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9781569903797

Pvc Handbook

by ; ; ;
  • ISBN13:

    9781569903797

  • ISBN10:

    1569903794

  • Format: Hardcover
  • Copyright: 2005-08-30
  • Publisher: Hanser Pub Inc
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List Price: $399.99

Summary

In this single handbook, the editors aim to give a diverse audience of readers a complete account of all aspects of PVC-from monomer manufacture to polymerization; the gamut of such additives as stabilizers, lubricants, plasticizers, impact modifiers, fillers and reinforcing agents; blends and alloys; compounding and processing; characterization; combustion resistance and weatherability; product engineering design; applications; environmental and safety; and finally the PVC industry dynamics. This handbook contains both practical formulation information as well as a mechanistic view of why PVC behaves as it does.

Table of Contents

List of Contributors
v
Dedication ix
Preface xi
Introduction
1(18)
James W. Summers
Chemistry and Physical Structure
1(5)
Raw Materials
1(1)
Chlorine Content and Combustion Resistance
2(1)
Polymerization Morphology
3(1)
Vinyl's Unique Melt Processing
3(1)
Properties Depend on Formulation and Processing History
3(1)
Vinyl as a Thermoplastic Elastomer (TPE)
4(2)
PVC's Solubility Parameter and Ease of Compounding
6(1)
Vinyl's Proud History
6(5)
PVC Meeting Society's Needs
6(1)
The PVC Industry as a Responsible Citizen
7(1)
Historic Events
7(1)
Chlorine
7(1)
Vinyl Chloride
7(1)
Polymerization
7(1)
Early Processing
8(1)
Plasticized PVC as a TPE
8(1)
Wire and Cable
8(1)
Pipe and Fittings
9(1)
Siding, Windows, and Packaging
10(1)
Society of Plastics Engineers, Vinyl Division
10(1)
Weatherability
10(1)
Vinyl Chloride Exposure and Responsible Care
10(1)
Recycling
11(1)
Commercial Significance
11(8)
Growth of the Vinyl Industry
11(2)
PVC as a Major Thermoplastic
13(1)
PVC as a Thermoplastic Elastomer (TPE)
14(1)
PVC as an Engineering Thermoplastic
15(4)
Vinyl Chloride Monomer
19(38)
Joseph A. Cowfer
Overview
19(1)
Introduction
19(2)
Physical Properties
21(1)
Reactions
21(5)
Polymerization
21(1)
Substitution at the Carbon-Chlorine Bond
22(1)
Oxidation
23(1)
Addition
24(1)
Photochemistry
25(1)
Pyrolysis
25(1)
Manufacture
26(7)
Direct Chlorination of Ethylene
29(1)
Oxychlorination of Ethylene
30(3)
Purification of Ethylene Dichloride for Pyrolysis
33(1)
Ethylene Dichloride Pyrolysis to Vinyl Chloride
34(1)
By-Product Disposal
35(1)
Economic Aspects
36(5)
Environmental Considerations
41(1)
Technology Trends
42(3)
Specifications
45(1)
Health and Safety Factors
46(1)
Uses
47(10)
Polymerization
57(38)
Donald E. Witenhafer
David J. Poledna
Basic Considerations
57(3)
Suspension Process Overview
60(6)
Polymerization
60(4)
Stripping
64(1)
Centrifugation
65(1)
Drying and Screening
66(1)
Mass Process Overview
66(3)
Special Considerations
69(10)
Polymerization Kinetics
69(1)
Resin Particle Structure and Formation
70(2)
Agitation and Dispersants
72(2)
Vinyl Chloride Recovery
74(1)
Increasing Reactor Productivity
74(3)
Chain Defects and Heat Stability
77(1)
Molecular Weight Extension
78(1)
Co-Polymerization
79(1)
Summary
79(1)
Microsuspension and Emulsion Polymerization
80(3)
