Announcements;

 Workshop practice groups can merge to have a 2 hour long slot

 Test is on Tuesday at 252 room and time to be communicated through Moodle.
 Test topics (Workshop safety, First aid, Production of materials; wood, metal and
plastics), workshop processes on on going projects, and a design question)

Production of Plastics

Oil refineries ‘refine’ oil in massive quantities, to produce the fuels we need. These
include diesel, petrol and heating oil. However, some of the raw materials we need to
manufacture plastics, are also extracted from oil at the refinery. When crude oil is
refined, four percent ends up as raw materials for the production of plastics.

Oil is used widely for the production of plastics as it is composed of carbon and
hydrogen. This is why oil is called a hydrocarbon. Oil and natural gas are the most
important raw materials for plastics manufacture. To the plastics industry, Naphtha is
the most important fraction distilled from crude oil. It is used in the production of a
range of plastics.

Crude oil is virtually unusable in its unrefined state. It is composed of a mix of

hydrocarbons, each with a different number of carbon atoms. The hydrocarbons are
different in weight, with the lightest being propane (gas) and heaviest asphalt (used
on roads). Extracting the various hydrocarbons from crude oil is a formidable challenge
and this process takes place in an oil refinery. The process is called ‘distillation’.

The distillation process takes place at an oil refinery in a distillation ‘Tower’. An

example is seen opposite.

When crude oil is refined it is ‘distilled’ into fractions. Each hydrocarbon extracted from
crude oil, is called a fraction. The refining process is also called the ‘cracking’ process.

Crude oil is heated to over 370 degrees Celsius and tit is pumped into the base of the
distillation tower. The crude oil vaporises and rises up the tower. As it cools the
molecules condense, with heavier molecules of asphalt, bitumen and tar at the bottom
and lighter molecules such as diesel, petrol and aviation fuel at the top. At each level,
the condensed hydrocarbons are siphoned off.

The fractions / hydrocarbons produced include gas, petrol, diesel, heating oils,
naphtha (important for plastics), ethylene and polyethylene. Bitumen / asphalt is also
produced, as a residue.
 All plastics are based on polymers and they are created by bonding molecules together.

The terms monomer and polymer are very important in the plastics industry. A
monomer is a relatively small molecule that can chemically bond to other monomers,
forming a polymer. Remember, all plastics are polymers.

What are plastics?

Plastics are the most widely used material in commercial production. Plastics can be
created from two main sources which are natural and synthetic materials.

Source one - Natural plastics: include amber which is fossilised tree resin, latex which is
a form of rubber.

Amber which is fossilised tree resin Rubber being drained from a rubber tree

Animals horns Casein (glue)

Animals milk Formaldehyde (glue)

Insects Shellac (French polishing)

Cellulose (table tennis balls)

Cellulose acetate (cloth, photographic film, handles)

Plants

Cellophane (wrapping)

Bitumen (roads, flat roofs)

Trees Latex (rubber)

 Rosin (resin) paint

Amber (semi-precious decoration)

Source one - Synthetic plastics: are chemically manufactured from carbon based
materials such as crude oil, coal and gas.

Crude oil works A piece of coal

How are plastics made?

Plastics are produced using a process known as polymerisation. Polymerisation occurs
when monomers join together to form long chains of molecules called polymers.

Polymerisation comes from the word 'POLY' which means 'MANY' and 'MER' which
means 'PART'. So Polystyrene means 'POLY' many single monomers of 'STYRENE',
joined together to form a long chain.

Two types of polymerization

Addition polymerization: In addition polymerization, like monomers react to form a

polymer without the formation of by-products. Addition polymerizations usually are
carried out in the presence of catalysts, which in certain cases exert control over structural
details that have important effects on the properties of the polymer.

Condensation polymerization; a form of step-growth polymerization in which different

monomers and/or oligomers react with each other to form larger structural units while
releasing smaller molecules as a byproduct such as water or methanol.
What groups of plastics exist?
There are two main groups of plastic which are thermosetting plastics and thermoplastics.

Thermoplastics
Thermoplastics can be heated and shaped many times. Thermoplastics will soften when it
is heated and can be shaped when hot. The plastic will harden when cooled, but can be
reshaped because there is no link between the polymer chains. Some common
thermoplastics are ABS (acrylonitrile butadienestyrene), Nylon (polyamide), acrylic
(polymethyl methacrylate), uPVC (polyvinyl chloride), polystyrene, polypropylene and
cellulose acetate.

Thermosetting plastics
Thermosetting plastics can only be heated and shaped once. If re-heated they cannot soften
as polymer chains are interlinked. Separate polymers are joined in order to form a huge
polymer. The main thermosetting plastics are epoxy resin, melamine formaldehyde,
polyester resin and urea formaldehyde.
Mr DT says 'Read the text above and then answer these questions below'. Write
your answers on a sheet of paper, don't forget to write your name on the sheet!:-

1). What two main sources from which plastic can be made?
2). Name a natural plastic?
3). How are synthetic plastics made?
4). What is polymerisation?
5). What two groups of plastics exist?
6). Describe thermosetting plastics and thermoplastics in your own words?
7). What is the main difference between thermosetting plastics and thermoplastics?
8). Name the main thermosetting plastics?
9). Name the main thermoplastics?

