Plastic large scale production

Since the first application of turbocompressors (Figure 4-1) in large-scale production of nitric acid as a raw material for fertilizers, explosives, plastics, and a variety of other chemical products, the requirements on processes as well as on rotating equipment have become increasingly demanding. Environmental as well as economic considerations have heavily influenced the development of such plants. 

The continuous process is appropriate for the large-scale production of polyesters used in bottle manufacture. Currently, reactors with capacities of more than 600 t/d have been employed. The discontinuous technology based on tumble dryers allows for the successful production of specialities on a smaller scale, particularly for engineering plastics and with respect to the fiber industry. This route is preferred due to its flexibility, simple process control and the excellent quality of the final product. It is, however, restricted by the volume of the reactors, which is generally limited to 44 m3. 

Large scale production of Vinylite resins, vinyl chloride-acetate copolymers, was started in 1933, at which time the material was marketed as molding compounds for the fabrication of phonograph records, dentures, rigid panels, and novelties (21). Several years elapsed before the introduction of highly plasticized polyvinyl chloride sheeting and the resultant widening market. 

Di-2-ethylhexyl phthalate (DOP) had already been patented as a composition of matter and examples of its use as a plasticizer for cellulosics, etc., but not PVC, were cited(2). However, it was not until later in the decade that the overall advantages of DOP were recognized. This was a key factor in the large scale production of 2-ethylhexanol (2EH) by Union Carbide Corp. starting in 1939(3), followed shortly by the commercialization of DOP — also by Union Carbide(4). 2-Ethylhexanol was made at that time via the "double aldol" route, starting with acetaldehyde. 

Since the amounts required are likely to be limited, only a few polymers have been developed specifically for use as adhesives more usually, the manufacturers have accepted polymers from large-scale production and modified them as necessary by compounding. In essence, work of this nature is based on formulation and mixing, and a very wide range of resins, ancillary chemicals, plasticizers, fillers, and so forth, is employed in order to create products which have the balance of properties required for each purpose. 

Some of the com-derived glucose goes into various fermentation processes that lead to other chemical products. For example, large-scale production was recently announced for lactic acid and polylactide plastic derived from it. Citric acid and lysine are two other important fermentation products. 

Further development of the technology of this process, which also involved the manufacture of diphenyl carbonate by an alternative process, led in 1993 to the construction of a new, large scale production (25,000 ton/yr) in Japan by GE Plastics/Mitsui Petrochemical. The manufacturing sequence is ... 

Extrusion is a cost effective manufacturing process. Extrusion is popularly used in large scale production of food, plastics and composite materials. Most widely used thermoplastics are processed by extrusion method. Many biopolymers and their composite materials with petroleum-based polymers can also be extruded. These include pectin/starch/poly(vinyl alcohol) (Fishman et al. 2004), poly(lactic acid)/sugar beet pulp (Liu et al. 2005c), and starch/poly(hydroxyl ester ether) (Otey et al. 1980), etc. In this study, composite films of pectin, soybean flour protein and an edible synthetic hydrocolloid, poly(ethylene oxide), were extruded using a twin-screw extruder, palletized and then processed into films by compression molding process or blown film extrusion. The films were analyzed for mechanical and structural properties, as well as antimicrobial activity. 

Ethylene was the building block of ICl s newly commercialized plastic known as polythene. Levinstein went on to remind British readers that even the source of ethylene had changed All the ethylene used during the war in this country was made from alcohol obtained by fermentation. Ethylene is, however, obtainable in enormous quantities from cracked (vapour phase) petroleum or from natural gas. Another source, and one that would permit self-sufficiency, was suggested by Levinstein. This was the large-scale production of calcium carbide from coal ... 

Abstract Polyhydroxyalkanoate (PHA) initially received serious attention as a possible substitute for petrochemical-based plastics because of the anticipated shortage in the supply of petroleum. Since then, PHA has remained as an interesting material to both the academia and indusby. Now, we know more about this microbial storage polyester and have developed efficient fermentation systems for the large-scale production of PHA. Besides sugars, plant oils will become one of the important feedstock for the industrial-scale production of PHA. In addition, PHA will find new apphcations in various areas. This chapter summarizes the future prospects and the importance of developing a sustainable production system for PHA. 

Braskem has also taken polypropylene, another bulk plastic, in its focus. At the end of 2009, they announced a research partnership with the world s leading producer of industrial enzymes, Novozymes. The focus of this cooperation will be on the development of a large-scale production of polypropylene from sugarcane [12]. 

This chapter highlighted the huge diversity of microbial PHAs, demonstrating that these versatile biopolyesters possess the potential to replace various contemporary fossil-based plastics. Drawbacks in the large-scale production of PHAs were discussed, and economic feasibility was considered. 

Poly(hydroxyalkanoate)s have been the focus of attention as a biodegradable and biocompatible substitute for the corresponding conventional non-degradable plastics (3). However, the costs of the large-scale production of these polymers have barred the widespread use. Now, new fermentation strategies have been developed for the efficient production of poly(hydroxyalkanoate)s. 

The first successful large-scale production of a polypropylene carbonate (PPC) polymer using waste carbon dioxide (CO ) was conducted by Novomer in collaboration with specialty chemical manufacturer Albemarle Corporation (Orangeburg, SC) in May 2013 (http //energy.gov/fe/articles/recycling-carbon-dioxide-make-plastics). 

Ljungberg N, Andersson T, Wesslen B (2003) Film extrusion and film weldability of poly(lactic acid) plasticized with triacetine and tiibutyl citrate. J Appl Polym Sci 88 3239-3247 Lunt J (1998) Large-scale production, properties and commercial applications of polylactic acid... 

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