Microsuspension Polymerization of Vinyl Chloride Compared to Emulsion and Suspension Polymerization
81(1)
Procedure and Variations
81(1)
Emulsion Polymerization of Vinyl Chloride Compared to Microsuspension and Suspension PVC Polymerization
82(1)
Procedure for Batch Polymerization
83(1)
Other Considerations for Microsuspension and Emulsion Polymerization of PVC
83(2)
Surfactant System
83(1)
Initiators
84(1)
Water
84(1)
Copolymers
84(1)
Primary Particle Size Microsuspension
85(2)
Primary Particle Size Emulsion
85(2)
Molecular Weight
87(1)
Polymerization Equipment Operation
87(3)
Homogenizers
87(1)
Reaction Vessels
87(1)
Agitation
88(1)
Heat Removal
89(1)
Downstream Equipment
90(2)
Residual Vinyl Chloride Removal (Stripping)
90(1)
Drying
91(1)
Grinding
92(1)
Packaging
92(1)
Product Quality
92(1)
Safety and Environment
93(2)
PVC Stabilizers and Lubricants
95(78)
Thomas C. Jennings
William H. Starnes, Jr.
Introduction
95(1)
World PVC Stabilizer and Lubricant Markets
96(1)
Structure and Degradation of PVC
97(4)
The General Stabilization of PVC
101(1)
The General Lubrication of PVC
101(1)
Lead Stabilizers
102(6)
Lead Stabilizer Chronology
103(1)
Lead Stabilizer Manufacturing
104(1)
Lead Stabilization Mechanisms
105(1)
Lead Stabilizers of Commercial Importance
105(1)
Lead Stabilizer Strengths and Weaknesses
106(1)
Lead Stabilizer/Lubricant Use Levels
107(1)
Organotin Stabilizers
108(8)
Organotin Stabilizer Chronology
108(2)
Organotin Stabilizer Manufacturing
110(2)
Organotin Stabilizer Mechanism
112(1)
Organotin Stabilizers of Commercial Importance
112(1)
Organotin Stabilizer Synergists
113(2)
Lubrication of Organotin Stabilizers
115(1)
Organotin Stabilizer Strengths and Weaknesses
115(1)
Organotin Stabilizer/Lubricant Use Levels
115(1)
Mixed Metal Stabilizers
116(13)
Mixed Metal Chronology
116(2)
Mixed Metal Manufacturing
118(2)
Mixed Metal Stabilizer Mechanisms
120(1)
Mixed Metal Stabilizer Synergists
120(3)
Epoxy Esters
123(1)
Phosphite Esters
124(2)
Minor Organic Synergists
126(1)
Inorganic Acid Scavengers
126(1)
Mixed Metal Strengths and Weaknesses
126(1)
Mixed Metal Stabilizer/Lubricant Use Levels
127(2)
PVC Lubricants
129(11)
Internal and External Lubricants
129(1)
Three Category Lubricant Classification
130(2)
Lubricant-Lubricant Interactions
132(2)
Stabilizer Lubricant Interactions
134(1)
Lubricating Stabilizers
135(1)
Stabilizer Lubricant One-Packs
135(2)
Lubricant Sources
137(1)
Petroleum Waxes
137(1)
Synthetic Hydrocarbon Waxes
137(1)
Mineral Waxes
138(1)
Natural Triglycerides
139(1)
Testing of Stabilizers and Lubricants
140(5)
Oven Stability Tests
141(1)
Press Clarity and Color
142(1)
Dynamic Milling
142(1)
Torque Rheometer Testing
142(1)
Plate-Out Test
143(1)
Volatility Tests
144(1)
Compatibility Tests
145(1)
Stabilizer-Stabilizer-Incompatibilities
145(1)
Suppliers of PVC Stabilizers and Lubricants
145(1)
PVC Stabilizer Environmental Concerns
146(9)
General Environmental Concerns
147(1)
Lead Environmental Concerns
148(1)
Cadmium Environmental Concerns
149(1)
Barium Environmental Concerns
149(1)
Organotin Environmental Concerns
150(1)
Stabilizers Based Upon Food Additives
151(4)
Chemistry of Degradation and Stabilization
155(1)
Mechanism of Thermal Dehydrochlorination
156(5)
Thermally Labile Structural Defects
156(1)
Hypothetical Labile Structures
157(1)
Polyene Elongation
