Preparation of HDPE:

High-density polyethylene (HDPE) is a thermoplastic polymer obtained by the polymerization of

ethylene. The production of HDPE involves several steps, including the production of ethylene
monomers and the subsequent polymerization process.

Ethylene is usually obtained by cracking hydrocarbons in processes such as steam cracking of natural gas
or naphtha. In this cracking process, larger hydrocarbons are broken down into smaller molecules,
including Ethylene molecules are polymerized into HDPE through a process called Ziegler-Natta
polymerization or Phillips polymerization. Catalysts, such as metal halides, are used to initiate the
polymerization reaction. The polymerization process can be carried out in solution, as a slurry or in the
gas phase, depending on the desired properties of the HDPE. The catalyst initiates the polymerization
reaction by interacting with the ethylene monomers. When ethylene monomers are added to the
growing polymer chain, the chain spreads and a polyethylene polymer is formed. Polymerization
conditions, including temperature, pressure and the type of catalyst used, are controlled to achieve the
desired molecular weight, and branching of the polymer chains High molecular weight and low
branching contribute to the characteristic properties of HDPE. The polymerization reaction is quenched
to stop the growth of the polymer chains. During quenching, the reaction mixture is cooled quickly, or
the catalyst is removed. The HDPE is separated from the reaction mixture, usually by precipitation or
filtration. [2]

Preparation of Rice husk:

Rice husk ash is the ash produced when rice husks, the outer layer of rice grains, are burned. The
following is a general process to produce rice husk ash:

Collect the rice husks in the rice mills where they are normally generated as waste. Remove impurities,
dust, and pollutants from the rice husks to ensure a clean incineration process, burn the rice husks in an
open field or in traditional ovens. Burning can be done outdoors under simple conditions and the ash
may be dark in color (black rice husk ash). This method is less controlled and may result in less
consistent ash properties. Use controlled burning methods in a controlled environment, such as a
combustion chamber or kiln. This method is more efficient and allows for better control of combustion
conditions, resulting in whiter ash (white rice husk ash). Allow the ash to cool after incineration.
Depending on the combustion method, the ash can be cooled naturally or by external means. Sieve the
cooled ash to remove larger particles or impurities. Grind the ash to obtain a finer particle size, which
can improve its reactivity and suitability for various applications. Perform quality control tests on the
rice husk ash to ensure it meets the desired specifications.[2]

Silane treatment process:

Silane treatment process involves coating the surface of rice husk with silane compounds. Silane
treatment can enhance the compatibility of rice husk with certain polymers or matrices, making it more
suitable for composite materials. Silane compounds can modify the surface properties of rice husk,
improving its adhesion to other materials like plastics or resins. Applying silane chemicals to the rice
husk's surface is known as silane treatment. The purpose of this treatment is to improve rice husk's
compatibility with matrices or polymers in composite products.

TESPT solution, a silane coupling agent containing four Sulphur atoms in its structure, was used to treat
the RHF surface utilizing unwashing and washing procedures. The presence of C-H stretching and Si-O-Si
stretching of TESPT in the FTIR spectra of the treated RHF corroborated the presence of TESPT molecules
deposited on the UW-ST and W-ST surfaces. Furthermore, the decrease in decomposition temperatures
and changes in UW-ST and W-ST residue levels demonstrated the elimination of physiosorbed silane
layers following washing. Both UW-ST and W-ST influenced the NR composites' cure characteristics, as
well as their mechanical, dynamic mechanical, and morphological qualities. The W-ST/NR M100, M300,
tensile strength, elongation at break, rip strength, storage modulus, loss modulus, tan, and cross-link
density of NR composites were all improved. SEM micrographs of both the UW-ST/NR and W-ST/NR
composites backed up the mechanical and dynamic mechanical property enhancements of these two
composites. The micrographs revealed that the RHF surfaces were coated with the NR matrix, indicating
that the filler-rubber interaction had increased. The washing silane treatment approach was more
effective than the unwashing silane treatment method for improving compatibility between RHF and NR
based on the mechanical characteristics of the NR composites. The modulus, tensile strength, and tear
strength of the W-ST/NR composite can be enhanced by 12%, 10%, and 5%, respectively, when
compared to those of the 2ALT/NR composite, without deterioration of the elongation at break.[1]

Fig: Tan δ of gum NR, 2ALT/NR, UW-ST/NR, and W-ST/NR composites.

Treatment of rice husk with MAPE:

In the context of rice husk treatment, it could be used to improve the compatibility between rice husks
and a polymer matrix and to increase the properties of a composite material.

