Polymers worldwide consumption

Historically, the development of the acrylates proceeded slowly they first received serious attention from Otto Rohm. AcryUc acid (propenoic acid) was first prepared by the air oxidation of acrolein in 1843 (1,2). Methyl and ethyl acrylate were prepared in 1873, but were not observed to polymerize at that time (3). In 1880 poly(methyl acrylate) was reported by G. W. A. Kahlbaum, who noted that on dry distillation up to 320°C the polymer did not depolymerize (4). Rohm observed the remarkable properties of acryUc polymers while preparing for his doctoral dissertation in 1901 however, a quarter of a century elapsed before he was able to translate his observations into commercial reaUty. He obtained a U.S. patent on the sulfur vulcanization of acrylates in 1912 (5). Based on the continuing work in Rohm s laboratory, the first limited production of acrylates began in 1927 by the Rohm and Haas Company in Darmstadt, Germany (6). Use of this class of compounds has grown from that time to a total U.S. consumption in 1989 of approximately 400,000 metric tons. Total worldwide consumption is probably twice that. 

Zinc Borates. A series of hydrated 2inc borates have been developed for use as fire-retardant additives in coatings and polymers (59,153). Worldwide consumption of these 2inc salts is several thousand metric tons per year. A substantial portion of this total is used in vinyl plastics where 2inc borates ate added alone or in combination with other fire retardants such as antimony oxide or alurnina trihydrate. 

An indication of the usefulness of polyurethanes can be found in worldwide consumption data as of 2000, urethanes of all types amounted to 9.25 million tons.10 The commercial success of urethane polymers can be attributed to the ability to conveniently manufacture and apply materials with specific combinations of physical properties. Furthermore, urethanes are often the best choice in demanding, high-performance applications. In this section, the applications listed in Table 4.1 are discussed and a few examples are given from each category. 

Polyurethanes (PUs) are among the most demanded polymers, are required by modern technologies, and the worldwide consumption of PU has steadily increased. Of PU production 80% now consists of resilient and rigid foams while 20% remains solid PU (elastomers, coatings, adhesives, etc.) [1],... 

Cellulose, which is found in plant walls, is the most abundant raw material on Earth. Millions of pounds of this biorenewable polymer are produced every year. The total worldwide consumption of cellulosic fibers in 1998 was 4817 million pounds [1]. Cellulose is plentiful, inexpensive, and biodegradable. It is capable of producing a number of fibrous products with excellent properties whose utility extends into numerous end uses and industries. Cellulose is an excellent source of textile fibers, for both the commodity and the high-end, fashion-oriented markets. A common example is rayon. In addition, cellulose provides fibers for industrial end uses requiring strong, tough fibers. A common example is fibers used in tire cord. 

Worldwide consumption of TPE for the year 2000 is estimated to be about 2.5 billion pounds, primarily due to new polymer and processing technologies, with an annual average growth rate of about 6% between 1996 and 2000. About 40% of this total is consumed in North America. TPE grades are often characterized by their hardness, resistance to abrasion, cutting, scratching, local strain (deformation), and wear. A... 

Production of colour compound is estimated at 1.5 million tonnes in Europe, mainly for cable and pipe grades and engineering resins. Demand is likely to slow down, in preference to coloured masterbatch. Pigmented masterbatches are used to modify an estimated 53% of polymers processed (and 45% of all performance additives used in Europe are incorporated via masterbatch). Compounder Ampacet estimates that worldwide consumption of masterbatch will reach 2.15 million tonnes in 2001. Film, blow moulding, and injection moulding make up about 70% of consumption. There are around 200 producers of colour masterbatch, the leaders being Cabot, Schulmann. Ampacet, and Ferro. 

Mineral fillers are a vital and significant part of the world s polymer industry. Consumption in rubber and plastics is currently estimated to be over 2.5 million tonnes per year in Western Europe. In the first edition of this book growth projections were very bullish and use in plastics especially was projected to grow at 8-12% per year. On a worldwide basis, it was predicted that 20 Mt per year would be used in polymers by the year 2000 [1]. However, local and world economies have suffered several blows since 1997 and this volume has not been reached. As a best guestimate the authors believe that filler use in polymers currently is about 15 Mt per year. 

The most widespread natural polymers are polysaccharides such as cellulose and starch and chitin, but also lignin, proteins and others find several applications. Most polysaccharides are composed of five or six-membered rings, usually with two or three hydrolysis attached, respectively. Chemically, they are hemiacetals with ether linkages joining the monomeric units. Cellulose in particular is enjoying a worldwide consumption volume for paper and cardboard manufacturing comparable to the overall synthetic polymeric materials that is above 205 Mtons [18]. 

Composites were only briefly mentioned earlier, but this area, which will supply shaped articles to the aircraft/aerospace, industrial, and recreation markets, is expected to grow at a compounded rate of 8 percent from 1988 through the year 2000. In 1988, worldwide consumption of such polymer composites was 2,300 million. 

A few numbers allow underlining the economical importance of filled polymers. According to recently published market research reports (2007), the worldwide consumption of fillers is more than 50 million tons with a global value of approximately 25 billion. Many application areas are concerned. 

In 1977, consumption of PET resin in bottie appHcations was dramatically increased when the EDA banned competing acrylonitrile resins owing to toxicity considerations (recentiy rescinded) (69) and when the 2 L bottie was accepted for beverage sales worldwide (70). The carbon dioxide barrier properties of PET are sufficient to provide the six-month shelf life necessary for carbonated beverages (qv) (see also Barrier polymers). 

There has been a tremendous interest in polymers since World War 11. In the US, consumption was 18 million metric tons in 1974, 25.7 million metric tons in 1984, and 41.3 million metric tons in 1994 [1]. Polymer production has increased from essentially zero at the end the World War II to about 101 million metric tons worldwide in 1993 [2] and 241 million metric tons in 2006 [3]. The reason for this increase is quite simple. Synthetic polymers are numerous in structure and are very diverse in their structure-property relationships. Polymers are used extensively in electrical applications, including insulators, capacitors, and conductors. They are also used in many optical applications, the biochemical industry, structural applications, packaging, and they are used extensively as thermal insulation [4]. 

Global consumption of thermoplastic rubbers of all types is estimated at about 600,000 t/yr (51). Of this, 42% was estimated to be consumed in the United States, 39% in Western Europe, and 19% in Japan. At present, the worldwide market is estimated to be divided as follows styrenic block copolymers, 48% hard polymer/elastomer combinations, 26% thermoplastic polyurethanes, 12% thermoplastic polyesters, 4% and others, 9%. The three largest end uses were transportation, 23% footwear, 18% and adhesives, coatings, etc, 16%. The ranges of the hardness values, prices, and specific gravities of commercially available materials are given in Table 4. 

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