158(1)
Ion-Pair/Quasiionic Mechanism
158(1)
Other Proposed Mechanisms
159(1)
Autocatalysis
160(1)
Thermal Stabilization
161(5)
General Mechanisms
161(1)
Stabilizers Containing Metals
162(1)
Organic Stabilizers
163(1)
Costabilizers
163(1)
Principal Stabilizers (Ester Thiols)
164(2)
Acknowledgments
166(7)
Plasticizers
173(28)
Leonard G. Krauskopf
Allen Godwin
Introduction
173(1)
Historical Developments
173(1)
Mechanisms of Plasticization
174(2)
Types of Plasticizers
176(6)
Plasticizer Performance
182(4)
Plasticizer Efficiency
186(1)
Low Temperature
187(3)
Permanence (Transience) of Plasticizers
190(1)
Solvency, Miscibility, or Compatibility
191(1)
Processability
192(1)
Plasticizer Markets
193(2)
Health Aspects of Plasticizers
195(2)
Future of Plasticizers
197(4)
Processing Aids and Impact Modifiers
201(34)
Carlos A. Cruz-Ramos
John R. Patterson
Processing Aids
201(11)
Introduction
201(1)
Development
201(2)
Role of Processing Aids in PVC
203(1)
Promotion of Homogeneous Melt
203(2)
Melt Homogeneity
205(2)
Melt Strength, Extensibility, and Elasticity
207(1)
Benefits of Processing Aids in PVC
207(1)
Extrusion
207(1)
Foam Extrusion
208(1)
Calendering/Thermoforming
209(1)
Injection Molding
209(2)
Blow Molding
211(1)
Commercial Sources of Processing Aids
212(1)
Impact Modifiers
212(23)
Introduction
212(1)
Development
213(1)
Impact and Toughness Testing
214(1)
Methodology
214(4)
Role of Fusion (Gelation)
218(2)
Impact Modification Theory
220(4)
Impact Modifiers -- Function, Features, and Types
224(2)
Predefined Particle Size Modifiers
226(1)
Intermediate Modifiers
227(1)
Modifiers with Non-Predefined Particle Size
228(1)
Other Types of Modification
229(1)
Impact Modifier Selection
229(2)
Commercial Sources
231(4)
Fillers and Reinforcing Agents
235(42)
Joel M. Zazyczny
Laurent M. Matuana
Mineral Fillers in PVC Matrix
235(5)
Introduction
235(1)
Mineral Properties
235(1)
Particle Properties
236(1)
Particle Size Distribution
236(1)
Surface Area
237(1)
Optical Characteristics
238(1)
Color
238(1)
Aspect Ratio
238(1)
Specific Gravity/Density
239(1)
Mohs Hardness
239(1)
Particle Packing Fraction
240(1)
Commercial Mineral Fillers and Reinforcing Agents
240(4)
Calcium Carbonate (CaCO3)
240(1)
Kaolin (Al2O3 2 SiO2 2 H2O)
241(1)
Talc (Mg3SiO10(OH)2)
241(1)
Mica (K2M(Al2Si6O20)(OH)4)
242(1)
Barite (BaSO4)
242(1)
Wollastonite (CaSiO3)
243(1)
Calcium Sulfate (CaSO2 2 H2O)
243(1)
Nepheline Syenite/Feldspar
244(1)
Glass Microspheres
244(1)
Applications and Development in PVC Compounds
244(4)
Surface Treatment and Coupling Agent Technology
246(1)
Stearates
247(1)
Zirconates, Titanates, and Zirco-Aluminates
247(1)
Silanes
247(1)
Natural Fillers in PVC Matrix
248(29)
Introduction
248(2)
Characteristics of Natural Fibers
250(1)
Wood Structure
250(1)
Chemical Composition of Wood
251(2)
PVC/Natural-Fiber Composites
253(1)
Influence of Processing Conditions
253(1)
Effects of Additives Used in the Formulations
254(10)
Foaming of PVC/Natural-Fiber Composites
264(5)
Durability of PVC/Natural-Fiber Composites
269(8)
PVC Blends and Alloys
277(12)
Donald E. Witenhafer
Introduction
277(2)
High Heat Distortion Temperature PVC Blends
279(2)
Glutarimide Copolymers
279(1)
ABS Blends
279(1)
Suprel
280(1)
Styrene/Maleic Anhydride (SMA) Copolymer Blends
281(1)
Flexible PVC Blends
