Plastics manufacturing, chemicals used nylon

Butadiene is used as a chemical intermediate and as a polymer component in the synthetic rubber industry, the latter accounting for 75% of the butadiene produced. Styrene-butadiene rubber, polybutadiene rubber, adiponitrile, styrene-butadiene latex, acrylonitrile-butadiene-styrene resins, and nitrile rubber are used in the manufacture of tires, nylon products, plastic bottles and food wraps, molded rubber goods, latex adhesives, carpet backing and pads, shoe soles, and medical devices. 

Parts are often manufactured using many different plastics (e.g., polypropylene housing and nylon gears) or else plastic blends (e.g., polycarbonate/ ABS blends). Recychng parts made from mixed plastics remains chemically complex because of the general lack of compafibihty. A review article [85] highlighted how new materials advance parts production and that the majority of the new materials identified were blends. 

Adipic acid is a very large volume organic chemical. Worldwide production in 1986 reached 1.6 x 10 t (3.5 x 10 lb) (158) and in 1989 was estimated at more than 1.9 x 10 t (Table 7). It is one of the top fifty (159) chemicals produced in the United States in terms of volume, with 1989 production estimated at 745,000 t (160). Growth rate in demand in the United States for the period 1988—1993 is estimated at 2.5% per year based on 1987—1989 (160). Table 7 provides individual capacities for U.S. manufacturers. Western European capacity is essentially equivalent to that in the United States at 800,000 t/yr. Demand is highly cycHc (161), reflecting the automotive and housing markets especially. Prices usually foUow the variabiUty in cmde oil prices. Adipic acid for nylon takes about 60% of U.S. cyclohexane production the remainder goes to caprolactam for nylon-6, export, and miscellaneous uses (162). In 1989 about 88% of U.S. adipic acid production was used in nylon-6,6 (77% fiber and 11% resin), 3% in polyurethanes, 2.5% in plasticizers, 2.7% miscellaneous, and 4.5% exported (160). 

Benzoic Acid. Ben2oic acid is manufactured from toluene by oxidation in the liquid phase using air and a cobalt catalyst. Typical conditions are 308—790 kPa (30—100 psi) and 130—160°C. The cmde product is purified by distillation, crystallization, or both. Yields are generally >90 mol%, and product purity is generally >99%. Kalama Chemical Company, the largest producer, converts about half of its production to phenol, but most producers consider the most economic process for phenol to be peroxidation of cumene. Other uses of benzoic acid are for the manufacture of benzoyl chloride, of plasticizers such as butyl benzoate, and of sodium benzoate for use in preservatives. In Italy, Snia Viscosa uses benzoic acid as raw material for the production of caprolactam, and subsequendy nylon-6, by the sequence shown below. 

In terms of tonnage the bulk of plastics produced are thermoplastics, a group which includes polyethylene, polyvinyl chloride (p.v.c.), the nylons, polycarbonates and cellulose acetate. There is however a second class of materials, the thermosetting plastics. They are supplied by the manufacturer either as long-chain molecules, similar to a typical thermoplastic molecule or as rather small branched molecules. They are shaped and then subjected to either heat or chemical reaction, or both, in such a way that the molecules link one with another to form a cross-linked network (Fig. 18.6). As the molecules are now interconnected they can no longer slide extensively one past the other and the material has set, cured or cross linked. Plastics materials behaving in this way are spoken of as thermosetting plastics, a term which is now used to include those materials which can in fact cross link with suitable catalysts at room temperature. 

Most of the benzene used in chemical applications ends up in the manufacturing processes for styrene (covered in Chapter 8), cumene (covered in Chapter 7), and cyclohexane (covered in Chapter 4), Polymers and all sorts of plastics are produced from styrene. Cumene is the precursor to phenol, which ultimately ends up in resins and adhesives, mostly for gluing plywood together. The production of styrene and phenol account for. about 70% of the benzene produced. Cyclohexane, used to make Nylon 6 and Nylon 66, is the next biggest application of benzene. 

Nearly all cyclohexane is used to make three intermediate chemicals. About 85% goes for caprolactam, and adipic acid. Another 10% goes for hexamethylene diamine (HMD). All three are the starting materials for Nylon 6 or Nylon 66 synthetic fibers and resins. Nylon fiber markets include the familiar applications hosiery, upholstery, carpet, and tire cord. Nylon resins are engineering plastics and are largely used to manufacture gears, washers, and similar applications where economy, strength, and a surface with minimum friction are important. 

Uses Manufacture of acetate rayon, acetic anhydride, acetone, acetyl compounds, cellulose acetates, chloroacetic acid, ethyl alcohol, ketene, methyl ethyl ketone, vinyl acetate, plastics and rubbers in tanning laundry sour acidulate and preservative in foods printing calico and dyeing silk solvent for gums, resins, volatile oils and other substances manufacture of nylon and fiber, vitamins, antibiotics and hormones production of insecticides, dyes, photographic chemicals, stain removers latex coagulant textile printing. 

