POLYMER SCIENCE SEMINAR

INDUSTRIAL POLYMERS
Guided By: Presented By:
Dr. Kuruvilla Joseph Soumyajyoti Dey
[SC21M021]
 Introduction
• Major chemical compounds used in the manufacture of synthetic industrial materials.
• Industrial polymers, chemistry of, polymers are categorized according to whether they are formed
through chain-growth or step-growth reactions.
• In plastic (thermoplastic and thermosetting resins), polymers are divided between those that are
soluble in selective solvents and can be reversibly softened by heat (thermoplastics) and those
that form three-dimensional networks which are not soluble and cannot be softened by heat
without decomposition (thermosets).
• Man-made fibre, fibres are classified as either made from modified natural polymers or made
from entirely synthetic polymers.
• The major commercially employed polymers are divided by the composition of their “backbones,”
the chains of linked repeating units that make up the macromolecules.
• Classified according to composition, industrial polymers are either carbon-chain polymers (also
called vinyl) or heterochain polymers (also called noncarbon-chain, or nonvinyl). In carbon-chain
polymers, as the name implies, the backbones are composed of linkages between carbon atoms;
in heterochain polymers a number of other elements are linked together in the backbones,
including oxygen, nitrogen, sulphur, and silicon.
Carbon – Carbon Chain Polymers
Polythene
• Polyethylene is the simple hydrocarbon polymer and has the following structure:

• Ethylene (b. p., - 104°C) is made from the thermal (steam) and catalytic cracking of a variety of
hydrocarbons, ranging from ethane derived from natural gas to fuel oil. Ethylene can be polymerised using
solution or bulk polymerization technique.
• There are 2 varieties of polyethylene namely Low-Density Polyethylene and High-Density
Polyethylene based on specific density.
Difference between LDPE & HDPE
LDPE HDPE
Have side branches Polymer chains line up regularly
LDPE’s structure is not crystalline. Can attain crystallinity
Irregularity is what gives LDPE its lower density Symmetry in structure affects its density
Forces of attraction between polymer molecules are Forces of attraction between polymer molecules are
weakened strong.
Flexible Semi-rigid; tough
Low Abrasion resistance High Abrasion Resistance

Figure shows linear structure of HDPE and branched

structure of LDPE
Low Density Polyethene
• Low Density Polyethylene is produced by high pressure polymerisation of ethylene (up to1.5 x 108
pascals) and high temperatures (up to 350° C, or 660° F) in the presence of peroxide/ oxygen
initiators. It is quite interesting to note that even an extremely small quantity of oxygen says 0.1%
is sufficient to initiate polymerization.
• Ethylene polymerization can also be carried out by solution method with benzene or
chlorobenzene as solvent. At the temperatures and pressures used, both polymer and monomer
dissolving these compounds so that the reactions are true solution polymerizations. Water or
other liquids may be added to dissipate the heat of reaction.
Properties of LDPE
• LDPE Melting point: 105 to 115°C
• Density of LDPE: 0.910–0.940 g/cm3
• Chemical resistance of LDPE:
a) Good resistance to alcohols, dilute alkalis and acids
b) Limited resistance to aliphatic and aromatic hydrocarbons, mineral oils, oxidizing agents
and halogenated hydrocarbons
• Temperature resistance up to 80°C continuously and 95°C for shorter times.
• Low cost polymer with good processability
• High impact strength at low temperature, good weatherability
• Excellent electrical insulating properties
• Very low water absorption
• FDA compliant
• Transparent in thin film form
Process Flow Diagram of LDPE
• In case of high-pressure LDPE synthesis process, ethylene gas is kept under conditions of high
temperature and pressure and is polymerized in presence of an initiator.
• Although polymerisation occurs through ordinary radicle mechanism, it is characterized with
polymerisation under high pressure.
• Generally selected pressure and temperature range from 1000kg/cm2 to 3000 kg/cm2 and from 100°c to
300°C respectively.
• The polymerisation mechanism of ethylene can usually be represented by means of an
elementary equation process in the ordinary radicle polymerisation:
• Since the polymerisation of ethylene is such an exothermic reaction as stated below, its yield
depends on the capability of the reaction to remove polymerisation heat:

• The post process comprises of the following:

1. Purification of ethylene gas. (99.9% or more): Ethylene gas can be purified by , selective absorption or
selective adsorption or Low temperature fractionation.[Major impurities: methane & Ethane. Besides if
the content of acetylene is not less than 10ppm formation of CO and aldehyde entail poorer electrical
property of the product.]
2. Compression and pressurisation of ethylene gas:Ethylene gas pressurised by means of compressor
through a high polymerisation pressure, which in most cases ranges from 1000 to 3000 kg/cm2.
3. Polymerisation:There are two types of reactors: one is of a vessel type and the other is of a tubular type.
In the case of the former, the pressurised ethylene gas is fed to the reactor after being cooled, while in the
later case the monomer gas goes through a preheating system and then polymerised after being heated
up to a given temperature. The polymerisation temperature usually ranges from 100°C-300°C. The types
and quantity of initiator to be fed to the reactor vary with polymerisation temperature. Peroxides and Di-
oxygens which generate free radicles are used as initiator.
4. Separation of polymer from unreacted ethylene monomer: Mixture of polyethylene and
unreacted ethylene gas flowing through the reactor is fed to the reactor where it is de-pressurised. The
reduction in pressure lowers the solubility of ethylene monomers in molten polyethylene, with the result of
their easy separation. The ethylene separated from polyethylene is recycled to the compressor through the
filter.
5. Pelletization of polymer: Polyethylene leaving the separator is fed to the extruder where the
synthesised polyethylene is extruded to be pelletized.
There are two types of cutting method during pelletization, one ‘under water cutting method’ and
another one ‘hot cutting method’ (under atmospheric conditions).

6. Recycling of ethylene gas.

Process Flow Diagram of LDPE

Process flow with Material Balance for LDPE plant

Process Flow Diagram of LDPE (Contd.)

Detailed Schematic of two step compression

Applications of LDPE
• LDPE plastic bags
• Light packaging materials: Six-pack rings, waterproof carton lining, plastic wraps, snap-on lids
• Wash bottles
• Corrosion protection layer for work surfaces
• Computer hardware covers and packaging
High Density Polyethylene
• HDPE synthesis processes are completely phase dependent i.e., the types of phases present in the
polymerization reactor although earlier other classifications were also considered. Some of the
process design can be grouped depending on their phases and can be classified as:
Phases Processes
Polymer formed in Solution: DuPont, Phillip, SOI
Soluble or finely divided catalyst
Supported Catalyst
Polymer forms a slurry with diluent: Zeigler (Mitsui Petrochemicals), Solvay,
Solid Catalysts Montedison, Phillips
Supported Catalyst
Polymer forms solid particles suspended in BASF, Union Carbide
vapor:
Solid Catalysts
Supported Catalysts
High Density Polyethylene
• HDPE synthesis processes are completely phase dependent i.e., the types of phases present in the
polymerization reactor although earlier other classifications were also considered. Some of the
process design can be grouped depending on their phases and can be classified as:
Phases Processes
Polymer formed in Solution: DuPont, Phillip, SOI
Soluble or finely divided catalyst
Supported Catalyst
Polymer forms a slurry with diluent: Zeigler (Mitsui Petrochemicals), Solvay,
Solid Catalysts Montedison, Phillips
Supported Catalyst
Polymer forms solid particles suspended in BASF, Union Carbide
vapor:
Solid Catalysts
Supported Catalysts
Properties of HDPE
• HDPE Melting point: 120-140°C
• Density of HDPE: 0.93 to 0.97 g/cm3
• High Density Polyethylene Chemical resistance:
• Excellent resistance to most solvents
• Very good resistance to alcohols, dilute acids and alkalis
• Moderate resistance to oils and greases
• Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)
• Continuous temperature: -50°C to +60°C, relatively stiff material with useful temperature
capabilities
• Higher tensile strength compared to other forms of polyethylene
• Low cost polymer with good processability
• Good low temperature resistance
• Excellent electrical insulating properties
• Very low water absorption
• Therefore, the major phase classifications are:
A) Solution
B) Slurry
C) Vapor Phase