281(4)
Butadiene Acrylonitrile Copolymer Blends
281(4)
Polyketone Blends
285(1)
Compatibilizers
285(1)
Summary
286(3)
Compounding Processes
289(26)
Rabeh Elleithy
James W. Summers
Introduction
289(1)
Connection Between Polymerization and Compounding
289(4)
Powder Mixing of PVC
293(5)
Role of High Speed Mixing
293(1)
Agglomeration Problems with High Speed Mixing
293(2)
Solutions to the Agglomeration Problems in High Speed Mixing
295(1)
Powder Flow and Packing
295(1)
Vinyl Chloride Monomer Removal
296(1)
Plasticizer Addition
296(2)
Distribution and Dispersion of Ingredients
298(8)
Effective Dispersion
298(1)
Interfacial Tension on Dispersion
298(1)
Compatibility of Materials for Dispersion
298(2)
Elongational Work for Dispersion
300(2)
Temperature Requirements
302(3)
Avoiding Shear Heating
305(1)
Powder to Product by Twin Screw Extrusion
306(1)
Powder to Compound with an Internal Batch Mixer (Banbury) and Mill
307(2)
Powder to Compound in an Internal Continuous Mixer and Mill
309(1)
Powder to Compound by Single Screw Compounding
310(1)
Powder to Compound by Reciprocating Single Screw Compounding
311(1)
Powder to Compound by Twin Screw Compounding
312(2)
Summary
314(1)
Flexible PVC
315(50)
William Coaker
Origins
315(1)
Types of PVC Resins Used in Flexible Applications
316(2)
Particulate Architecture of PVC Resins Used in Flexible Products
318(3)
Favored Processing Methods for Flexible PVC
321(2)
Designing Flexible PVC Compounds
323(6)
Formulation Development
323(1)
General Problems in Formulation Development
324(3)
Properties Often Specified for Semi-Rigid and Flexible PVC Products
327(2)
Additives Used in Flexible PVC Compounds
329(12)
Liquid Plasticizers and Solid Flexibilizers
329(2)
Lead-Based Stabilizers
331(2)
Mixed Metal Stabilizers
333(1)
Fillers
334(3)
Lubricants
337(1)
Light Stabilizers
337(2)
Flame Retardants and Smoke Suppressants
339(2)
Other Additives
341(1)
Markets for Flexible and Semi-Rigid PVC
341(15)
Specifications for and Quality Control Testing on Flexible PVC Products
356(4)
Tensile Properties after Oven Aging
356(1)
Thermal Stability by Torque Rheometer
357(1)
Melt Viscosity
358(1)
Hardness
358(1)
Low Temperature Brittleness
358(1)
Plasticizer Compatibility
359(1)
Moisture
359(1)
Poor Dispersion, Contamination, and Resin Gels
360(1)
Small-Scale Defects and Surface Phenomena
360(1)
Regulatory Issues
360(1)
Future Projections
360(5)
Specialty Grade PVC Resins
365(30)
Ashok Shah
David Poledna
Andy Olah
Dispersion and Blending Resins
365(7)
Powder Process Resins
372(1)
PVC for Powder Coating and Powder Molding Systems
372(1)
Specialty Suspension PVC Resins
373(6)
Ultra High Molecular Weight Resins
374(1)
Ultra High Absorptive Resin
375(2)
Deglossing or Dulling Resins
377(1)
Specialty Grade Emulsion Resins
378(1)
Copolymer Resins
379(3)
Conventional VCl/VAc Copolymers
380(1)
Solution Polymers
380(1)
Elastomeric Resins
381(1)
Overview of Chlorinated Polyvinyl Chloride Materials, Products, and Applications
382(13)
Introduction
382(1)
The Chlorination Process
383(3)
Chlorinated Polyvinyl Chloride Compounds
386(1)
End Use Applications for Chlorinated Polyvinyl Chloride Compounds
386(1)
Potable Water Distribution at Elevated Temperatures
386(4)
Industrial Handling of Corrosive Fluids at Elevated Temperatures
390(1)
