United States plastics industry

The term amino resin is usually appHed to the broad class of materials regardless of appHcation, whereas the term aminoplast or sometimes amino plastic is more commonly appHed to thermosetting molding compounds based on amino resins. Amino plastics and resins have been in use since the 1920s. Compared to other segments of the plastics industry, they are mature products, and their growth rate is only about half of that of the plastics industry as a whole. They account for about 3% of the United States plastics and resins production. 

Polymer science and technology have developed tremendously over the last few decades, and the production of polymers and plastics products has increased at a remarkable pace. By the end of 2000, nearly 200 million tons per year of plastic materials were produced worldwide (about 2% of the wood used, and nearly 5% of the oil harvested) to fulfill the ever-growing needs of the plastic age in the industrialized world plastic materials are used at a rate of nearly 100 kg per person per year. Plastic materials with over 250 billion per year contribute about 4% to the gross domestic product in the United States. Plastics have no counterpart in other materials in terms of weight, ease of fabrication, efficient utilization, and economics. 

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 cost of composites was estimated by one major manufacturer of fiber-reinforced plastics (FRP) for corrosion-resistant applications to be 9.70/kg ( 4.41 /lb). This works out to 1.864 billion spent on composites in the United States for industrial corrosion-resistant applications. 

Plastics in MSW The Americas, in the United States, plastic resin sales and captive use reached 46.2 million tons in 2001, a 4% decrease from 2000, according to the American Plastics Council (1). Resin production rose to 45.9 milUon tons in 2001, up 4.8% from the previous year. The U.S. plastics industry continues to expand into new markets as plastic products come to replace ones made of wood and metal (Fig. 1). In the United States, some 232 million tons of MSW were generated in 2000, an increase of 0.9 million tons over 1999 (Fig. 2). Of this stream, plastics constitute about 10.7 wt%. Plastic containers and packaging dominate, followed by materials in goods such as automobiles, appliances, electronics, furniture, and carpeting. Plastic resins used in containers and packaging include poly(ethylene terephthalate) (PET in soft drink bottles with polypropylene [PP] caps), high density polyethylene (HDPE in milk and water bottles), poly(vinyl... 

Benzene was prepared from coal tar by August W von Hofmann m 1845 Coal tar remained the primary source for the industrial production of benzene for many years until petroleum based technologies became competitive about 1950 Current production IS about 6 million tons per year m the United States A substantial portion of this ben zene is converted to styrene for use m the preparation of polystyrene plastics and films... 

Economic Aspects. In 1994 there were 8 operational insulation board producers in the United States. These mills produced about 1.15 X 10 m (2). The number of mills and total production volume have also decreased in this industry, primarily as a result of changes in building codes and avadabihty of other competitive sheathing products. Both wood composite panels and plastic foam sheathings have captured a segment of these markets. 

Annual Proceedings of the Safety Seminars, Dept, of Defense, Explosive Safety Board, Washington, D.C. International symposia on explosives and closely related subjects are excellent sources of information, ie, international symposia on detonation symposia on combustion symposia on chemical problems connected with the stabiUty of explosives international pyrotechnics seminars symposia on compatibiUty of plastics and other materials with explosives, propellants, and pyrotechnics, and processing of explosives, propellants, and ingredients and symposia on explosives and pyrotechnics Mineral Industy Surveys, U.S. Bureau of Mines, Pittsburgh, Pa. Periodic pubhcations dedicated primarily to explosive studies in Propellants and Explosives Journal of Ha yardous Materials, and apparent consumption of industrial explosives and blasting agents in the United States. 

Eastman Goal Chemicals. In 1983 Eastman Chemical Co. became the first chemical producer in the United States to return to coal as a raw material for large-scale manufacture of industrial chemicals (35). In that year, Eastman started manufacturing acetic anhydride from coal. Acetic anhydride is a key intermediate for production of coatings, ceUulosic plastics, and cellulose acetate fibers. Acetic anhydride from other sources also is used in the manufacture of pharmaceuticals, starches and sweeteners, and flavors and fragrances. 