• It is important to mention that the reaction medium used does affect the structure of the
polymer, independent of catalyst effects. In turn this will give rise to basic differences in
properties between polymers produced by different processes, these differences can be
overcome, in part by catalyst technology.
• In addition, other considerations, such as ease of process control, catalyst efficiency, ability to
switch from one grade to another with minimum “twilight” material, process complexity, and
product purity, must be weighed in choice of the optimum process.
A. Solution Phase:
• In solution processes, ethylene monomer and comonomers are dissolved in hot cyclohexane or
other solvent suitable for polyethylene.
• Catalyst is introduced is into the reactor, and the temperature maintained above 140°~150°c-the
polyethylene melting point at reactor - pressure.
• Some processes use water jacketing to remove reaction heat while others are cooled by
monomer refrigeration.
• Solution processes are generally run at moderately high pressures and require heavier wall
reactors than slurry-type processes.
• However, because of the beneficial effect of increased temperature on reaction rates, catalyst
efficiencies are usually high with short residence times. This allows a higher production rate for a
given size reactor.
• This type of process is inherently limited in the amount of polymer, which can be kept in solution-
-35-40 percent is the maximum.
• Also, making high molecular weight polymer gives difficulties such as putting high torque on the
stirrer, dropping out of solution as a gel, and fouling the reactor.
• Thus, it is generally more difficult to make extrusion blow moulding grades with solution
processes, particularly those requiring a very high molecular weight component for high melt
strength and die swell.
• 0n the other hand, solution processes generally excel in producing injection moulding grades,
where narrower molecular weight distribution and lower molecular weight are required.

Process Flow Diagram of HDPE in Solution

Phase

HDPE Solution Process

B. Slurry (particle form) process :
• In this type of process, a poorer solvent (diluent) for polyethylene is used: the polymer or
copolymer is separated from the diluent in fine particles.
• In this way, the viscosity of the diluent does not increase as rapidly as in the solution processes,
and a higher concentration of polymer can be maintained in the reactor.
• However, many slurry processes are susceptible to fouling: a build-up of polymer adhering to
stirrer blades and shafts; reactor walls and flow lines.
• The time between turnarounds to clean reactors can vary considerably from one process to
another, and is, at least in part, dependent on the nature of the catalyst.
• Some of the advantages of slurry-type processes include a higher volume yield of product for a
given reactor size, as well as the greater ease of diluent removal.
• Another advantage is the potential for making powders suitable for rota-moulding directly in the
reactor, and thus, cutting out the expensive grinding step.
• Reactors used for slurry processes may take any of several forms, from kettles to loop-type
designs. The latter has high surface-to-volume ratios, which is necessary for controlling reactor
temperature, to keeping molecular weight and molecular weight distribution on target.
• In practice, most slurry processes. unless modified, tend to yield very high molecular weight
materials which are not commercially useful. Thus, a "chain stopper" or chain transfer agent is
often required.
• Because of their tendency to make higher molecular weights, most slurry processes perform well in making
blow moulding grades: in some instances, however tandem reactors may be required for broad molecular
weight distribution.
• In general, three types of catalysts are employed in slurry processes: a) pure Ziegler, b) supported Ziegler,
and c) Phillips.

Process Flow Diagram of HDPE in Slurry

Phase

HDPE Slurry Process

C. Vapour Phase Process:
• Theoretically; a vapor phase process appears to have the lowest investment and operating costs,
provided several conditions could be met.
• Problems regarding the preparation of a suitable catalyst hindered early commercialization.
• Excessive catalyst particle size was one difficulty and another was finding catalyst of sufficiently
high activities (to eliminate deashing) along with the desired molecular weight and molecular
weight distribution.
• Other problem concerned heat removal and maintenance of constant temperatures.

HDPE Vapour Phase Process

Applications of HDPE
• HDPE filament for 3D printers
• Strong packaging materials: bottle caps, plastic milk bottles, drums, bulk containers for industrial
use
• Fibres for ropes, nets, and industrial fabrics
• Vehicle fuel tanks
• Boat parts
• HDPE pipes and tubing
• HDPE plastic chairs and tables
• Playground structures: slides, swing seats
• Consumer products: trash and recycling bins, ice cube containers, toys, ice chests
Polystyrene
Monomer: Styrene
• Also called vinylbenzene.

• made from benzene and ethylene. ethylene is passed into liquid. Benzene under pressure, in the
presence of aluminium chloride catalyst.