CPVC-Based Fire Sprinkler Systems
391(2)
CPVC Based Non-Pipe Products that Offer Alternatives to Other High Temperature Thermoplastics
393(1)
Summary
393(2)
Physical Properties and Characterization of PVC
395(24)
Charles A. Daniels
Introduction
395(1)
Characterization at the Molecular Level
395(5)
Characterization at the Particulate Level
400(3)
Characterization of Vinyl Compounds
403(10)
Typical Characterization Requirements in the Laboratory
413(2)
Miscellaneous Properties
415(1)
Summary
415(4)
Flammability and Fire Performance
419(64)
Marcelo M. Hirschler
Introduction
419(1)
Thermal Degradation and Thermal Decomposition
419(4)
Thermal Decomposition and Fire Properties
423(1)
Fire Performance: General
424(1)
Individual Fire Properties and Associated Test Methods
425(40)
Ignitability
425(14)
Ease of Extinction
439(2)
Flammability
441(2)
Flame Spread
443(6)
Heat Release
449(9)
Smoke Obscuration
458(7)
Fire Retardance and Smoke Suppression
465(18)
Smoke Toxicity
468(2)
Fire Modeling and Fire Hazard Assessment
470(7)
Appendix 1 -- Fire Safety Definitions
477(4)
Appendix 2 -- Meaning of Major Cone Calorimeter Fire Properties
481(2)
Weathering of PVC Compounds
483(28)
Elvira Rabinovitch
Introduction
483(1)
Weathering Mechanism
483(4)
Weatherability Comparison Between PVC and Other Polymers
487(2)
Weathering Testing Methods
489(2)
Outdoor Exposure
489(1)
Accelerated Laboratory Exposure
489(1)
Outdoor Exposure Standards
490(1)
Factors Affecting Outdoor Performance of PVC
491(14)
Color Stability
491(1)
Stabilizers
491(2)
Pigments
493(2)
Effect of Calcium Carbonate on PVC Weatherability
495(1)
Effect of Process Conditions on Color Weatherability
496(1)
Impact Retention
497(1)
PVC Resin
497(1)
Impact Modifier
498(1)
Stabilizer
499(1)
Filler
499(1)
Compound Processing Conditions
500(1)
Dimensional Stability
501(1)
Material Properties
501(3)
Product Design Considerations
504(1)
Internal Stresses in the Profile
505(1)
Industry Trends and Recommendations
505(1)
US Industry Standards
506(2)
Conclusions
508(3)
Fabrication Processes
511(90)
James L. Throne
Introduction
511(2)
Rigid PVC Processes
513(55)
Extrusion
513(1)
Single-Screw Extruder
513(4)
Twin-Screw Extruder
517(2)
Cylindrical versus Conical Twin-Screw Extruders
519(1)
Melt Flow Path to the Die
520(1)
Gear Pump
521(1)
General Die Design
522(6)
Foam Extrusion
528(2)
Downstream Calibration and Take-Off
530(1)
Calendering
531(3)
Injection Molding
534(1)
Screw Injection Molding Machine
535(4)
Injection Mold Design2
539(4)
Blow Molding
543(1)
Extrusion Blow Molding
543(6)
Injection Blow Molding
549(1)
Thermoforming
550(1)
Thin-Gauge Thermoforming
551(9)
Heavy-Gauge Thermoforming
560(5)
Other Heavy-Gauge PVC-Type Sheet Forming
565(1)
Compression Molding with Radio-Frequency Heating
566(2)
Composite Processing
568(11)
Fillers
568(3)
Foams
571(4)
Effect of Fillers and Reinforcements on Viscosity
575(2)
Effect of Dissolved Gases on Viscosity
577(1)
Filled and Reinforced Foams -- A Comment
577(1)
The Role of Additives
578(1)
Processing PVC-Containing Polymers
579(2)
Processing Chlorinated PVC
579(1)
PVC-ABS
580(1)
PVC-PMMA
580(1)
Plasticized PVC Processes
581(12)
Liquid Processing
582(1)
Coating
582(1)
Slush Molding
583(1)
Rotational Molding
583(4)
Soft Processing
587(1)
Flow Molding
587(1)
Drysol Rotational Molding
