Improving safety of chemical powder systems using .... Improving... · 9 Irganox 1010 Irganox 1010 can be used in polyolefin, such as polyethylene, polypropylene, poly-butane and

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Improving safety of chemical powder systems using

masterbatch in polymer and petrochemical industries

S.A. Razavi Alavi, M. Torabi Angaji, M. Shirazi,

Y. Bahrami, M.R. Mozdianfard

Presented by: M. Torabi AngajiDepartment of Chemical Engineering, Tehran University

Paper Code: (imbpa15-00660045)

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Table of Contents

• Introduction

• Introducing additives

• Environmental issues

• Strategies for solving problems

• References

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IntroductionIn the polyethylene extrusion process, polymer materials in

powder or granule forms undergo compression, melting and

transmission operations, whereby extrudate is produced on a

special base form.

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Introduction

The powder/granule mixes with chemical additives and melts by

thermal and mechanical energy in three feed, compression and

metering zones, and converts to final product in the last plate

using gear pump and screw's pressure.

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Introducing additives

Using additives in polyethylene

•Calcium stearate•Zinc stearate•Carbon black•Irganox 1010•Irgafos 168•Viton FFGB

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Calcium stearate

Applications:

Lubricant, Prevent clotting agent, Stabilizer, release agents and rubber industry.

CHARACTERISTICS DENSITY(KG/L)

MELTING POINT(C)

HUMIDITY WEIGHT (%)

SPECIFIC WEIGHT

ASH (%)

AMOUNT 0.2 150-160 3.5-4 1.01 10.5

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Application

It is used as a raw material commonly along with other stearate salts such as calcium stearate zinc, barium and used for the thermal stability of PVC.

It is used in plastic industry as scavengers, lubricants, and release for polyethylene, polypropylene.

Zinc stearate

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Carbon black

CHARACTERISTICS ASH CONTENT

(%W)

PH VALUE PURE DENSITY(GR/L)

CARBON (%)

AMOUNT 0.75 6-10 330-380 88-99.5

Industrial soot brand carbon black (Carbon Black) with uniqueproperties that has been shown is used in the manufacture ofpigments, master batch, inks and paint and coatings industry inrespect of properties such as specific surface area, structureand size particles, conductivity and color.

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Irganox 1010

Irganox 1010 can be used in polyolefin, such as polyethylene,polypropylene, poly-butane and olefin copolymers such asethylene vinyl acetate copolymers. It is also suggested to use forprocessing of polymers such as polyacetal and polyamide andpolyurethane, polyester, polyvinyl chloride, polystyrene Homo,elastomers such as butyl rubber (IIR), synthetic rubber,adhesives, natural and synthetic resins, and other organicmaterials.

CHARACTERISTICS MOLECULAR WEIGHT(GR/MOL)

MELTING POINT(C)

VAPOR PRESSURE AT 20C

BOILING POINT(C)

DENSITY(GR/CM3)

AMOUNT 1177.63 115-118 7 E-10 PA 1005.8 1.077

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Irgafos 168

This phosphorus compounds has a low volatility and isparticularly resistant to hydrolysis. Polymer protects againstoxidation and during processing of molecular weight change andprevents discoloration.

It is used as an antioxidant in the composition of polyolefin andolefin copolymers, such as high density polyethylene andpolypropylene lightweight and functional that can also be usedin polyester and polystyrene and their co-polymers and glue,etc.

CHARACTERISTICS MOLECULAR WEIGHT

(GR/MOL)

MELTING POINT

(C)

COMBUSTING POINT

(C)

BOILING POINT(C)

AMOUNT 646.93 181-184 257 594.2(760MMHG)

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Environmental issues

According to eye observations and scientific investigations, it isobvious that the mentioned materials exit from additives bagsby leaking and some part spread out as dust that put bad effectsboth on workers and making maintenance and repair costs(Failure of electrical connection devices etc.)

Inhalation of this material causes pneumonia, shortness ofbreath, cough and sputum plus much, scaling fingers and nails,thick skin tissues in the lungs, heart problems and reducedlongevity.

Calcium and Zinc stearate environmental effects

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Environmental issues

This material is in group that there possibly carcinogenic forhuman. It was indicated by more studies that some black carbongrids have a little amounts of polycyclic aromatic on theirsurfaces which have danger of carcinogenic in highconcentrations, but frequently explosion to black carbon makessome problems such as coughing, chest pain, lethargy, fatigueand wheezing for breathing this material. Permanent skincontact with this material make skins dry which is intensified byrapidly usage of detergents, but eyes can be safe by simplewashing by water, because carbon is not a chemical stimulus.

Carbon Black environmental effects

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Strategies for solving problems

According to studies on carbon black is the most harmfulmaterial to the human body. Furthermore, zinc stearate, calciumstearate and similar structures because of particles sizedistribution will be as materials with the same risks for humans.

Therefore , investigation of particles size distribution in theseadditives for improving safety is essential test in our work.

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Strategies for solving problems

Comparison of particle size distribution in additives

0

1

2

3

4

5

6

7

8

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0.2 200.2 400.2 600.2 800.2 1000.2

Vo

lum

e (

%)

Particle Size(μm)

Irgafos168

Irganox1010

Calcium Stearate

Zinc Stearate

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Strategies for solving problemsSuggested methods for Improving safety of the system :

V-2

Loading bin

Waste additives

Worker

Blower

Filter

Mixer

Hazard to health

hazard to environment

waste of materials

Present system

V-2

Loading bin

Waste additives

Skilled

Worker

Blower

Filter

Mixer

Using skilled worker

Hazard to health: Low

hazard to environment: Low

waste of materials: Low

Cost: Very low

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Strategies for solving problemsUsing modified filtering system

Using automatic feeding system

Hazard to health: Low

hazard to environment: Medium

waste of materials: Medium

Cost: Medium

V-2

Loading bin

Waste additives

Worker

Blower

Modified FilterMixer

Hazard to health: Medium

hazard to environment: Very low

waste of materials: Medium

Cost: Low

V-2

Loading bin

Waste additives

Automatic

feeding system

Blower

Filter

Mixer

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Strategies for solving problemsExisting master batch

methods - encapsulation

Hazard to health: Very low

hazard to environment: Very low

waste of materials: Very low

Cost: Low

Hazard to health: Very low

hazard to environment: Very low

waste of materials: Very low

Cost: High

V-3

Encapsulation system

Mixer

Filling Bin

Waste powder

Worker Blower

Filter Combination of using skilled worker and using modified filtering system

will be our offer.

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Refrences

1. Razavi Alavi S.A., Torabi Angaji M., Gholami. Z., ‘Twin-screw extruder & effective parameters on the HDPE extrusion process’, World Accad of Sci., Eng. and Technology,. Vol:25, 24th Jan. 2009.

2. Mather P.J., Thomas K.M., ‘Carbon black/ high density polyethylene conducting composite materials’. Journal of Material Science,. 32 (1997) 401Ð407.

3. Sigris S., Jullien R., Lahaye J., ‘Agglomeration of solid particles’, Cement & Concrete Composites, Vol 23, 153-156, 2001.

4. Zeng X.M., Martin G., Marriott C., “Particulate interactions in dry powder formulations of inhalation”, Taylor & Frances, 2001.

5. Rhodes M., “Introduction to particle technology”,. 2nd Ed., John Wiley & Sons Ltd. ISBN: 978-0-470 -01427-1,. 2008.

6. Crosbie, W.A., ‘The Respiratory Health of Carbon Black Workers’, Archives of Environmental Health: An International Journal, 41:6, 346-353, 3rd Aug. 2010.