• The resulting ethylbenzene is dehydrogenated to styrene by passing it over an iron oxide or

magnesium oxide catalyst at about 600°C.
• The styrene is then refined by distillation.
Structural properties of Polystyrene
• Polystyrene is a linear polymer, the commercial product being atactic and therefore amorphous
Isotactic polystyrene can be produced, but offers little advantage in properties except between
the glass transition (about 80°C) and its crystalline melting point (about 240°C), where it is much
like other crystalline plastics. Isotactic polystyrene is not of commercial interest because of
increased brittleness and more difficult processing than the atactic product.
• Like most polymers, polystyrene is relatively inert chemically.
• It is quite resistant to alkalis, halide acids, and oxidizing and reducing agent. polystyrene is
outstandingly easy to process, its stability and flow under injection-moulding conditions make it
an ideal polymer for this technique.
• Its optical properties-colour, clarity, and the like--are excellent, and its high refractive index (1.60)
makes it useful for plastic optical components.
• Polystyrene is a good electrical insulator and has a low dielectric loss factor at moderate frequencies. Its
tensile strength reaches about 8000 psi.
• polystyrene melting point is 240 °C.
Process Flow Diagram of Polystyrene
• The production of general-purpose polystyrenes (GPPS) and high impact polystyrenes (HIPS) is
essentially the same with the exception of the initial, rubber-dissolution step for HIPS.
• The following diagram describes the flow of material and major equipment involved in the
manufacturing process:

Process Flow Diagram of Polystyrene

Process Flow of Polystyrene
• The production of HIPS begins with the granulating and dissolving of rubber and other additives in
styrene monomer (101) and then transferring the rubber solution to a storage tank (102). For
general- purpose product, controlled amounts of ingredients are fed directly to the feed
preheater (103).
• From this point on, the production steps for GPPS and HIPS are the same. The feed mixture is
preheated (103) and continuously fed to the pre polymerizer (104) where the rubber morphology
is established.
• Following pre polymerization, the polymer mixture is pumped to the polymerization reactor (105)
of proprietary design. At the exit of the reactor, the polymerization is essentially complete. The
mixture is then preheated (106) in preparation for devolatization.
• The devolatilizer (107) is held under a very high vacuum to remove unreacted monomer and
solvent from the polymer melt. The monomer is distilled in the styrene recovery unit (108) and
recycled back to the prepolymizer. The polymer melt is then pumped through a die head (109) to
form strands, a water bath (110) to cool the strands, a pelletizer (111) to form pellets and is
screened to remove large pellets and fines. The resultant product is air-conveyed to bulk storage
and packaging facilities.
Applications of Polystyrene
• Medically it is used for sterilizing test tubes, diagnostic components, and other medical devices.
• It is used to manufacture car parts which include knobs, instrument panels, sound dampening
foam, etc.
• Polystyrene food service packaging keeps the food fresh for a longer period of time and is less
expensive than alternatives.
• It is used in packaging consumer goods such as DVD cases, egg cartons, to protect against spoilage
or damage.
• It provides thermal insulation and is used in refrigerators, freezers, etc.
• Used in housing in all IT equipment such as Television, computer, etc.
Bakelite
• Bakelite, trademark of phenol-formaldehyde resin, trademarked synthetic resin is a hard,
infusible, and chemically resistant plastic, based on a chemical combination of phenol and
formaldehyde (phenol-formaldehyde resin).
• These are one of the oldest polymers that were synthesized by man also known as the material of
thousand uses. Bakelite is used for making electrical materials, automobile parts, radio and T.V set
bodies etc.
Desirable Properties of Bakelite
• It can be quickly molded.
• Very smooth molding can be obtained from this polymer.
• Bakelite moldings are heat-resistant and scratch-resistant.
• They are also resistant to several destructive solvents.
• Owing to its low electrical conductivity, bakelite is resistant to electric current.
• Bakelite's dielectric conductivity falls from 4.4 to 5.4.
Process Flow Diagram of Bakelite

Process Flow Diagram

Process Flow of Bakelite
1. Reaction: The reaction kettle is charged with Ca(OH)2 (1-2 parts), phenol, and formaldehyde (100 parts),
with a formaldehyde to phenol ratio of (1.1-1.5). At 930°C to 1000°C, the reaction takes only a few minutes,
whereas at 650°C to 750°C, it takes around 2 or 3 hours. The reactions, on the other hand, are determined by
the total exchanging capacity of the reaction equipment, the catalyst concentration, and the type of resin to be
manufactured.
Process Flow Diagram of Bakelite

