Polymers

introduction
 Polymers are very large molecules made when hundreds of
monomers join together to form long chains.

 The word polymer is derived from the Greek words :

poly + meros
Poly = many
Meros= parts

 Some common examples of synthetic polymers include

polyethylene, polypropylene, polyvinyl chloride (PVC), polystyrene,
and nylon. These polymers are derived from petrochemical
sources and can be tailored to meet specific requirements through
modifications in their chemical structure.
 Types of Polymer
Polymers possess a wide range of properties, including
mechanical strength, flexibility, thermal stability, and electrical
conductivity, which make them versatile and suitable for
different applications. They can be classified into different
categories based on their structure, origin. , and behavior. Here
are some common types of polymers:

 Natural Polymers
 Homopolymer
 Copolymer
 Thermoplastics
 Thermosets
 Types of Polymer
 Natural polymer is a polymer that results from only raw
materials that are found in nature or derived from biological
sources and are often biodegradable.

 For example, cotton , wool , wood, silk, DNA, cellulose, and

natural rubber are some of the naturally occurring polymers.

Wood Cotton
 Types of Polymer

 Homopolymers: Homopolymers
are composed of a single type of
monomer. The repeating units in
the polymer chain are identical.

 Polyethylene, which is made from

repeating ethylene units, is an
example of a homopolymer.

polystyrene
 Types of Polymer
 Copolymers: Copolymers are formed by the polymerization of
two or more different monomers. These monomers can be
arranged in different patterns within the polymer chain.
Copolymers can exhibit a combination of properties from
each monomer and may have improved characteristics
compared to homopolymers.
 Examples include nitrile rubber and polyethylene-vinyl
acetate.

nitrile rubber
 Types of Polymer
 Thermoplastic polymers are a type of polymer that softens
when heated and solidifies when cooled, undergoing a
reversible transition between solid and molten states.
 Examples: Polyvinyl chloride, Polyethylene, polypropylene
(PP), and Nylon.

Polyvinyl chloride
 Types of Polymer

 Thermosetting polymers are commonly

known as thermosets, are a type of
polymer that undergoes a permanent
chemical change when heated and,
once cured, cannot be re-melted or re-
shaped by heating. Unlike
thermoplastics, which can be melted
and solidified repeatedly, thermosets
undergo a crosslinking reaction during
curing, forming a rigid and infusible
three-dimensional network structure.
Epoxy resins
 Examples: Epoxy resins, Phenolic
resins, Unsaturated polyester resins.
 Polymer processing
 Polymer processing refers to the methods and techniques used
to convert polymer materials into useful products or shapes.
It involves various operations, such as shaping, forming, and
assembling polymers to meet specific application
requirements.

 Polymer processing techniques can be broadly categorized

into two main types:

a. Primary processing (Molding processes )

b. Secondary processing
 Molding processes (Primary processing )

 There are several types of molding processes used in polymer

processing. Each process has its own characteristics and is
suitable for specific applications. The common types of
polymer molding:

1. Compression molding.

2. Extrusion molding.

3. Injection molding.

4. Blow molding.
 Compression molding

 In this process the appropriate amount of heated polymer is

placed between male and female part of mold.

 The material is compressed and compacted into the shape

inside cavity.

compression molding
 Compression molding

 Materials produced by compression molding:

 Ceramics.

 Kitchenware and cookware handles (bowl and cups etc.)

 Gaskets and brake pads.

 Extrusion molding
 The extruder contains a hydraulic plunger or motor, which
turns a screw and the polymer is propelled to the heater.
Polymer is melted into liquid and pushed through a die.
Polymer from the die is cooled rapidly.

 The product is cut into desired length.

Extrusion molding
 Extrusion molding

 Materials produced by extrusion molding:

 Hoses.

 Pipes.

 Plastic films, and packaging materials.

 Injection molding
 Polymeric material is fed into hopper at definite time
intervals. Pressure is applied through hydraulically driven
piston. Piston pushes the molten polymer through the
cylinder. The material is then injected through a nozzle into a
mould cavity.

Injection of molding
 Injection molding
 Mold is held under pressure till the
polymer cools and hardens.

 Mold is opened and the article is

removed. Meanwhile the Piston
moves back to take the charge for
the next cycle.

 Materials produced by injection

molding:
 Bottle caps.
Injection moulding parts
 Toys.

 Musical instruments and parts.