588(1)
Lower-Durometer or Semi-Rigid Processing
589(1)
Extrusion
589(1)
Blow Molding
590(1)
Injection Molding
590(1)
Blown Film
591(2)
Joining and Assembly
593(8)
Dielectric Welding
593(1)
Solvent Welding
594(1)
Thermal Welding
594(1)
Heat Staking
595(1)
Mechanical Fastening
595(1)
Electromagnetic Welding
595(6)
Product Engineering Design
601(18)
Rabeh Elleithy
Introduction
601(1)
Making a Good Product
601(2)
Designing a Good Injection Molding Product
603(1)
Processing Effect on PVC Products
604(4)
Material Properties of PVC Molded Products
608(6)
End-Use Effects on PVC Molded Products
614(1)
Concluding Remarks
615(4)
PVC Applications, their Standards and Regulations, and Starting Formulations
619(20)
Mark T. Berard
Introduction
619(3)
Applications Information Sources
621(1)
Organizations
621(1)
Standards and Codes
621(1)
Pipe
622(2)
Organizations
623(1)
Water Service Distribution
623(1)
Drain, Waste, and Vent
623(1)
Starting Point Formulations
624(1)
Construction
624(5)
Siding
625(1)
Windows and Doors
626(1)
Fencing and Railing
627(1)
Decking
627(1)
Flooring
628(1)
Single Ply Roofing
628(1)
Other Construction
629(1)
Wallcovering
629(1)
Landfill Liners
629(1)
Expansion Joints
629(1)
Consumer Goods and Home Furnishings
629(3)
Flexibles
631(1)
Packaging
632(1)
Electrical/Electronic
632(3)
Conduit
634(1)
Transportation/Automotive
635(1)
Other Applications
635(1)
Medical
635(1)
Coatings
635(1)
Organizations
636(3)
PVC Environmental, Health, Safety
639(40)
D'Lane Wisner
James Lewis
Fred Krause
Ronald Kaminski
Introduction
639(1)
Industry Size and Safety Record
639(1)
Overview of Monomer and Polymer Regulatory Issues (EDC/VCM/PVC)
640(4)
U.S. Environmental Releases
641(1)
Ambient Air Concentrations in Communities Near Manufacturing Facilities
641(1)
Workplace Exposure
641(1)
Dioxins
642(2)
Compounding Processes
644(12)
Raw Materials
644(1)
PVC Resins -- Safe Handling of PVC Resins
644(1)
CPVC
645(1)
Stabilizers
646(1)
Plasticizers
647(2)
Operations
649(1)
Processing and Materials Handling -- Resin and Compounding
649(3)
Workplace Exposure and Emissions
652(1)
Safety
653(1)
PVC Dust
653(1)
Fabrication
653(1)
General
653(1)
Equipment Hazards
654(2)
Product Applications
656(14)
Building and Construction
656(1)
Pipe and Fittings
656(2)
Siding, Windows, and Fencing/Decking/Railing
658(4)
Packaging
662(2)
Medical Products
664(1)
Automotive
665(1)
Toys
666(1)
Combustion Safety and Toxicity
667(3)
End of Life
670(9)
Reduce, Reuse, Recycle
670(3)
Incineration
673(1)
Landfill
673(6)
PVC Industry Structure and Dynamics
679(22)
David Smalley
Supply and Producers
679(7)
Global Regional Supply
679(1)
Leading Producers
679(2)
Producer Back Integration
681(2)
Producer Forward Integration
683(2)
Industry Restructuring
685(1)
Demand
686(9)
Global Regional Demand
686(1)
Per Capita Consumption
687(1)
Demand by End Use
687(2)
Market Status of Specialty Resins
689(1)
Merchant Resin vs. Compound Sales
690(1)
Impact of Regulations
691(1)
Interregional Trade
692(1)
Growth Forecast until 2010
692(3)
Capacity Needs
695(1)
Pricing and Economics
695(6)
Resin Price Structure
695(1)
Price Cyclicality
696(1)
Price Determinants
697(1)
PVC Resin Cost Components
698(2)
New Plant Capital Investment
700(1)
Index 701

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