Extending the Processing Window of Ca/Zn-stabilised PVC Window Profiles by the Use of Metallocene Waxes

Transcription

1 Window of Ca/Zn-stabilised PVC Window Profiles by the, Clariant Produkte (Deutschland) GmbH / Gersthofen 10 th PVC Conference / Brighton Dome 22 nd -24 th April 2008

2 Overview Comparison of polyolefin waxes based on conventional and metallocene - catalysed production Processing behaviour of these waxes in Calcium - / zinc stabilised PVC window profiles Calcium - / zinc stabilised PVC Wood Compounds Testing on - Single screw laboratory extruders - Twin screw extruders Comparisons of results regarding - Pressure formation - Energy consumption - Appearance of profiles Slide 2 Summary Metallocene waxes as universal carrier for pigmentation of PVC

3 Accessible PE- and PP-Waxes by Metallocene-Catalysis Drop/Softening Point vs. Melt Viscosity 170 PP PP 6102 PP 6502 [ C] PE 4201 PP 4202 PE 5301 PE 3401 PE 2401 PP 2602 PP 1302 PP 1502 PP Slide [mpa.s] (Measuring temp. PE: 140 C, PP: 170 C)

4 PP- and PE- Metallocene Waxes Crystallinity vs. Melt Viscosity PE 4201 PP 6102 Hard, grindable crystallinity PP 4202 PE 3401 Soft, tacky PP 2602 PP 1302 PP 1502 PP 1602 Slide 4 viscosity

5 Novel Materials between Wax and Resin Accessible Crystallinity medium to high: e.g. PE 4201, PP 6102 classic wax character: hard, brittle medium or high m.p. opaque soluble in hot (unpolar) solvents high shrinking low: PP 1602 novel species: soft, flexible, tacky very low m.p. (<100 C) translucent soluble in cold (unpolar) solvents very low shrinking Slide 5 Application: PVC processing PO compounding and masterbatches Application: Universal carrier for colour- and additives concentrates used in PVC and other polymers

6 Metallocene Waxes in Ca/Zn-Stabilised PVC Window Profiles Test formulation: S-PVC k-value 68 Ca/Zn-Stabiliser compound Impact modifier Processing aid TiO 2 Test products: Standard PE wax PP 6102 PE phr 2,4 phr 7 phr 1 phr 4 phr Chalk Di stearyl phthalate Calcium stearate Oxidised PE-wax Test product 6 phr 0,5 phr 0,5 phr 0,2 phr 0,2-0,3 phr Slide 6 Extruders: Single screw: Extrusiometer E 30 M: D= 30 mm, 25 L/D, n= 30 rpm, Temperature: C, round-section die: 195 C Twin screw: DS twin screw: D= 48 mm, 17 L/D, n= 25 rpm, Temperature: C, die: 195 C

7 Metallocene Waxes in Ca/Zn-Stabilised PVC Window Profiles Pressure Formation along the Single Screw Extruder Pressure [bar] Slide 7 0 p1 p2 p3 p4 p5 0,3 0,3 phr phr standard PE PE wax wax 0,2 0,3 phr phr PE mpp ,2 0,3 phr phr PP mpe ,3 0,2 phr phr PP mpe ,3 0,2 phr phr PE mpp

8 Metallocene Waxes in Ca/Zn-Stabilised PVC Window Profiles Output and Energy Consumption (Single Screw Extruder) 9 Output e - Value 0,1 8 0,08 Output [kg/h] 7 0,06 e - Value [kwh/kg] 6 0,04 Slide 8 5 standard PE wax PP 6102 PE 4201 PP 6102 PE 4201 Dosage: 0,3 phr Dosage: 0,2 phr 0,02

9 Metallocene Waxes in Ca/Zn-Stabilised PVC Window Profiles Round-Section Die (Single Screw Extruder) Standard PE wax PE 4201 PP 6102 Dosage: 0,3 phr PP 6102 PE 4201 Dosage: 0,2 phr Slide 9