 Storage container.
 Blow molding
 Blow molding is used to create hollow objects. The process begins
with a molten polymer parison (a hollow tube) that is placed inside a
mold. Compressed air is then blown into the parison, causing it to
expand and take the shape of the mold. After cooling, the mold is
opened, and the final product is removed. Blow molding is known
for its efficiency in producing large quantities of hollow plastic
parts.

Blow moulding Bottle

 Blow molding

 Types of blow molding:

 Extrusion blow molding.

 Stretch blow molding.

 Blow molding
 Extrusion blow molding
 Plastic is melted and extruded into
a hollow tube.

 Parison is then captured by

closing it into a cooled metal mold.

 Air is then blown into the parison

inflating it into the shape of the
hollow bottle.

 After the plastic has cooled

sufficiently, the mold is opened
and the part is ejected. Extrusion blow moulding
 Blow molding
 Stretch blow molding
 The plastic is first molded into a "preform" using the injection
molding process.
 These preforms are produced with the necks of the bottles ,
including threads on one end
 These preforms are packaged, and fed later (after cooling) into a
reheat stretch blow molding machine.
 Characteristics of Polymer
 Polymers exhibit a wide range of characteristics that make them
suitable for various applications. Here are some common
characteristics of polymers and their corresponding applications:
 Lightweight
 Flexibility
 High Strength
 Chemical Resistance
 Electrical Insulation
 Thermal Stability
 Transparency and Optical Clarity:
 Biocompatibility
 Durability
 Cost-Effectiveness
 Application of Polymer

 Medicine: Many biomaterials especially heart valve

replacements and blood vessels are made up of polymers
like Dacron, Teflon.

blood vessel hear valve

 Application of Polymer

 Consumer Science: Plastic containers of all shapes and

sizes are light weight and economically less expensive
than more traditional containers.

 Industry: Pipes, tanks, packing material, adhesives are all

polymer application used in industrial market.

 Sports: Playground equipment, golf clubs, swimming

pools and protective helmets are produced from
polymers.
 Polymers
Example 1:
500 kg of reactants available for producing a polymer
through a polymerization reaction. The conversion of the
reactants to the desired polymer product is 95%. Calculate
the expected yield of the polymer?
Solution:
Reactant mass = 500 kg
The conversion of the reactants = 95%
The expected yield = reactant mass X the conversion =500 kg X 0. 95 = 475 kg

This means that out of the 500 kg of reactants, you can expect to
obtain 475 kg of the desired polymer product.
 Polymers
Example 2:

1000 kg of monomer input to the plant to produce 850 kg of

a polymer through a polymerization reaction taking 8 hr.
while the actual production time is 6 hr, monomer purity is
98%, and polymer purity is 95%. Calculate:
a. The effective monomer input.
b. The effective production time.
c. The production efficiency.
 Polymers
Solution:
a. Effective Monomer Input = Total Monomer Input x Monomer Purity
= 1000 kg x 0.98= 980 kg
b. Effective Production Time = (Actual Production Time /Total
Production Time) x 100 = (6 hours / 8 hours) x 100= 75%
c. Production Efficiency = (Actual Polymer Output / Effective
Monomer Input) x 100 = (850 kg / 980 kg) x 100= 86.73%

This indicates that 86.73% of the effective monomer input

resulted in the desired polymer output. Additionally, the effective
production time accounts for 75% of the total production time.
 Polymers
Example 3:
Determine the batch size (monomer input) and reaction time to
produce 500 kg polymer. If the polymerization rate is 2 kg/hr and
reaction efficiency is 80%.

Solution:
a. Batch Size = Desired Polymer Output / Reaction Efficiency
= 500 kg / 0.8 = 625 kg
a. Reaction Time = Batch Size / Polymerization Rate
= 625 kg / 2 kg/hr = 312.5 hours
To achieve the desired polymer output it needs a batch size of 625
kg and a reaction time of approximately 312.5 hours.
 Polymers
Example 4:
Estimate the energy consumption in (kWh) for melting 1000 kg
of polymer has specific heat capacity 2.5 kJ/kg·°C, from 25 to
200°C for 1 hr.

Solution:

Energy Consumption = Polymer Melt Mass × Specific Heat Capacity × ΔT

= 1000 kg × 2.5 kJ/kg·°C × 175°C = 437,500 kJ
Energy Consumption in kWh = Energy Consumption in kJ / 3.6 × 10^3 kJ
= 437,500 kJ / 3.6 × 10^3 ≈121.5 kWh
The estimated energy consumption for the polymer melt
processing operation would be approximately 121.5 kWh.