© PlasticsEurope 2016 HOW PLASTICS ARE MADE. © Plastics Europe 2016 amorphous structure Standard Plastics Engineering Thermoplastics TI = 100 - 150 °C.

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Presentation transcript:

© PlasticsEurope 2016 HOW PLASTICS ARE MADE

© Plastics Europe 2016 amorphous structure Standard Plastics Engineering Thermoplastics TI = °C High Performance Polymers TI > 150 °C 100 °C 150 °C Capability by Temperature Index by Underwriter Laboratories, USA > 2,000 EUR/ton* > 4,000 EUR/ton* > 10,000 EUR/ton* PEEK FP LCP PPS PPA PA 46 PET (Injection) PBT POM PA 6 PA 66 PP HDPE, LDPE, LLDPE PI PAI PEI PES PSU PPE mod. PC PMMA PA 11 PA 12 ABS, SAN, ASA EPS PS PET (Bottle grade) PVC Source: PlasticsEurope Market Research Group (PEMRG) / Consultic Marketing & Industrieberatung GmbH; * Average 2010 indicative prices Standard Plastics includes Polyolefins, PS, EPS, PVC and PET (Bottle grade). Engineering Plastics with improved performance at higher costs. High Performance Polymers permitting exceptional end-use-applications, specialized niche products at high costs. Thermosets generally stronger than thermoplastics, generally better suited to high temperatures, easy to prototype Thermoset Resins Acrylic, Epoxy, Polyester, Vinylester, PUR, Phenolic semi-crystalline structure PLASTICS – A WEALTH OF DIFFERENT MATERIALS Triangle of thermoplastics by Structure, Capability and Price

© Plastics Europe 2016 PLASTICS ARE MADE FROM: Natural materials like cellulose, coal, crude oil, natural gas and salt. And these can include renewable sources like corn, potatoes and sugar cane.

© Plastics Europe 2016 PROTECTING THE ENVIRONMENT Just 4% of the world’s oil is used to produce all of our plastics needs. Most plastics products are designed to save other natural resources.

© Plastics Europe 2016 PROCESSING CRUDE OIL TO MAKE NAPHTA A distillation process turns heavy crude oil into lighter fractions. One fraction, naphtha, is a major raw material for plastics.

© Plastics Europe 2016 THE NAPHTA CRACKING PROCESS Refinery Propane Butane Ethane LPG Steam cracker Crude oil Extraction Basic petrochemicals Polymers Intermediates Specialities Ethylene Propylene Petrol & gasoline Aromatics A ‘cracking process’ breaks naphtha down into: Ethylene ; Propylene ; Butylene

© Plastics Europe 2016 Offgas Naphta quality carry over detection Real-time saybolt colour CDU control system Heavy gas oil Light gas oil Residue Crude oil in Continuous CDU Process control and sybolt colour trending CDU process control Operator alarms Crude distillation unit THE POLYMERIZATION PROCESS Hydrocarbon molecules are basic building blocks of plastics. During polymerization, a large number of individual molecules form a polymer chain.

© Plastics Europe 2016 THE POLYMER STRUCTURE Plastics have: Different polymer chain structures Two main families: thermoplastics and thermosets A chain structure that determines physical characteristics

© Plastics Europe 2016 THERMOPLASTICS Thermoplastics soften when heated. All thermoplastics can be melted and reshaped many times.

© Plastics Europe 2016 THERMOSETS During moulding, thermoset molecules form a tightly woven three-dimensional network. Thermosets cannot be re-melted and changed in shape.

© Plastics Europe 2016 WHAT PLASTICS MATERIALS LOOK LIKE An assortment of granules or powders. Nearly everything can be made out of plastics.

© Plastics Europe 2016 FROM RAW MATERIAL… TO FINISHED PRODUCT

© Plastics Europe 2016 DESIGN Plastic products are designed and manufactured by the converting industry. The type of material and manufacturing technique used depends on: Product shape: flat, 3D, long, etc. Characteristics: rigid, solid, soft Surface effects: colours, tactility Quantity: from composite parts for planes to millions of bottle caps

© Plastics Europe 2016 ECO-DESIGN To reduce the product’s environmental impact, plastic converters take into account the product’s full life cycle by optimising: The amount of raw materials The manufacturing energy required The product’s operating life and end-of-life treatment

© Plastics Europe 2016 Blown film extrusion Blow Moulding (injection & extrusion) Compression moulding Extrusion Injection moulding Thermoforming Rotational moulding Calendering MAIN PLASTICS CONVERTING PROCESSES

© Plastics Europe 2016 BLOWN FILM EXTRUSION

© Plastics Europe 2016 INJECTION BLOW MOULDING

© Plastics Europe 2016 EXTRUSION BLOW MOULDING

© Plastics Europe 2016 COMPRESSION MOULDING

© Plastics Europe 2016 EXTRUSION

© Plastics Europe 2016 INJECTION MOULDING

© Plastics Europe 2016 THERMOFORMING

© Plastics Europe 2016 ROTATIONAL MOULDING

© Plastics Europe 2016 CALENDERING