Simulation & Modeling
Parisa Mohammadzadeh Pakdel; Reza Yegani; Mahdi Salami Hosseini; Elham Shokri
Abstract
In the current study, the flow field and morphology development of a polyethylene (PE) and ethylene vinyl acetate (EVA) blend were investigated numerically during extrusion through a spinneret using Fluent 6.3.26 software. The interface of the two phases was tracked using the volume of fluid (VOF) method. ...
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In the current study, the flow field and morphology development of a polyethylene (PE) and ethylene vinyl acetate (EVA) blend were investigated numerically during extrusion through a spinneret using Fluent 6.3.26 software. The interface of the two phases was tracked using the volume of fluid (VOF) method. In a conventional spinneret, EVA droplets near the walls break up due to the high shear rate, while the central droplet deforms without breaking up. To enhance the breakup of EVA droplets, the effects of device geometry, including the spinneret angle and the presence of one or two lamps, were investigated in detail. The numerical results indicated that a decrease in the spinneret angle from 60° to 45° causes the central droplet to become more elongated in the flow direction. Additionally, the results showed that the presence of one or two lamps in the conical zone of the spinneret causes a portion of the central droplet to break up.
Polyolefin blends
Somayeh Rafiei; Davood Soudbar; Minoo Sadri; Fatemeh Shafiei
Abstract
Thermoplastic vulcanizates (TPVs) were prepared based on polypropylene (PP) and polybutadiene rubber (PBR) at different PP/PBR compositions (70/30 and 60/40). PP-grafted-maleic anhydride (PP-g-MA) was introduced into the TPVs at different concentrations (10 and 20%). The compatibilizing effect of PP-g-MA ...
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Thermoplastic vulcanizates (TPVs) were prepared based on polypropylene (PP) and polybutadiene rubber (PBR) at different PP/PBR compositions (70/30 and 60/40). PP-grafted-maleic anhydride (PP-g-MA) was introduced into the TPVs at different concentrations (10 and 20%). The compatibilizing effect of PP-g-MA was demonstrated through cross-sectional morphology. PP-g-MA exhibited a suppressing impact on the coalescence of the rubber domains, leading to a finer and more uniform distribution of the PBR phase. Due to the higher rubber content, the compatibilizing effect was more pronounced for the 60/40 composition, which was on the averge of forming a co-continuous morphology. However, it was found that a higher PP-g-MA content is needed to effectively compatibilize the TPVs. Rheological results revealed opposing effects on the viscoelastic response of the system. However, the elastic response was intensified once higher content of PP-g-MA was used, suggesting its compatibilizing role. Dynamic mechanical analysis results proved the existence of opposing effects and revealed the profound compatibilizing effects of PP-g-MA, especially at higher content (20%). Izod impact strength exhibited moderate and notable enhancements in both TPV compositions by adding 10% and 20% of PP-g-MA, respectively, attributed to the highly increased compatibility of the PP/PBR TPVs, especially at higher levels of PP-g-MA content.
Simulation & Modeling
Yogeshwar N Thakare; Ajay V Kothari; Saurabh Shinde; Pooja Kadam; Natarajan Venkateswaran; Virendrakumar Gupta
Abstract
MgCl2 supported Ti catalyst is used in commercial propylene polymerization process. Morphology is a key performance determination parameter for polymer resins produced by commercial olefin polymerization process. Higher resin flowability and bulk density (greater than 0.38g/cc) are demonstrated by ‘good’ ...
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MgCl2 supported Ti catalyst is used in commercial propylene polymerization process. Morphology is a key performance determination parameter for polymer resins produced by commercial olefin polymerization process. Higher resin flowability and bulk density (greater than 0.38g/cc) are demonstrated by ‘good’ morphological resins (sphericity close to ‘1’). Polymer resin morphology is controlled by morphology of the catalyst used as well as polymerization conditions. The industrially accepted approaches to control polymer resin morphology are by controlling catalyst morphology through various approaches like pre-polymerization of the catalysts. Morphology of the catalyst is dependent on precursor (support) morphology and process parameters for making the catalyst. In this work, we have developed magnesium alkoxide precursor, a Ziegler-Natta catalyst using the precursor and studied its performance in gas phase propylene polymerization process. Further, morphology of different precursor and catalyst samples is evaluated and correlated it using a “computer vision” based approach. The approach involves modeling the circularity (as an analog of sphericity) of a catalyst and precursor particle. It is observed that the circularity of catalyst particles is lower than that of precursor, due to attrition in the process. It is also reflected in increase in particle size distribution span from 0.83 to 1.32 while synthesis of catalyst from precursor. This approach provides a tool to evaluate and screen the catalysts for using in polymerization.
