ACRYLONITRILE THERMOPLASTICS

Transcription

1 Report No. 78 ACRYLONITRILE THERMOPLASTICS by ROBERT H. SCHWAAB August 1972 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION, SUMMARY... General Aspects... Technical Aspects a 3 INDUSTRY STATUS... High-Nitrile Resins... Standard Oil (Ohio)... Monsanto... DuPont Other Producers s' and Acrylic Competition Between High-kirili Rekk Multipolymers Opportunities for Barrier Resins in Bottles Opportunities for Barrier Resins in Films CBARACTERISTICS AND PROPERTIES OF ACRYLONITRILE THERMOPLASTICS.... Barrier Properties... Impact Strength... Transparency... Heat Deflection Temperature... Creep Strength... Waste Disposal Considerations... 5 CHEMISTRY... Ungrafted Resins... Kinetics of Interpolymerization... Azeotrope Formation in Copolymerization... Mechanism of Graft Polymerization... 6 BARRIER RESIN FROM ACRYLONITRILE... Review of Processes... Process Development... Processing Sequence... Rubbery Substrate... Graft Polymerization... Polymer Latex Finishing... Polymer Finishing V

3 CONTENTS 6 (continued) Process Description... Preparation of Nitrile Rubber Latex... Preparation of Blending Resin Latex or Graft Resin Latex,, Continuous Production of Dry Crumb from Mixed Latex... Polymer Blending and Finishing Section... Process Discussion... Plant Capacity... Design Basis... Production of Rubbery Substrate... Graft Latex Production and Blend Latex Production.,..,. Continuous Production of Dry Polymer Crumb... Additives... Extrusion... Packaging... Materials of Construction... Cost Estimates... Capital Costs... Production Costs... 7 BARRIER RESIN FROM METHACRYLONITRILE... Review of Processes... Process Development... Processing Sequence... Rubbery Substrate... Graft Polymerization... Polymer Latex Finishing... Matrix Resin Copolymerization... Polymer Blending and Finishing... Process Description... Preparation of Acrylate Rubber Latex... Preparation of Graft Resin Latex.,.,..,.,..,,, Continuous Production of Dry Polymer Crumb from Latex... Preparation of Matrix Copolymer by Suspension Polymerization... Polymer Blending and Finishing Section... Process Discussion... Plant Capacity... Design Basis... Production of Rubbery Substrate... Graft Resin Production... Matrix Copolymer Production vi

4 CONTENTS 7 (continued) Additives Extrusion Packaging., Materials of Construction Cost Estimates Capital Costs Production Costs ACRYLIC MULTIPOLYMER Review of Processes Other Processes Graft Polymer Terpolymer Polymer Blending and Finishing Process Description Continuous Production of Terpolymer Solution 186 Preparation of Graft Resin Latex Polymer Blending and Finishing Section Process Discussion Graft Latex Production 196 Solvent Extruder 197 Packaging... : 197 Cost Estimates Capital Costs Production Costs CONVERSION OF BARRIER RESIN TO FINISHED ARTICLES... Continuous-Extrusion Blow-Molding... Review of Processes... Process Description... Injection Blow-Molding... Review of Processes... Process Description... Cold-Parison Blow-Molding... Review of Processes... Process Description... Process Discussion... Thermoforming... Review of Processes... Process Description vii

5 CONTENTS 9 (continued) Cost Estimates , Capital Costs...,...,, ,...,.. Production Costs.,.,,,,...,.,,...., APPENDIX A DESIGN AND COST BASIS,....,.,,,, APPENDIXB THE MARKET FOR CARBONATED BEVERAGE CONTAINERS,, APPENDIXC DESIGN OF A PLASTIC BO'ITLE FOR CARBONATED BEVERAGES. 267 APPENDIXD MOLECULAR ORIENTATION OF FILMS AND BOTTLES,., APPENDIX E APPENDIX F MEASUREMENT OF BARRIER PROPERTIES,.....,... GENERAL REVIEW OF EMULSION POLYMERIZATION.., APPENDIX G EQUIPMENT SUPPLIERS.,..,.,......,.,. 283 CITED REFERENCES PATENT REFERENCES BY COMPANY Viii

6 ILLUSTRATIONS , ,. Effect of Plant Capacity on Total Fixed Capital....,, Effect of Operating Level and Plant Capacity on Production Cost., ,...., ,.... Effect of Plant Capacity on Total Fixed Capital.,..,. Effect of Methacrylonitrile Monomer Cost on Production Cost , Effect of Operating Level and Plant Capacity on Production Cost s Compositions , ,......, Production of..,..,.....,, Effect of Plant Capacity on Total Fixed Capital..,,,. Effect of Operating Level and Plant Capacity on Production Cost....,... ;..,.,.,..,... Bottle Production by Continuous-Extrusion Blow Molding... Bottle Production by Injection Blow-Molding......,. Bottle Production from Cold Parisons by Corpoplast Process. Corpoplast Cold-Parison Blow-Molding ,,. Packaging of Parisons., ,.. Bottle Production from Sheet by Thermoforming and Spin Welding IX

7 TABLES High-Nitrile Thermoplastics and Comparison of Processes, , High-Nitrile Thermoplastics and Comparison of Estimated Capital and Manufacturing Costs,.. 6 Production of Bottles from Barrier Resin Comparison of Estimated Costs....,.,......,.. 7 and Clear ABS Comparison of Properties ,...,.. 18 Comparison of Physical Properties of Acrylonitrile Thermoplastics ,...,......, 24 Gas Permeation Rates of High-Barrier Polymers..,...,, 25 Properties of Transparent Polymers ,.., 33 Heat Distortion Temperatures of Typical Bottle Resins..,. 38 Reactivity Ratios of Acrylonitrile in Copolymerization Barrier Resins from Acrylonitrile Patent Summary , Major Process Equipment and Utilities Summary,..,.,.. 85 Stream Flows Total Capital Investment , , 103 Major Capital Equipment Production Costs,......,.,,...,...., Barrier Resins from Methacrylonitrile PatentSummary Major Process Equipment and Utilities Summary......,. 141 Stream Flows....,.., ,....., Total Capital Investment, Xi

8 TABLES Major Capital Equipment,..,.....,.,...., Production Costs ,....,,,,,. 165 s PatentSummary , Major Process Equipment and Utilities Summary.,,,,.., 191 Stream Flows..,...,,......, Total Capital Investment....,.,..,,..,., Major Capital Equipment..,., ,,,, 204 Production Costs...,..,....,,,.,.., Bottle Production by Continuous-Extrusion Blow-Molding Selected List of Equipment Manufacturers.,..,,,,,,, 213 Bottle Production by Continuous-Extrusion Blow-Molding Major Process Equipment and Utilities Summary..,,..,. 219 Bottle Production by Injection Blow-Molding Selected List of Equipment Manufacturers,..., Bottle Production by Injection Blow-Molding Major Process Equipment and Utilities Summary..,, Bottle Production by Cold-Parison Blow-Molding Effect of Molecular Orientation on Physical Properties Bottle Production from Cold Parisons by Corpoplast Process Major Process Equipment and Utilities Summary.,.,.., 235 Bottle Production from Sheet by Thermoforming and Spin Welding Major Process Equipment and Utilities Summary.., Bottle Production Total Fixed Capital......, Bottle Production Conversion Costs , ,.,,., 253 xii