Uses Manufacture of ethylbenzene (preparation of styrene monomer), dodecylbenzene (for detergents), cyclohexane (for nylon), nitrobenzene, aniline, maleic anhydride, biphenyl, benzene hexachloride, benzene sulfonic acid, phenol, dichlorobenzenes, insecticides, pesticides, fumigants, explosives, aviation fuel, flavors, perfume, medicine, dyes, and many other organic chemicals paints, coatings, plastics and resins food processing photographic chemicals nylon intermediates paint removers rubber cement antiknock gasoline solvent for fats, waxes, resins, inks, oils, paints, plastics, and rubber. 

Uses The alicyclic hydrocarbons have numerous industrial applications. Cyclopropane (C3H6) is used as an anesthetic. Cyclohexane (CgH ) is used as a chemical intermediate as an organic solvent for oils, fats, waxes, and resins and for the extraction of essential oils in perfume manufacturing industries. Cyclohexene (C6H10) is used in the manufacture of maleic acid, cyclohexane carboxylic acid, and adipic acid. Methyl cyclohexane (C7H14) is used for the production of organic synthetics such as cellulose ethers. These compounds are used in different industries such as adipic acid makers, benzene makers, fat processors, fungicide makers, lacquerers, nylon makers, oil processors, paint removers, plastic molders, resin makers, rubber makers, varnish removers, and wax makers. 

Nitrogen products are among the most important chemicals produced in the world today. The largest quantities are used as fertilizers, but nitrogen products also find very important uses in the manufacture of nylon and acrylic fibers, methacrylate and other plastics, foamed insulation and plastics, metal plating, gold mining, animal feed supplements, herbicides, and many pharmaceuticals. 

Chemical manufacturing and petroleum refining have enriched our lives. Few individuals in the developed world stop to realize how the chemical industry has improved every minute of their day. The benefits of the industries are apparent from the time our plastic alarm clock tells us to wake up from a pleasant sleep on our polyester sheets and our polyurethane foam mattresses. As our feet touch the nylon carpet, we walk a few steps to turn on a phenolic light switch that allows electrical current to safely pass through polyvinyl chloride insulated wires. At the bathroom sink, we wash our face in chemically sanitized water using a chemically produced soap. 

PVOH (or tradename PVAL) is a crystalline, white powder soluble in water and alcohols. It is characterized by water solubility, low gas permeability barrier, high resistance to organic solvents other than alcohol, and crystallinity when stretch oriented. Crystallinity allows the material to polarize light. A series of hydrolysis levels of the plastic are available that range from room temperature solubility to those not soluble at all. The major applications of the PVOHs are in elastomeric products, adhesives, films, and finishes. Extruded PVOH hoses and tubing are excellent for use subjected to contact with oils and other chemicals. PVOH is used as a sizing in the manufacture of nylon. 

Benzene found in the environment is from both human activities and natural processes. Benzene was first discovered and isolated from coal tar in the 1800s. Today, benzene is made mostly from petroleum sources. Because of its wide use, benzene ranks in the top 20 in production volume for chemicals produced in the United States. Various industries use benzene to make other chemicals, such as styrene (for Styrofoam and other plastics), cumene (for various resins), and cyclohexane (for nylon and synthetic fibers). Benzene is also used for the manufacturing of some types of rubbers, lubricants, dyes, detergents, drugs, and pesticides. Natural sources of benzene, which include volcanoes and forest fires, also contribute to the presence of benzene in the environment. Benzene is also a part of crude oil and gasoline and cigarette smoke. For more information on the nature and uses of benzene, see Chapters 3 and 4. 

The primary use for phenol is as an intermediary chemical, a compound used in the synthesis of other chemicals. About 40 percent of all the phenol produced in the United States is used to make hisphenol A, while a similar amount is used in the production of a variety of polymers, such as phenol-formaldehyde plastics and nylon-6. The third largest application of phenol is in the manufacture of a host of other chemicals, xylene and aniline being the most important. 

MAJOR USES Manufacture of chemicals including acrylic fiber, plastics, rubber elastomers, plasticizers, solvents, polymeric materials, dyes, pharmaceuticals, insecticides and nylon formation of high impact resins such as styrene acrylonitrile and acrylonitrile butadiene styrene. 

Du Font s major contribution to the country s war effort in World War 1 was the manufacture of explosives. By the time World War 11 erupted, explosives was just one of the many Du Pont products needed in the war effort. The insatiable appetite of the war machine imposed numerous demands on technical personnel to build new process lines (over 50 plants were built) in record time and to develop specialty products by yesterday. Chemical engineers played a key role in meeting these demands. Since natural rubber was no longer available, plants to manufacture synthetic rubber such as neoprene had to be built. Rayon and nylon were used in tire cord. Industries producing combat equipment needed heavy chemicals. The emergence of air power required special chemical materials such as plastic enclosures. 

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