Characterization
Reza Poorghasemi; Yousef Jahani
Abstract
In this work, the compatibility and crystallinity of low density polyethylene (LDPE) and polybutene-1 (PB-1) blends were studied. Various blends of LDPE/PB-1 containing 5, 10 and 20 wt.% PB-1 were prepared in a corotating twin-screw extruder and characterized by scanning electron microscopy (SEM), shear ...
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In this work, the compatibility and crystallinity of low density polyethylene (LDPE) and polybutene-1 (PB-1) blends were studied. Various blends of LDPE/PB-1 containing 5, 10 and 20 wt.% PB-1 were prepared in a corotating twin-screw extruder and characterized by scanning electron microscopy (SEM), shear oscillation rheology and wide-angle X-ray diffractometry (WAXD). A matrix-droplet morphology was observed in SEM images, indicating incompatibility of the two polymers in the solid state. Compared to neat LDPE, the relaxation spectra of the blends were broadened, and a slight increase in their relaxation times was observed. The relaxation time of the blends was enhanced by increasing PB-1 content, which was further proved by fitting rheological data in the Carreau-Yasuda model. Deviation of Cole-Cole diagrams from circular shape means that the blend samples were not miscible and the positive-deviation behavior of the complex viscosity and storage modulus from the mixing rule revealed the formation of strong interfacial interactions. The crystallinity of both LLDPE and PB-1 was decreased as a result of blending. The peaks attributed to the form II of PB-1 crystals were eliminated and the peaks related to LDPE were obviously weakened, suggesting to prevent crystallinity of polymers which is associated with a reduction in the total crystallinity percentage for the blend. The reduction of crystallinity was more pronounced in PB-1 phase.
Polymeric foams
Hossein Hazrati; Nader Jahanbakhshi; Mohammad Rostamizadeh
Abstract
In this study, the response surface methodology (RSM) based on the central composite design (CCD) was used to optimize the preparation condition of polypropylene-grafted maleic anhydride (PP-g-MA) microporous membrane by thermally-induced phase separation (TIPS) method. A mixture of dibutyl phthalate ...
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In this study, the response surface methodology (RSM) based on the central composite design (CCD) was used to optimize the preparation condition of polypropylene-grafted maleic anhydride (PP-g-MA) microporous membrane by thermally-induced phase separation (TIPS) method. A mixture of dibutyl phthalate (DBP) and dioctyl phthalate (DOP) was used as diluent. The effect of polymer composition and quenching bath temperature on the morphology and performance of the fabricated microporous membranes was investigated by using RSM. Analysis of variance (ANOVA) was used to determine which variables and interactions between variables had a significant effect on our responses. The ANOVA revealed that the bath temperature was the most significant variable associated with porosity and pure water flux responses and the polymer concentration was the most significant variable associated with tensile response. The obtained results also showed that with increasing the polymer concentration and decreasing the quenching bath temperature, the membrane porosity and pure water flux decreased, whereas the membrane tensile increased. The regression equations were reasonably validated and used to predict and optimize the performance of PP-g-MA membranes within the limits of the variables. Finally, the maximum responses (flux of 115.6 L/m2h, porosity of 62% and tensile of 1.6 MPa) were obtained under the following conditions: polymer concentration of 28.5 wt% and temperature of 329 K. Further, comparison of laboratory-made and commercial membranes in a membrane bioreactor (MBR) system showed that the rate of membrane fouling was decreased by 4.2 times.
Polymer processing
Jun Huang; Guanghua Tian; Huayi Li; Lei Li; Qian Li; He Huang; Shuirong Zheng; Youliang Hu
Abstract
In this work, a series of polypropylene/polyvinyl butyral (PP/PVB) blends were prepared by melt-blending process, at PVB loadings 3 wt%, 10 wt%, and 30 wt%. The effects of PVB on crystallization behavior of PP were investigated by differential scanning calorimetry (DSC), and polarized optical ...
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In this work, a series of polypropylene/polyvinyl butyral (PP/PVB) blends were prepared by melt-blending process, at PVB loadings 3 wt%, 10 wt%, and 30 wt%. The effects of PVB on crystallization behavior of PP were investigated by differential scanning calorimetry (DSC), and polarized optical microscopy (POM). The isothermal crystallization kinetics were analyzed by Avrami equations. It was found that the addition of PVB strikingly reduced the overall crystallization rate of PP. The POM results further indicated that the crystallization rate of PP/PVB was significantly reduced by reducing the nucleation density of PP with the addition of PVB. The fractured surface morphology of PP/PVB blends was characterized by scanning electron microscopy (SEM), and the results showed that the PVB was uniformly dispersed in the PP matrix as small spherical particles, with a good dispersion and dimensional stability.