Total consumption of lead in the United States in 1993 reached 1,318,800 t. Of this, 766,000 t (58%) is allocated to battery use suppHed as either a mixed oxide or as metal. Approximately 95% of batteries are recycled and the lead recovered. In 1993, 908,000 t of lead came from secondary smelters and refiners compared to 350,000 t originating in primary mines and smelters (39). Approximately 51,000 t of lead was consumed in U.S. production of all oxides and chemicals appHcable to all industries other than batteries. Estimates include 8000 t for plastics, 6000 t for gasoline additives, 2000 t for mbber, and 30,000 t for ceramics, glass, and electronics. Lead is not used to any extent in dispersive appHcations such as coatings. 

The uniqueness of methyl methacrylate as a plastic component accounts for its industrial use in this capacity, and it far exceeds the combined volume of all of the other methacrylates. In addition to plastics, the various methacrylate polymers also find appHcation in sizable markets as diverse as lubricating oil additives, surface coatings (qv), impregnates, adhesives (qv), binders, sealers (see Sealants), and floor poHshes. It is impossible to segregate the total methacrylate polymer market because many of the polymers produced are copolymers with acrylates and other monomers. The total 1991 production capacity of methyl methacrylate in the United States was estimated at 585,000 t/yr. The worldwide production in 1991 was estimated at about 1,785,000 t/yr (3). 

Formaldehyde. Worldwide, the largest amount of formaldehyde (qv) is consumed in the production of urea—formaldehyde resins, the primary end use of which is found in building products such as plywood and particle board (see Amino resins and plastics). The demand for these resins, and consequently methanol, is greatly influenced by housing demand. In the United States, the greatest market share for formaldehyde is again in the constmction industry. However, a fast-growing market for formaldehyde can be found in the production of acetylenic chemicals, which is driven by the demand for 1,4-butanediol and its subsequent downstream product, spandex fibers (see Fibers, elastomeric). 

Commodity Phthalate Esters. The family of phthalate esters are by far the most abundandy produced woddwide. Both orthophthaUc and terephthahc acid and anhydrides are manufactured. The plasticizer esters are produced from these materials by reaction with an appropriate alcohol (eq. 1) terephthalate esterification for plasticizers is performed more abundandy in the United States. Phthalate esters are manufactured from methanol (C ) up to Qyj alcohols, although phthalate use as PVC plasticizers is generally in the range to The lower molecular weight phthalates find use in nitrocellulose the higher phthalates as synthetic lubricants for the automotive industries. 

Silver Thick Films. About half of the silver consumed in the United States for its electrical properties is used by the electronics industry. Of this amount some 40% is used for the preparation of thick-film pastes in circuit paths and capacitors. These are silk-screened onto ceramic or plastic circuit boards for multilayer circuit sandwich components. 

There are many common misconceptions about vinyl. Eor example, the idea that vinyl is not recycled is untme. Industrial scrap vinyl has been recycled for years, but in more recent years, post-consumer vinyl recycling is growing, too, with about 3.25 x 10 tons (6.5 x 10 lb) of post-consumer vinyl (primarily botdes) being recycled in the 1990s. When the Council for SoHd Waste Solutions (now the American Plastics Council) conducted a nationwide survey in 1991, it found that there were an estimated 1100 municipal recycling programs in place or plaimed in the United States that include vinyl. 

In the United States all other processes have been completely phased out and virtually all benzoic acid is manufactured by the continuous hquid-phase air oxidation of toluene. In the late 1950s and the early 1960s both Dow Chemical and Snia Viscosa constmcted faciUties for Hquid-phase toluene oxidation because of large requirements for benzoic acid in the production of phenol and caprolactam. Benzoic acid, its salts, and esters are very useful and find appHcation in medicinals, food and industrial preservatives, cosmetics, resins, plasticizers, dyestuffs, and fibers. 

CdS finds its main use as a pigment, particularly in the glass and plastics industry. Production of CdS in the United States is shown (15). 

Industrial ethanol is one of the largest-volume organic chemicals used in industrial and consumer products. The main uses for ethanol are as an intermediate in the production of other chemicals (Table 8) and as a solvent. As a solvent, ethanol is second only to water. Ethanol is a key raw material in the manufacture of dmgs, plastics, lacquers, poHshes, plasticizers, perfumes, and cosmetics. Around 1960, manufacture of ethanol was the top consumer of ethylene in the United States, but since 1965 it has rated below manufacture of ethylene oxide and polyethylene. 

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