10 Metallocene Waxes in Ca/Zn-Stabilised PVC Window Profiles Output and Energy Consumption (Twin Screw Extruder) 45 Output Torque 75 Output [kg/h] Torque [%] 20 standard PE wax PP 6102 PE 4201 PP 6102 PE 4201 Dosage: 0,3 phr Dosage: 0,2 phr 40 Slide 10

11 Metallocene Waxes in Ca/Zn-Stabilised PVC/Wood-Compounds Test formulation: S-PVC k-value 68 Wood pellets Ca/Zn-Stabiliser Impact modifier Processing aid 100 phr 50 phr 2,4 phr 7 phr 1 phr Chalk Di stearyl phthalate Oxidised PE wax Test product 6 phr 0,5 phr 0,2 phr 1,0 1,25 phr Test products: Standard PE wax PP 6102 PE 4201 Slide 11 Extruder: Single screw: Extrusiometer E 30 M: D= 30 mm, 25 L/D, n= 15 rpm, Temperature: C, round-section die: 200 C

12 Ca/Zn-Stabilised PVC/Wood-Compounds Pressure Formation along the Single Screw Extruder Pressure [bar] p1 p2 p3 p4 p5 1,25 1 phr phr standard PE PE wax wax 11,25 phr phr standard PE PE wax wax Slide 12 1 phr mpe phr mpp 6102

13 Outcomes for Ca/Zn-stabilised PVC and PVC/Wood-Compound The metallocene waxes PP 6102 and PE 4201 provide: Lowest pressure along the extruder and lowest energy consumption Similar to higher output Even at lower dosage (0,30 0,20 phr; 1,25 1,0 phr in PVC/Wood) No influence on mechanical properties Interesting first trial results regarding plate-out behaviour (PP 6102) Slide 13

14 General Summary for Metallocene Waxes in PVC Profile Extrusion Similar to better performance when using % less amount of metallocene wax compared to standard PE waxes Slide 14

15 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Inorganic Brown Concentrates Carrier PP 1602 (metallocene wax) H 29 (oxidized PE-wax) Formulation of concentrates A50 = 50 % [PP H 29 (4:1)] + 50 % Brown 29 B70 = 30 % [PP H 29 (2:1)] + 70 % Brown 29 Mixing: Cold mix 7 m/s, 4 min, room temperature Slide 15

16 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Production of Concentrate Equipment: Compounder ZE 25/48 material flow Slide 16 l/d = 48 D, d = 25 mm Main feed Screw speed: 500 rpm Temperature: Output: 15 kg/h (die)

17 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Physical Properties of Extrusion Strand Slide 17 High elasticity of the pigment/metallocene concentrate

18 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Behaviour in PVC Formulation Addition of inorganic brown concentrate into a Ca/Zn-stabilised PVC window profile compound 0,7 % B70 (70 % pigment) Processing on a sheet line extrusion in order to have big surface for inspection regarding dispersion quality Slide 18

19 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Processing on Sheet Line Extrusion Equipment: KMD 2-25 L conical twin screw with an internal screw heating tool: flat die, width 200 mm, gap 1 mm temperature profile: screw: 160 C; barrel: 175 / 180 / 185 C (Adaptor); tool: 195 C screw speed: 40 rpm; throughput: approx. 10 kg/h Slide 19 Results: Nice and smooth sheet surface, no specs No effect on: torque level pressure level over the barrel length gelation

20 Metallocene Waxes as Universal Carrier for Pigmentation of PVC - Summary Novel metallocene wax species can be used as sole carriers for colour concentrates used in PVC and other polymers: Easy to process (low temperature) Easy to handle (elastic, non-brittle) High loadings of pigment or additives Universal compatibility (PVC, PO etc.) Slide 20

21 Thank you for attention! QUESTIONS?