Structure and property relationship
Qian Li; Yongjie Zhang; Huayi Li; Zhongchuan Peng; Yu Zhang; Youliang Hu
Abstract
PP-g-PS copolymer is a typical compatilizer used in polypropylene and polystyrene immiscible blends. PP-g-PS copolymers with different side chain lengths were synthesized, and their thermal and mechanical properties were characterized by differential scanning calorimetry (DSC), polarizing optical microscopy ...
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PP-g-PS copolymer is a typical compatilizer used in polypropylene and polystyrene immiscible blends. PP-g-PS copolymers with different side chain lengths were synthesized, and their thermal and mechanical properties were characterized by differential scanning calorimetry (DSC), polarizing optical microscopy (POM) and dynamic mechanical analysis (DMA), respectively. The DSC and POM results show that the introduction of PS side chain dramatically accelerates the crystallization rate of the PP main chain due to the covalent bond in the PP and PS copolymer. Furthermore, the copolymers become more rigid as the PS component content increases. Blend of PP with PP-g-PS copolymer was prepared to investigate the compatibility between PP and PS. The properties of five PP/PP-g-PS binary blends were characterized by DSC, DMA, scanning electron microscopy (SEM) and mechanical testing. Well dispersion of PS and small PS particle size are detected in the binary blends. The formation of covalent bond between PP and PS also increases the compatibility and interfacial adhesion between these two phases.
Catalysis
Goond Hongmanee; Patchanee Chammingkwan; Toshiaki Taniike; Minoru Terano
Abstract
Mg(OEt)2 with spherical morphology is one of the most important precursors for the preparation of industrial Ziegler-Natta catalysts. In the present article, morphology evolution of Mg(OEt)2 particles is studied in the course of the synthesis. The morphology of Mg(OEt)2 particles is observed throughout ...
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Mg(OEt)2 with spherical morphology is one of the most important precursors for the preparation of industrial Ziegler-Natta catalysts. In the present article, morphology evolution of Mg(OEt)2 particles is studied in the course of the synthesis. The morphology of Mg(OEt)2 particles is observed throughout the process by SEM. The results show that Mg(OEt)2 particles are formed through i) seed generation on Mg surfaces, ii) seed growth and isolation as independent particles, and iii) further growth and shaping into smoother and more spherical particles. The size of Mg sources greatly affects the rates of these processes to different extents. A larger size of Mg leads to slower seed formation and growth, and detachment of clustered seeds, making the final particles larger and less spherical, respectively. The crystal growth of Mg(OEt)2 is also affected by the size of Mg sources, which in turn differentiates the pore size distribution to affect the catalyst composition and performance.
Characterization
Sepideh Gomari; Ismaeil Ghasemi; Mohammad Karrabi; Hamed Azizi
Abstract
Nanocomposites based on polyamide 6 (PA6) and poly(ethylene-co-1-butene)-graft-maleic anhydride (EB-g- MAH) blends have been prepared via melt mixing. The effect of blend ratio and organoclay concentration on the crystallization and melting behavior of specimens were studied. Three types of commercial ...
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Nanocomposites based on polyamide 6 (PA6) and poly(ethylene-co-1-butene)-graft-maleic anhydride (EB-g- MAH) blends have been prepared via melt mixing. The effect of blend ratio and organoclay concentration on the crystallization and melting behavior of specimens were studied. Three types of commercial organo-modified clay (Cloisite 30B, Cloisite 15A and Cloisite 20A) were employed to assess the importance of the nanoclay polarity and gallery distance. The crystallization behavior was investigated using differential scanning calorimetry (DSC) and wide angle X-ray diffraction spectroscopy (WAXD). The strong interactions between amine end groups of PA6 and maleic anhydride groups of EB-g-MAH led to complete inhibition of EB-g-MAH crystallization according to the DSC results. A transformation from the α form to the γ form crystals of PA6, induced by both organoclays and EB-g-MAH, was monitored by WAXD and DSC. Small angle X-ray scattering (SAXS) was used to evaluate the morphology of nanocomposites. Moreover, transmission electron microscopy (TEM) was conducted to determine the location of organoclays and indicated that the organoclays mainly present in the PA6 matrix and rarely distribute in the EB-g-MAH phase in the case of low polarity organoclays. It was also evidenced that the organoclay with the most affinity to PA6 (Cloisite 30B) had the largest effect on the thermal and crystallization behavior of this phase in the blend.