2)Separation: After the reaction is completed, the water is removed by distillation under reduced
pressure at 700C - 720C. The catalyst is neutralised by adding a weak acid, such as lactic acid in hot
solution. About (13-15) % glycerol is added to the solution, if transparent castings are required. The
trace of water is removed by dehydration in vacuum at 750C - 850C. The product of the reaction is
either moulded directly or converted into moulding powder.
Process Flow of Bakelite
3) Molding & Finishing: Molding is carried out by passing the liquid resin into preheated moulds
and allowed to cool slowly at 600C - 800C. Molding powder is obtained by pouring the liquid resin
into large steel floor under which cold water flows for uniform cooling of the mass. After cooling the
resin is powdered and then blended with filters, coloring materials and mould releasing agents etc.
The blended product is then fused on hot ball mills into molding powder.
Applications of Bakelite
• Bakelite is a good insulator used in non-conducting parts of radio and electric devices like
switches, automobile distribution caps, insulation of wires, Sockets, etc.
• It is used to make clocks, buttons, washing machines, toys, kitchenware, etc.
• It can be made into different colors so it is used in producing vibrant and attractive products.
Polyester
Poly(vinyl)ester
• Polyesters have the structure with ester linkages as follows:

• They are prepared by a polycondensation reaction between a dicarboxylic acid and a diol. If both
R' and R are aliphatic, the resultant polyester will be a fully aliphatic polyester.
• For a long time, aliphatic polyesters were not of much industrial importance, mainly because of
their low melting points.
• For instance, the polyester with a degree of polymerisation comparable to that of commercial
polyethylene melts somewhere in the range of (50 — 80) °C. whereas, the melting point of
polyethylene is around 120 ° C.
• This problem of a low melting point was overcome by introducing aromatic rings into the
polyester chain. This is evident from the following examples:

• The remarkable rise in the melting point of polyesters produced by the incorporation of the
aromatic ring is due to the stiffening of the polymer backbone.
• Thus, a polyester such as polyethylene terephthalate (PETP) has a high melting point because of
the presence of the aromatic ring and is commercially one of the most popular polymers
marketed under the trade name of Terylene or Terene.
PROCESS FLOW CHART OF POLYESTER
• Preparation of raw material
(Terephthalic acid, DMT, ethylene glycol preparation)
↓
Mixing tank
↓
Polymerization in reactor
(Ester interchange and polycondensation, Temperature: 260-2800C, Time: 3-6 hours)
↓
Polymer chips
↓
Melt spinning
↓
Polyester filament produced from spinneret holes
(Monofilament, multifilament)
↓
Drawing
↓
Reeling onto a package or Texturization
• Polyester is polymers made by a condensation reaction taking place between small molecules, in
which the linkage of the molecules occurs through the formation of ester groups.
• Polyesters are commonly made by the interaction of a dibasic acid with dihydric alcohol:

HOOC-X-COOH + HO-Y-OH → …OC-X-COO-Y-OCO-X-COO-Y-OCO…

Process Flow Diagram of Polyester

Process Flow Diagram of Polyester

• Polymerisation: Condensation polymerization occurs when the acid and alcohol are reacted in a
vacuum at high temperatures. The polymerized material is extruded in the form of a ribbon onto
a casting trough or cooling wheel. After the ribbon hardens, it is cut into chips.
• Melt Spinning: The chips are dried and then put into hopper reservoirs for melting. Polyester is a
"melt spun" fibre, which means that it is heated, extruded through the spinnerets, and cools upon
hitting the air. From there it is loosely wound around cylinders.
• Drawing: The fibres are then hot stretched until they are about five times their original length in
order to decrease their width. The fibre is then wound onto cones as filaments or is crimped and
then is cut into staple lengths.
• Finishing Process: Finally, after the fabric is made, one or more of the following finishing
processes is often used to improve the quality of the fabric:
1. Heat setting--creates a permanent shape.
2. Singeing--improves the hand, reduces pilling, and increases smoothness
3. Anti-static finish--reduces static electricity
4. Water and stain repellence--increases comfort and makes it easier to clean; also used for
rainwear.
5. Resin finishes--increases ease of care.
6. Calendaring--increases smoothness and reduces pilling
7. Embossing--creates a design and/or luster.
Applications of Polyester
• Polyesters are widely used in clothing fabrics. Several types of clothing apparel are woven from
polyester yarns or polyester threads. Examples include polyester shirts, polyester jackets,
polyester pants, and polyester hats.
• Polyester is also used in upholstered furniture.
• Liquid crystal displays (often referred to as LCDs) are often manufactured with the help of certain
polyesters.
• Polyesters are also used in the manufacture of dielectric films that are used in capacitors.
• Polyester is known to play a vital role in the manufacture of certain types of car tyre
reinforcements.
• Owing to the time-dependent shear thinning properties of polyesters (often referred to as the
thixotropic properties of polyesters), these polymers are employed for spray-based application on
certain open-grain timbers.
Polycarbonate (Polyester)
• Polycarbonate is a high-performance tough, amorphous and transparent thermoplastic polymer
with organic functional groups linked together by carbonate groups (–O–(C=O)–O–) and offers a
unique combination of properties. PC is popularly used as an engineering plastic owing to its
unique features that include:
High impact strength
High dimensional stability
Good electrical properties
Though polycarbonate has similar properties to polymethyl methacrylate (PMMA, acrylic), it is
stronger, has a larger temperature range (melting point: 155°C), and is more expensive. PC is
commonly utilised in blends, such as PC/ABS, PC/ PET, and PC/PMMA, due to its great compatibility
with specific polymers. Compact discs, safety helmets, bullet-proof glass, automotive headlamp
lenses, baby feeding bottles, roofing and glazing are just a few examples of frequent applications.
Process Flow Diagram of Polycarbonate

