Polyethylene

Industrial Production Of Polyethylene

Raw Material:
The first polyethylene plant built by ICI used ethylene produced by dehydration of
ethanol. Modern ethylene production plants are based on the thermal cracking of
hydrocarbon feed stock at 800-900°C The polymerization grade ethylene is 999 vol%
pure The main impurities of importance to free radical polymerization are oxygen and
water. Oxygen could cause inhibition of low temperature initiators, or uncontrolled
initiation of reaction at higher temperatures Water can form ethylene hydrate in the
cooler parts of high-pressure process, completely blocking the pipes. Hydrogen is poison
only for Phillips catalyst.

[ad#aryshi1]

The main types of processes used to manufacture polyethylene are:

1.High-pressure autoclave.
2.High pressure tubular
3.Gas-phase fluidized bed
4.plurry phase autoclave/loop
5.Solution autoclave

Modern polyethylene production processes offer the possibilities of a versatile range of

products. High-pressure processes can produce LLDPE in addition to the normal range of
LDPEs and ester copolymers. As well as HDPE some low-pressure plants can also
produce LLDPE and VLDPE

Following Table gives the technical applicability of processes for polyethylene

manufacture.
+ Suitable; 0 Technically feasible with some limitations; – Unsuitable

From the above Table following conclusions can be drawn.

1. LDPE, EVA and Acrylate copolymers can be manufactured only by high-pressure
processes.
2. HDPE is preferably manufactured by low-pressure catalytic process.
3. LLDPE can be manufactured by both processes.
4. Gas-phase fluidized bed is the most popular process.
[ad#aryshi1]

Categories: Polyethylene (PE) Tags: Gas-phase, HDPE, High pressure tubular, High-
pressure autoclave, LLDPE, Polyethylene, VLDPE

Polyethylene
aryshi No comments

Polyethylene has simplest structure of all the polymers but involves very complex
chemistry. Polyethylene is available in different types. There are many different types of
manufacturing processes also. It is the major commercial plastics sold and used
throughout the world.
Polyethylene was discovered in 1933 at lei UK

Three major types:

LOPE Low density polyethylene (density 0915 – 0.93 g/cm3) HDPE High density
polyethylene (density 0.94 – 0.98 g/cm3) LLDPE Linear low density polyethylene
(density 0.92 – 0.94 g/cm3)

[ad#aryshi1]
LDPE has random long-branching structure, with branches on branches. The short
branches are not uniform in length but are mainly 4 to 2 carbon atom long. The molecular
mass distribution is broad.
HDPE is free of both long and short branching The molecular weight distribution
depends upon catalyst type but is typically of medium width.
LLPDE has branching of uniform length, which is randomly distributed along a chain.
Fairly narrow molecular weight distribution.
LDPE and LLDPE are flexible and in the form of films are transparent with only slight
milkiness. HDPE is white opaque solid that is more rigid and forms films, which have a
more turbid appearance and a crisp feel.
There are some less common types of polyethylene such as HMWPE (High Molecular
Weight Polyethylene), HMWPE (Ultra High Molecular Weight Polyethylene). HMWPE
is HDPE with MFI in the range of 0.01 – 0.1. UHMWPE have extremely high molecular
mass (3 – 6×106) The viscosity is too high to be measured by MFI test. This material is
abrasion resistant, chemically inert and tough.
Polyethylene is also copolymerized with different monomers. Vinyl acetate copolymers
(VLDPE) are produced in largest quantities and improve flexibility. Copolymerization
reduces crystallinity Following Table gives principal types of ethylene copolymers

Principal types of ethylene copolymers

Comonomer Abbreviation Feature

Vinyl acetate EVA Flexibility
Methyl acrylate, Ethyl
Flexibility, Thermal
acrylate, Butyl acrylate, EMA,EEA,EBA,EMMA
Stability
Methyl methacrylate
Flexibility at low
Butene, Hexene, Octene LLDPE temperature, thermal
stability
Comonomer Abbreviation Feature
Acrylic acid, Methacrylate Adhesion, toughness,
EAA,EMAA
acid stiffness

Comparison of typical properties of polyethylenes

Property LDPE HDPE LLDPE UHMWPE

MFI(190C/2.16 kg) 1.1 1.1 0,85 -
Density(gm/cm3) 0.924 0.961 0.922 0.94
Crystallinity(%) 40 67 40 50
Mw 200000 136300 158100 4500000
Mn 44200 18400 35800 -
Yield Strength(MPa) 12.4 26.5 10.3 22
Modulus of elasticity(Mpa) 240 885 199 -

Different product densities and rheological characteristics (MFI) mean different end-uses
and applications. The Melt Flow Index or Melt Index of a polyolefin is essentially
inversely proportional to its molecular weight. Examples of different applications of
polyethylene according to its melt index and density are shown in following figure
Cellular Plastics

A type of plastic with apparent density decreased substantially by the presence of

numerous cells disposed throughout its mass