Handbook of Solvents - George Wypych - ChemTech - Ventech!

1016 George Wypych
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14.22 POLYMERS AND MAN-MADE FIBERS
George Wypych
ChemTec Laboratories, Inc., Toronto, Canada
The resin production industry has over 450 plants in the USA with total sales of $33
billion/year and about 60,000 employees. The man-made fiber industry has over 90 plants.
It employs about 45,000 people and it has sales of $13 billion/year.
In the polymer manufacture industry, production processes are diverse both in technology
and equipment design. They have common steps which include preparation of reactants,
polymerization, polymer recovery, polymer extrusion (if in pelletized form), and
supporting operations. In some preparation operations, solvents are used to dissolve or dilute
monomer and reactants. Solvent are also used to facilitate the transportation of the reaction
mixture throughout the plant, to improve heat dissipation during the reaction, and to
promote uniform mixing. Solvent selection is optimized to increase monomer ratio and to
reduce polymerization costs and emissions. The final polymer may or may not be soluble in
the solvent. These combinations of polymers and solvents are commonly used: HDPE - isobutane
and hexane, LDPE - hydrocarbons, LLDPE - octene, butene, or hexene, polypropylene
- hexane, heptane or liquid propylene, polystyrene - styrene or ethylbenzene, acrylic -
dimethylacetamide or aqueous inorganic salt solutions. These examples show that there are
options available. Excess monomer may replace solvent or water can be used as the solvent.
During polymer recovery unreacted monomer and solvents are separated from polymer
(monomers and solvents are flashed off by lowering the pressure and sometimes degassing
under vacuum), liquids and solids are separated (the polymer may be washed to remove sol-