Process flow sheet for manufacturing of Bis-Phenol A

Polycarbonates by interfacial polymerization
Process Flow Diagram of Polycarbonate
• Production of polycarbonate pass through three stages; starting from reaction of bis-phenol A and
phosgene, then separation process until getting polycarbonate powder and finally drying of
polycarbonate paste extrusion and getting of PC-pellets and packaging it. Figure shows process
flow sheet for that.
• In production of polycarbonate by interfacial polymerization method these raw materials are
required; Solution of Bis-Phenol A and methylene chloride, phosgene in liquid form at 8.2°C,
phenol in liquid form at 4°C, which used as molecular weight regulator, to inactivate some
carbonate oligomer ends to get required weight, triethylamine added in liquid form at 20°C used
as catalyst to prevent revere of reaction, and sodium hydroxide is added in solid form to get
sodium salt of bis-phenol A.
Process Flow Diagram of Polycarbonate
1)Reaction: The interfacial polymerization done in patch reactor on two steps:
❑bis-phenol A reacts with sodium hydroxide to get sodium salt of bis-phenol A at 25-30°C in
average time 25 minute as shown in equation (1).

❑at same temperature phosgene react with sodium salt of bisphenol A to get polycarbonate as
shown in equation (2).
Process Flow Diagram of Polycarbonate

2)Separation: The separation process done through passing the effluent of reactor to a scrubber, where the
effluent of the reactor washed with water to get rid of any miscellaneous attached in polycarbonate solution,
after that the solution is fed to solvent recovery unit, where the solvent is extracted and recycled again to the
reactor.
3) Drying, Extruding, Pelletizing & Packaging: The product of solvent recovery unit is a paste need to be dried
by using a dryer at 120°C for three or four hours to get rid of humidification, and after that powder is fed to
an extruder, it may be single or twin-screw extruder, and since extruder work with direct extrusion technique
talk powder added to reduce friction, poly carbonate melted at 250°C so through group of parallel heaters.
Process Flow Diagram of Polycarbonate
After extruding molten ribbons pass through tank of water supplied with water pump to cool these
ribbons, after those cooled ribbons cut with blades set at axis it may be 16, 20, 24 knifes, the
pelletizer rotates with 600 to 850 rpm. After that polycarbonates pellet are charged to silos to be
packaged.
Applications of Polycarbonates
• High impact resistance applications such as bulletproof glass.
• Plastic lenses in eyewear, in medical devices, automotive components, protective gear,
greenhouses, Digital Disks (CDs, DVDs, and Blu-ray), and exterior lighting fixtures.
Polyamides
Nylon 6,6
• Nylon 6,6 is a semi-crystalline polyamide that is extensively used in carpeting, clothes, and tyre
wire.

