor Benjamin Davis PEEK PMMA Kevlar PTFE PLA PC POM Polyether Ether Keton e Rabia Akhtar and ID: 375748
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Slide1
Chemical Engineering
Cooper Union for the Advancement of Science and Art
Summer Research Internship Program, Summer 2013 Professor Benjamin Davis
PEEK
PMMA
Kevlar
PTFE
PLA
PC
POMSlide2
Polyether Ether Keton
eRabia Akhtar and Ozzy Khan Slide3
History Markets
The percentage share of world consumption
of Victrex PEEK by sector for the year 2012
.Slide4
Properties and Uses Slide5
Chemistry and Raw MaterialsSlide6
Safety and Disposal Slide7
Reactor design
Time: 41.7 days/batch
Batch 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: 90ºCSlide8
Polymethyl Methacrylate: PMMA
Saijah WilliamsMia RodieSlide9
History and Markets
Discovered in 1877 by Fittig and Paul Slide10
Uses and Properties
1972 Olympic Stadium- Munich, Germany
(pontiacgrandprix.net)
Edge-lighting.com
Headlights made of PMMA
Lighting Applications of PMMA
LG LCD televisionSlide11
Polymer ChemistryPMMA 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 bindersSlide12
Raw Materials and Production Process
Hydrogen Cyanide
Acetone
Methyl formateSlide13
Reactor Design
Goal: 100 sheets of Plexiglas® per day
Amount of PMMA per year: 800 metric tonsAmount of time per batch: 5.6 minutesEquation 1
Variable
Meaning
K
i,
K
p
,
K
t
Rate
constants
pPolydispersity[M]
Concentration of monomer[I]Concentration of initiator Slide14
Kevlar
By: Caroline Hunt & Isael LuperonSlide15
History and Market
Created in 1964 by Stephanie KwolekProduced by DuPont
First commercial use in 1971Mainly produced in USACosts : $12 - $27 Slide16
Uses & Properties
Advantages:Tensile strength Chemical resistanceStructural rigidityThermal resistance
Lightweight Disadvantages:Absorbs moisturePoor against compression Poor against UV rays
4
5
6
7
3
2Slide17
Polymer Chemistry
1,4-phenylene-diamine
(para-phenylenediamine)TerephthaloylChlorideHydrochloricAcid (byproduct)
Poly-
para
-
phenylene
Terephtalamide
(Kevlar)Slide18
Results of Reactor Design
Goal: 1,000 pairs of Kevlar gloves per dayTotal monomer: 835 moles
Total solvent: 278 molesTotal volume of tank: 150 Liters Time for one reaction: 9.7 secondsSlide19
By Sally Kramer
Properties, Uses, and Production of Polytetrafluoroethylene
Dr. Roy PlunkettSlide20
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
Figure 2Slide21
Uses and PropertiesSlide22
Polymer Chemistry, Raw Materials, and Production Process
CHCl3 + 2HF CHClF2 + 2HCl (1)2CHClF2 F
2C=CF2 + 2HCl (2)Fluorspar, water, sulfur, air, natural gasSlide23
Ethics and Safety
Carcinogens 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!Slide24
Reactor Design for Gaskets
Goal:
10,000 Teflon gaskets per day, each 12.947gTen hours per batch, two batches per day
24.399 kg dimethylamine oxide dihydrate
8.714 kg glacial acetic acid
87.14 kg TFE
26,142 kg water
64.725 kg PTFESlide25
Producing Polylactic Acid
By: Kevin Garcia and Janki Tailor Slide26
History/ Discovery/ Introduction
Similar to petroleum based plastics but its biodegradable
Lactic acid discovered in 1780 by Carl Wilhelm Scheele and PLA discovered in 1932 by Wallace Carothers.First official PLA production plant launched in Blaire, Nebraska.Slide27
Markets/ Demand/ Prices
Used in fibers, packaging, and chemical products markets
Archer Daniels Midland Company, Cargill Inc., and Ecochem6.6 billion lbs. PLA produced annually$6 billion per yearGlobal 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). Slide28
Uses/ Properties
Rigids
The Potential of Bio-Based Plastics. Steeman, A. http://bestinpackaging.com/2009/11/30/the-potential-of-bio-based-plastics/ (accessed August 7, 2013).
Food Serviceware
Excellent Packaging & Supply (EPS). http://www.packaging-int.com/suppliers/excellent-packaging-supply-eps.html (accessed August 7, 2013).Slide29
Polymer Chemistry
Monomer: L-Lactide (two lactic acids combined)
Lactic Acid
Intech. Jamshidian et al. http://www.intechopen.com/books/biodegradation-life-of-science/biodegradable-polymers (accessed July 23, 2013).
L-Lactide
Futerro. http://www.futerro.com/products_lactide.html(accessed August 7, 2013).
Most methods for making PLA are not economically viable
Methods to synthesis PLA:
Step Growth
Ring Open PolymerizationSlide30
Raw Materials/ Production/ Safety
PLA is eco-friendly, and releases carbon dioxide and methane when it degrades
C
orn
Starch
Fermentation
Lactic Acid
PLA
Step Growth
Lactide
Ring
-
open Polymerization
Slide31
Batch Design
Task: To design a batch reactor to make these cups
Goal: Make 10,000 plastic cups/dayBulk ReactionCatalyst used for reaction: Tin Octoate
Fabri-Kal. http://www.fabri-kal.com/product/greenware-cold-drink-cups/ (accessed August 6, 2013)Slide32
Results for our Batch Reactor
Time per batch: 200 hours
Batches per year: 44 batches Cups produced per batch: 82,955 cupsMass of monomer used per cup: 48.65 gVolume of batch reactor: 3.16 cubic meters
Lactide
PLASlide33
Polycarbonate (PC)
Paulina BabiakAndFradah GoldSlide34
Uses and PropertiesSlide35
Polymer Chemistry
Phenyl Groups
Methyl Groups
Carbonate
and SafetySlide36
Raw Materials
$1.75/
lb$0.94/lb$0.74/lbSlide37
Phenol
NaOH
Phosgene
Acetone
Diphenyl
carbonate
Bisphenol- A
NaCl
POLYCARBONATE
(
Condenser
)
Caustic soda
200 L 200
º
C 153 min
Process Design for 10 Million CDsSlide38
MarketsSlide39
Polycarbonate Life CycleSlide40
By Olivia Kazior and Reecan
JuarezPolyoxymethylene (POM)Slide41
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 DuPontSlide42
markets
Table 2.
Percentage share of world POM consumption by market sector, 1999-20025 19992000
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
43Slide43
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 paperCan modify toxicity of viruses medicines
Image Source: DuPont Chemical
C
ompanySlide44
Polymer chemistry
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. Slide45
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.pdf
Centers for Disease Control and Prevention. http://www.cdc.gov/niosh/docs/81-111
/ Slide46
Reactor Design
To make 1000 POM guitar picks per 15 seconds, you would need:
100 metric tons of POM per yearTime to make one batch of POM:
~40 hours
Volume of
reactor:
532
liters
Moles of POM: 1445 moles per liter
Image Source: Dunlop
. http://www.jimdunlop.com/product/delrinSlide47
Acknowledgments