Thermosetting plastics
Thermosetting plastics can only be heated and shaped once. If re-heated they cannot
soften as polymer chains are interlinked. Separate polymers are joined in order to
form a huge polymer. The main thermosetting plastics are epoxy resin, melamine
formaldehyde, polyester resin and urea formaldehyde.

Thermosetting Thermosetting Thermosetting plastic Example

plastics plastic Properties
Epoxy resin Good electrical
(Epoxide, ER) insulator, hard, brittle
unless reinforced,
resists chemicals well.
uses product
Used for casting and
encapsulation, adhesives,
bonding of other
materials. Used for
printed circuit boards
(PCB’s) and surface
coatings.
Melamine Stiff, hard, strong, Used for Laminating
formaldehyde resists some chemicals work surfaces, electrical
(MF) and stains. insulation, tableware.

Polyester resin Stiff, hard, brittle Used for casting and

(PR) unless laminated, encapsulation, bonding of
good electrical other materials, car
insulator, resists bodies, boats.
chemicals well.
Urea Stiff, hard, strong, Used for electrical
formaldehyde brittle, good electrical fittings, handles and
(UF) insulator. control knobs, adhesives.

Phenol A colourless polymer Used for dark coloured

formaldehyde - coloured with electrical fittings and
(PF, Bakelite) artificial pigments to parts for domestic
produce a wide range appliances, bottle tops,
of different colours. kettle handles, saucepan
handles.

Memory tip: Remember Bets Pup!

B - Bakelite
E - Epoxy resin
T - Thermosetting
S - Shaped once

P- Polyester resin
U - Urea formaldehyde
P- Plastic

Mr DT says 'Read the text above and then answer these questions below'.
Write your answers on a sheet of paper, don't forget to write your name on the
sheet!:-
 1). Describe thermosetting plastics in your own words?
2). What are the properties of epoxy resin?
3). What are the uses of melamine formaldehyde?
4). What is polyester resin used for?
5). Why is urea formaldehyde used for plugs?
6). What is Phenol formaldehyde used for?

Thermoplastics
Thermoplastics can be heated and shaped many times. Thermoplastics will soften
when it is heated and can be shaped when hot. The plastic will harden when cooled,
but can be reshaped because there is no links between the polymer chains. Some
common thermoplastics are ABS (acrylonitrile butadienestyrene), Nylon (polyamide),
acrylic (polymethyl methacrylate), uPVC (polyvinyl chloride), polystyrene,
polypropylene and cellulose acetate.

Thermoplastic Example
Thermoplastic Thermoplastic uses
properties product
Polymethyl Stiff, hard but Used for signs, covers of
methacrylate scratches easily, storage boxes, aircraft
(Acrylic) durable, brittle in small canopies and windows,
sections, good covers for car lights,
electrical insulator, wash basins and baths.
machines and polishes
well.
High impact Light but strong Used for vacuum
polystyrene plastic. Widely forming. Common for
(HIPS) available in sheet school projects which
softens at about 95 include products outer
degrees. casings or packaging.
Polypropylene Light, hard but can Used for medical
(PP) scratch easily, tough, equipment, laboratory
good resistance to equipment, containers -
chemicals, resists work especially with built-in
fatigue. hinges, 'plastic' seats,
string, rope, kitchen
equipment.
Polythene: Tough, good resistance Used for packaging,
- low density to chemicals, flexible, especially bottles, toys,
(LDPE) fairly soft, good packaging film and bags.
electrical insulator.

Polythene: Hard, stiff, able to be Used for 'plastic' bottles,

- high density sterilised. tubing, household
(HDPE) equipment and milk
crates.

PVC Stiff hard wearing. Used for air and water

Plasticiser can be pipes, shoe soles, blister
added to create a softer packaging.
more rubbery material.

Memory tip: Remember Paps Hat !

P - Polythene
A - Acrylic
P - Polypropylene
S - Shaped many times

H- HIPS
A - ABS (acrylonitrile butadienestyrene)
T- Thermoplastics
 Mr DT says 'Read the text above and then answer these questions below'.
Write your answers on a sheet of paper, don't forget to write your name on the
sheet!:-
1). Describe thermoplastics in your own words?
2). What are the properties of acrylic?
3). What is HIPS used for?
4). What does HIPS stand for?
5). What is low density polythene used for?
6). Plasticiser is added to what to make it more soft?
7). What are air and water pipes made from?
8). What does LDPE stand for?

POLYURETHANE AND FOAM RUBBER

In the 1930s, Germany lead the world in the development of chemicals and plastics.
In1937, Otto Bayer mixed two chemicals, polyol (an alcohol) and isocyanate
(sometimes called isonitrile or carbylamine). The two chemicals formed a solid plastic.
The resulting plastic was polyurethane (PUR), a new plastic. However, occasionally
when the process was repeated, something different happened. Sometimes the
chemicals were contaminated with water and when mixed, a significantly different
reaction took place. The chemicals ‘fizzed’ with bubbles and the polyurethane
expanded. The resulting plastic is now called foam rubber. Polyurethane was discovered
by mistake, although now it has many uses around the home and in manufacturing
industry.
Assignment;

Read about BIOPOL (a bio-degradable plastic from www.technologystudent.com)