Maleic anhydride polyethylene (MAPE) can be used to modify the surface of the rice husk particles. This
modification aims to increase the compatibility between the hydrophobic polymer matrix and the
hydrophilic rice husk. The maleic anhydride functional groups on MAPE can form bonds with both the
polymer matrix and the rice husk, improving adhesion and compatibility. Treatment with MAPE can lead
to improved mechanical properties such as tensile strength and impact resistance, as well as improved
thermal stability of the composite material by improving the compatibility between the polymer and the
rice husk, the water absorption of the composite material can be reduced.

Fabrication techniques

Extrusion:

One popular technique for combining polymers with reinforcements or fillers is extrusion. This method
involves feeding rice husk powder and HDPE pellets into an extruder, where they melt and combine.
After that, a die is used to press the molten mixture through to create a continuous profile or shape. It is
possible to cool and cut the extruded material into the necessary shapes.

Injection Molding:

A molten HDPE and rice husk combination is injected into a mold cavity during the injection molding
process, after which the material is cooled and solidified to take on the required shape.

Compression Molding:
Compression molding is a molding process in which the molding material is first placed in an open, heate
d mold chamber. The mold is closed with a jacket or plug, pressure is used to force the material into cont
act with all parts of the mold, and heat and pressure are maintained until the molded product solidifies; Th
is process is called compression molding or vulcanization in rubber. This technology involves some curin
g of thermosetting resins in the form of pellets, paste-like products or preforms.[3]

In our project, for various suitable reasons, we use the compression molding process for the production
of high-density polyethylene resin Polyethylene is a thermoplastic polymer that is both strong and
durable. It serves as the matrix material for the composite material.

Compression molding process and its condition:

Rice husks, a by-product of rice milling, are treated, dried and ground into fine particles. During the
treatment process, impurities can be removed, and the compatibility of HDPE can be improved. Rice
husks can be further processed by heating them to 400 and 700 degrees Celsius to obtain amorphous
and crystalline silica respectively, assuring that the HDPE resin is of good quality and has an appropriate
melt flow index. HDPE preferably has a melt index of 0.01 to 1.5 and a density of 0.941 to 0.970 g/cm ^3.
Rice husk particles are combined with HDPE resin. To ensure uniform dispersion of the rice husks in the
HDPE matrix, use a mixer or blender. Adhesion promoters can be used in this phase to increase the
adhesion of the HDPE matrix to the rice husk fibers. Adhesion promoters such as silanes are used to
increase the adhesion between the HDPE matrix and the rice husk fibers. The mixed material is placed in
a mold designed in advance for the intended shape of the final product. The mold is then sealed,
applying heat and pressure simultaneously. The temperature and pressure values are determined by the
specific requirements of the HDPE and rice husk composite material assuring the mold in the shape and
size you need for the final product and make sure the mold is made of materials that can withstand the
temperatures and pressure. The mold is heated to a temperature above the melting point of HDPE,
which makes the material softer and more pliable. At the same time, pressure is applied to compress the
material and force it into the shape of the mold. Heat the mold to a temperature above the melting
point of HDPE. The exact temperature depends on the grade of HDPE used, but is usually between 180
and 240 degrees Celsius (356 to 464 degrees Fahrenheit). Apply enough pressure to the mold to
compact the HDPE-rice husk combination. The pressure is usually between 10 and 50 MPa
(megapascals). The time of the molding cycle depends on the thickness and complexity of the product.
It can last from a few minutes to several hours. Give the material sufficient time to melt, flow and
harden in the mold. At atmospheric pressure and temperature, this process can take up to 24 hours. The
temperature should be high enough to melt the HDPE and allow it to flow properly in the mold. Once
the desired shape is achieved, the mold is cooled to solidify the composite material. To ensure that the
composite retains its shape and properties, the cooling process is carefully controlled. Once the desired
shape is achieved, the mold is cooled to solidify the composite material. To ensure that the composite
retains its shape and properties, the cooling process is carefully controlled. Carefully remove the
finished product from the mold. Depending on the application and product requirements, post-
treatment steps such as the removal of additional material or the application of surface treatments may
be required. Carry out quality control tests on the finished product, e.g. testing mechanical properties,
checking dimensional accuracy and other relevant criteria.[4]

References:

1. https://www.sciencedirect.com/science/article/abs/pii/S0950061821014902
2. https://www.researchgate.net/profile/Mohamad-Ali-Selimin/publication/
348409411_A_Review_Chemical_Treatments_of_Rice_Husk_for_Polymer_Composites/links/
6007c79745851553a0584ae0/A-Review-Chemical-Treatments-of-Rice-Husk-for-Polymer-
Composites.pdf
3. https://www.researchgate.net/publication/
324079648_MOULDING_note_ppt_for_study_purposec
4. https://patents.google.com/patent/WO2013173939A1/en