Improving safety of chemical powder systems using masterbatch in polymer and petrochemical industries

Transcription

1 Paper Code: (imbpa ) 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 Angaji Department of Chemical Engineering, Tehran University 1

2 Table of Contents Introduction Introducing additives Environmental issues Strategies for solving problems References 2

3 Introduction In 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. 3

4 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. 4

5 Introducing additives Using additives in polyethylene Calcium stearate Zinc stearate Carbon black Irganox 1010 Irgafos 168 Viton FFGB 5

6 Calcium stearate CHARACTERISTICS DENSITY (KG/L) MELTING POINT(C) HUMIDITY WEIGHT (%) SPECIFIC WEIGHT ASH (%) AMOUNT Applications: Lubricant, Prevent clotting agent, Stabilizer, release agents and rubber industry. 6

7 Zinc stearate 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. 7

8 Carbon black CHARACTERISTICS ASH CONTENT (%W) PH VALUE PURE DENSITY (GR/L) CARBON (%) AMOUNT Industrial soot brand carbon black (Carbon Black) with unique properties that has been shown is used in the manufacture of pigments, master batch, inks and paint and coatings industry in respect of properties such as specific surface area, structure and size particles, conductivity and color. 8

9 Irganox 1010 CHARACTERISTICS MOLECULAR WEIGHT (GR/MOL) MELTING POINT (C) VAPOR PRESSURE AT 20C BOILING POINT (C) DENSITY (GR/CM3) AMOUNT E-10 PA Irganox 1010 can be used in polyolefin, such as polyethylene, polypropylene, poly-butane and olefin copolymers such as ethylene vinyl acetate copolymers. It is also suggested to use for processing of polymers such as polyacetal and polyamide and polyurethane, polyester, polyvinyl chloride, polystyrene Homo, elastomers such as butyl rubber (IIR), synthetic rubber, adhesives, natural and synthetic resins, and other organic materials. 9

10 Irgafos 168 CHARACTERISTICS MOLECULAR WEIGHT (GR/MOL) MELTING POINT (C) COMBUSTING POINT (C) BOILING POINT(C) AMOUNT (760MMHG) This phosphorus compounds has a low volatility and is particularly resistant to hydrolysis. Polymer protects against oxidation and during processing of molecular weight change and prevents discoloration. It is used as an antioxidant in the composition of polyolefin and olefin copolymers, such as high density polyethylene and polypropylene lightweight and functional that can also be used in polyester and polystyrene and their co-polymers and glue, etc. 10

11 Environmental issues According to eye observations and scientific investigations, it is obvious that the mentioned materials exit from additives bags by leaking and some part spread out as dust that put bad effects both on workers and making maintenance and repair costs (Failure of electrical connection devices etc.) Calcium and Zinc stearate environmental effects Inhalation of this material causes pneumonia, shortness of breath, cough and sputum plus much, scaling fingers and nails, thick skin tissues in the lungs, heart problems and reduced longevity. 11

12 Environmental issues Carbon Black environmental effects This material is in group that there possibly carcinogenic for human. It was indicated by more studies that some black carbon grids have a little amounts of polycyclic aromatic on their surfaces which have danger of carcinogenic in high concentrations, but frequently explosion to black carbon makes some problems such as coughing, chest pain, lethargy, fatigue and wheezing for breathing this material. Permanent skin contact with this material make skins dry which is intensified by rapidly usage of detergents, but eyes can be safe by simple washing by water, because carbon is not a chemical stimulus. 12

13 Strategies for solving problems According to studies on carbon black is the most harmful material to the human body. Furthermore, zinc stearate, calcium stearate and similar structures because of particles size distribution will be as materials with the same risks for humans. Therefore, investigation of particles size distribution in these additives for improving safety is essential test in our work. 13

14 Volume (%) Strategies for solving problems Comparison of particle size distribution in additives Irgafos168 Irganox1010 Calcium Stearate Zinc Stearate Particle Size(μm) 14

15 Strategies for solving problems Suggested methods for Improving safety of the system : Present system Using skilled worker Worker Loading bin Skilled Worker Loading bin Mixer Filter Blower Mixer Filter Blower V-2 V-2 Waste additives Hazard to health hazard to environment waste of materials Waste additives Hazard to health: Low hazard to environment: Low waste of materials: Low Cost: Very low 15

16 Strategies for solving problems Using modified filtering system Using automatic feeding system Worker Loading bin Automatic feeding system Loading bin Blower Filter Blower Mixer Modified Filter Mixer V-2 V-2 Waste additives Waste additives Hazard to health: Medium hazard to environment: Very low waste of materials: Medium Cost: Low Hazard to health: Low hazard to environment: Medium waste of materials: Medium Cost: Medium 16

17 Strategies for solving problems Existing master batch methods - encapsulation Filling Bin Encapsulation system Worker Mixer Filter Blower Combination of using skilled worker and using modified filtering system will be our offer. V-3 Waste powder Hazard to health: Very low hazard to environment: Very low waste of materials: Very low Cost: High Hazard to health: Very low hazard to environment: Very low waste of materials: Very low Cost: Low 17

18 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 Mather P.J., Thomas K.M., Carbon black/ high density polyethylene conducting composite materials. Journal of Material Science,. 32 (1997) 401Ð Sigris S., Jullien R., Lahaye J., Agglomeration of solid particles, Cement & Concrete Composites, Vol 23, , Zeng X.M., Martin G., Marriott C., Particulate interactions in dry powder formulations of inhalation, Taylor & Frances, Rhodes M., Introduction to particle technology,. 2nd Ed., John Wiley & Sons Ltd. ISBN: , Crosbie, W.A., The Respiratory Health of Carbon Black Workers, Archives of Environmental Health: An International Journal, 41:6, , 3rd Aug