• In the presence of water, equimolar quantities of ADA and HMDA react to generate high
molecular weight Nylon 6 6.
• A water molecule is released and a polypeptide link is produced when the carboxyl group of the
ADA monomer reacts with the amino group of the HMDA monomer.
Nylon 6,6
• If too many reactants are utilized, the polymer chain will be terminated by the creation of an acid
or amino end group, resulting in a low molecular weight polymer.
• As a result of the polycondensation reaction, Nylon salt is produced.
• Water is extracted from the Nylon salt to generate molten Nylon 6 6. 1,6 to accelerate the process
towards polymerization. The intermediate component hexane diamine, or diamine, is also
extracted with the water and sold as a by-product stream.
• The product is next either extruded and granulated to make solid pellets or extruded and spun
into fibers.
Structural Properties of Nylon 66
• High mechanical strength, stiffness, hardness and toughness.
• Good fatigue resistance.
• High mechanical damping ability.
• Good sliding properties.
• Excellent wear resistance
• Good electrical insulating properties
• Good resistance to high energy radiation (gamma & x-ray).
• Good machinability.
PFC of Nylon6,6
Process Flow of Nylon 6,6
1. Manufacturing Process of Nylon 6,6:
a) The manufacturing process starts with the production of two chemicals hexamethylene
diamine and adipic acid both of which contains 6 carbon atoms from coal.
b) These chemicals are combined to form the nylon salt, which is dissolved in water and sent to
the spinning mill.
c) The nylon salt solution is made into a concentrated solution by heating in large evaporators.
d) The concentrated solution is then heated in an autoclave under the pressure and temperature.
The polymerization takes place combining the two chemicals into polymers which are like a
giant chain.
2. Melt spinning:
• Two-step melt spinning, comprised of spinning and drawing, is considered to be the conventional
method to manufacture nylon filaments.
• After melting, filtering, and deaerating, the molten polymer is extruded through a spinneret into
a chamber where the melt solidifies into a filament form.
3. Drawing
• When the molten polyester gets solid and gets converted into filament. It has little molecular
orientation, and its slight birefringence is.
• The desired orientation of molecule and degree of crystallinity is improved by drawing the
filaments.
4. Finishing
a) Scouring: Acrylic, wax, and other sizing agents are used in the warp of nylon woven fabric, just as
they are in polyester. This is a secondary pollutant used in the weaving process. To eliminate these
secondary pollutants in the primary continuous processing during the scouring phase. Secondary
pollutants are eliminated from the scouring process by continuous treatment. In addition, the
continual scouring process removes secondary pollutants like as oils and moisture heat set by the
polyurethane blend knit. Some woven fabrics are subjected to continuous range scouring and de-
sizing, followed by batch scouring with relax. In the dyeing bath, general knit fabrics are scrubbed. In
the dyeing bath, general knit fabrics are scrubbed.
The amount of scouring agent required varies depending on whether the procedure is done on a
continuous range or in a bath. As a result, the final product's quality is heavily influenced by the
choice of the best agent and processing.
b)Dyeing: When dyeing nylon, acid dyes and premetallized dyes are utilised. Water-soluble acidic
dyestuffs and premetallized dyestuffs use ionic bonding to dye. The dyestuff used in nylon dyeing
varies depending on the desired shade density. When it comes to lighter shades, it's a levelling type
acidic dye that's great for migration, and when it comes to darker shades, it's a milling type or
premetallized dyestuff. To achieve even dyeing, levelling agents are required, and the sort of
levelling agent employed will vary depending on the dyestuff. For levelling dyestuff, a fiber-friendly
anionic active agent is utilized, and for milling and premetallized dyestuff, a cationic non-ionic agent
is used. Dyeing is usually done in batches, and it is done by looping the cloth inside the machine and
running it through the machine. The fabric's runnability must be stable for even dyeing; if it isn't,
colour differences in batches will result, as will scraped and damaged fabric. If this happens, it's a
good idea to use a dye bath quality enhancer.
c) Soaping: It eliminates unexhausted dyestuff on fibres and dispersion by soaping after a cold-
water rinse when dyeing is finished.
d) Fixing: It is feasible to improve the fastness of dyed nylon fiber treated with an acidic dye or
premetallized by employing an anionic polymer fixative. Fixatives are typically employed in a
medium to dark tint, however they have an influence on hand feeling. Fixatives are sometimes used
for lighter shades to reduce the amount of time the hand feels changed by the color. Depending on
the color concentration, adjust the amount of fixative applied.
e) Finishing: It is the process of improving the end product's hand feel and functional performance.
The continuous pad procedure is popular, and pad bath stability is a requirement of the finishing
process. Add soft feeling, water repelling, and rapid dry properties to the mix (moisture
management).
Applications of Nylon 66
• Clothing – Shirts, Foundation garments, lingerie, raincoats, underwear, swimwear and cycle wear.
• Industrial uses – Conveyer and seat belts, parachutes, airbags, nets and ropes, tarpaulins, thread,
and tents.
• It is used to make a fishnet.
• It is used as plastic in manufacturing machine parts.
Thank You