Troubleshooting the. Update on. PVC Extrusion Process. ismithers. Natami Subramanian Muralisrinivasan

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1 Update on Troubleshooting the PVC Extrusion Process Natami Subramanian Muralisrinivasan Smithers ismithers /Smithers - A Smithers Group Company Shawbury, Shrewsbury, Shropshire, SY4 4NR, United Kingdom Telephone: +44 (0) Fax: +44 (0)

2 ontents Introduction 1 Poly (Vinyl Chloride) Characteristics Poly (Vinyl Chloride) Structure Crystallinity Thermal Stability of Poly (Vinyl Chloride) Manufacture of Poly (Vinyl Chloride) Resin Raw Material Energy Requirement Process K-Value Modification of Poly (Vinyl Chloride) By the Addition of Metal Compounds Structural Modification Regrind Poly (Vinyl Chloride) Material Advantages of Poly (Vinyl Chloride) Disadvantages 16 Additives and Compounding Poly (Vinyl Chloride) Formulation 23

3 Update on Troubleshooting the PVC Extrusion Process 3.2 Role of Additives Classification of Poly(Vinyl Chloride) Additives Heat Stabilisers Lead Stabilisers Secondary Heat Stabilisers Tin Stabilisers Calcium-zinc Stabilisers Other Heat Stabilisers One-pack Stabilisers Lubricants Impact Modifiers Plasticisers Fillers Flame Retardants Blowing Agents Pigments Coupling Agents Smoke Suppressants Migration of Additives Compounding Technology 41 4 Poly(Vinyl Chloride) Extrusion Basic Requirement of Poly (Vinyl Chloride) Compounds Machine 50 vi

4 Contents Processing Extrusion Extruder: Operating Conditions Screw Processing Technology Processing Temperature Power Consumption Extrusion Single-screw Extruder Advantages/Disadvantages Twin-screw Extrusion Advantages Die Design Calibration System Poly (Vinyl Chloride) Pipe Extrusion Pipe Dies Cooling System Poly (Vinyl Chloride) Profile Extrusion Calibrator Cooling System Poly (Vinyl Chloride) Sheet Extrusion Poly (Vinyl Chloride) Films Regrind 68 5 Degradation and Stabilisation of Poly (Vinyl Chloride) Degradation of Poly (Vinyl Chloride) 71 vii

5 Update on Troubleshooting the PVC Extrusion Process 5.2 Structural Defects Tacticity Dehydrochlorination Stabilisers Impurities Photochemical Degradation Mechanism of Degradation Polyvinyl Chloride) Stabilisation 78 6 Poly(Vinyl Chloride)-Wood Composites Additives Properties of Wood-Poly(vinyl Chloride) Composites Processing Advantages of Wood-Poly(Vinyl Chloride) Composites 98 7 Poly(Vinyl Chloride) Extrusion: Problems and Defects Troubleshooting Problems in Poly(Vinyl Chloride) Extrusion Problems and Troubleshooting in Pipe/Profile Extrusion Production Problems in the Extruder Problem: Difficult to String-up Melt during Startup 109 viii

6 Contents Problem: Powder Pulled into a Vacuum Problem: High Bearing Throat at Back Pressure Problem: Motor Load is too High Problem: Low Output Product Problems Production Problems in Downstream Areas Problem: A Longitudinal Scratch in Pipe or Profile is Found While Sizing Problem: Folding of Material in the Calibrator Problem: Blowouts in the Cooling Zone Problem: Uncontrolled Wall Thickness Problem: Poor Inner Surface Problem: Regular Wavy Lumps Problem: Irregular Lumps (Random With No Regular Pattern) Problem: Dimples on the Product Problem: Burning or Yellowing of the Extrudate 122 ix

7 Update on Troubleshooting the PVC Extrusion Process Problem: Poor Overall Appearance Problem: Dull Surface Appearance Problem: Low Results in the Drop Weight Impact Test Problem: Gauge Variation Problem: Degassing is Difficult Problem: Frictional Heat: Zone-4 Overheating Problem: Melt Fracture and Surface Roughness Problem: Lumpy, Cold or Oval (egg-shaped) mark Surfaces Problem: Over-lubrication Problem: Impact Failure Problem: Black Specks Problem: Variation in Load Quality or Amperage from Batch-to-Batch or Between Batches 135 Problems in the End Product Problem: Failure in the Methylene Chloride Test Problem - Inside Portion Granular Problem: Middle Portion is Mealy 138 x

8 Contents Problem: Outside Portion is Mealy Problem: Bubbles at the Oil Reversion Test at the Inner Surface Quality Problems in Pipes Troubleshooting for Poly (Vinyl Chloride) Blown Film Troubleshooting for Poly (Vinyl Chloride) Sheets Future Requirements: Developments in Polyvinyl Chloride) Poly(Vinyl Chloride) Formulation Wood - Polyvinyl Chloride) Composites Medical Applications Construction Biodegradation 150 xi

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