Polyethylene terephthalate process

Condensation polymerization differs from addition polymerization in that the polymer is formed by reaction of monomers, each step in the process resulting in the elimination of some easily removed molecule (often water). E.g. the polyester polyethylene terephthalate (Terylene) is formed by the condensation polymerization (polycondensation) of ethylene glycol with terephthalic acid ... 

The primary substrates or support iaclude many types of paper and paperboard, polymer films such as polyethylene terephthalate, metal foils, woven and nonwoven fabrics, fibers, and metal cods. Although the coating process is better suited to continuous webs than to short iadividual sheets, it does work very well for intermittent coating, such as ia the printing process. In general, there is an ideal coater arrangement for any given product. 

PE. See polyethylene (PE) pendulum test method perfonnance of product design affecting predicting process and penneability of plastic PET. See polyethylene terephthalate (PET)... 

Polyethylene terephthalate (PET) is one of the most important commercial thermoplastic polyesters, which has been on the market since 1977 and is widely used in both industrial and household applications. Under specific conditions, plastics can be converted into their primary components for use in other chemical processes by chemical recycling. PET is a thermoplastic, and so recycling by chemical methods, which converts it into primary components, can be achieved. This study examines the optimal routes of the existing chemical methods. For chemical recycling, acidic hydrolysis is used and PET is converted into terephthalic acid (TPA) and... 

This comprehensive article supplies details of a new catalytic process for the degradation of municipal waste plastics in a glass reactor. The degradation of plastics was carried out at atmospheric pressure and 410 degrees C in batch and continuous feed operation. The waste plastics and simulated mixed plastics are composed of polyethylene, polypropylene, polystyrene, polyvinyl chloride, acrylonitrile butadiene styrene, and polyethylene terephthalate. In the study, the degradation rate and yield of fuel oil recovery promoted by the use of silica alumina catalysts are compared with the non-catalytic thermal degradation. 9 refs. lAPAN... 

When the new product to be manufactured is the same as what it started as, for example a new bottle made from bottle scrap, the recycling is referred to as closed-loop. When the new application is different from the starting one, the process is referred to as open-loop recycling, as is the case when the polyethylene terephthalate bottle is used to produce polyester fiber for carpeting. 

Polyethylene terephthalate also has the tendency, because it is produced by a condensation polymerization process, to depolymerize under high pressure and temperatures in the presence of water. Although this is usually a negative attribute, it can be utilized to regenerate pure monomers which can be repolymerized to make fresh polymer. This avoids the issues experienced by reprocessing resins, as the new resin has not experienced a previous heat history. A major drawback to this process is the requirement that the monomers used in polymerization processes must be highly pure, Unfortunately, this process is extremely costly and not performed on a commercial scale. 

Figure 24.3 Two-step polymerization process for the manufacture of polyethylene terephthalate ...

In addition to the desired polymerization reaction, the dialcohol reactants can participate in deleterious side reactions. Ethylene glycol, used in the manufacture of polyethylene terephthalate, can react with itself to form a dialcohol ether and water as shown in Fig. 24.4a). This dialcohol ether can incorporate into the growing polymer chain because it contains terminal alcohol units. Unfortunately, this incorporation lowers the crystallinity of the polyester on cooling which alters the polymer s physical properties. 1,4 butanediol, the dialcohol used to manufacture polybutylene terephthalate, can form tetrahydrofuran and water as shown in Fig. 24.4b). Both the tetrahydrofuran and water can be easily removed from the melt but this reaction reduces the efficiency of the process since reactants are lost. 

Polyethylene terephthalate is most often extruded into films or fibers, or blow molded into bottles. Polybutylene terephthalate is primarily found in injection molded parts. Such parts are highly crystalline, which makes them opaque. Polybutylene terephthalate is often modified with glass fibers or impact modifiers. Table 24.1 contains applications by processing method and resin. 

Table 24.1 Applications of polyethylene terephthalate and polybutylene terephthalate by processing method...

Polyesters exhibit excellent high temperature strength and electrical properties making them a good choice for many demanding applications. They also are physiologically inert allowing them to be used in food contact applications. The two common polyesters, polyethylene terephthalate and polybutylene terephthalate, are both used in injection molded products. Polyethylene terephthalate is often used in both extrusion and blow molded processes also. 

Direct evidence of nucleation during the induction period will also solve a recent argument within the field of polymer science as to whether the mechanism of the induction of polymers is related to the nucleation process or to the phase separation process (including spinodal decomposition). The latter was proposed by Imai et al. based on SAXS observation of so-called cold crystallization from the quenched glass (amorphous state) of polyethylene terephthalate) (PET) [19]. They supposed that the latter mechanism could be expanded to the usual melt crystallization, but there is no experimental support for the supposition. Our results will confirm that the nucleation mechanism is correct, in the case of melt crystallization. 

Much more information can be obtained from the DSC experiment than simply an observation of the transition from a solid to a liquid phase. A plot of heat flow against temperature is a true depiction of the continuity of the heat capacity at constant pressure (Cp). If the entire temperature range of a given process is known, the physical state of a material will reflect the usefulness of that material at any temperature point on the plot. For polyethylene terephthalate (see Fig. 4.9), a stepshaped transition is interpreted as a change in Cp resulting from a... 

Oxidation is the first step for producing molecules with a very wide range of functional groups because oxygenated compounds are precursors to many other products. For example, alcohols may be converted to ethers, esters, alkenes, and, via nucleophilic substitution, to halogenated or amine products. Ketones and aldehydes may be used in condensation reactions to form new C-C double bonds, epoxides may be ring opened to form diols and polymers, and, finally, carboxylic acids are routinely converted to esters, amides, acid chlorides and acid anhydrides. Oxidation reactions are some of the largest scale industrial processes in synthetic chemistry, and the production of alcohols, ketones, aldehydes, epoxides and carboxylic acids is performed on a mammoth scale. For example, world production of ethylene oxide is estimated at 58 million tonnes, 2 million tonnes of adipic acid are made, mainly as a precursor in the synthesis of nylons, and 8 million tonnes of terephthalic acid are produced each year, mainly for the production of polyethylene terephthalate) [1]. 

Reimschuessel, H. K Polyethylene terephthalate formation. Mechanistic and kinetic aspects of the direct esterification process, Ind. Eng. Prod. Res. Dev., 19, 117-125 (1980). 

Ravindranath, K. and Mashelkar, R. A., Modeling of polyethylene terephthalate) reactors. IX. Solid state polycondensation process,./. Appl. Polym. Sci., 39, 1325-1345 (1990). 

Devotta, I. and Mashelkar, R. A., Modelling of polyethylene terephthalate reactors - X. A comprehensive model for a solid-state polycondensation process, Chem. Eng. Sci., 48, 1859-1867 (1993). 

Droscher, M. and Wegner, G., Polyethylene terephthalate) a solid state condensation process, Polymer, 19, 43-47 (1978). 

Franz, R., Recycled Polyethylene terephthalate) for direct food contact application, FDA submission CTS 71903, Petitioner Buhler A. G, Representative Laboratory Fraunhofer Institute for Process Engineering and Packaging, Freising, Germany, Petition to the FDA, 2000. 

Japon, S., Boogh, L., Leterrier, Y. and Manson J. A. E., Reactive processing of polyethylene terephthalate) modified with multifunctional epoxy-based additives, Polymer, 41, 5809 (2000). 

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