hsu‐chihyen (george yen) formosa plastics corporation ... pam 2016 presentations u… · and...

Hsu‐Chih Yen (George Yen) Formosa Plastics Corporation I has been a researcher in the technical department of Formosa Plastics Corporation for 10 years and my research focuses on the synthesis and processing of PVC / MBS / PA.

I also served 15 years as a manufacturing section chief of Lin‐Yuan PVC plants of Formosa Plastics Corporation.

[email protected]

Formosa Plastics Group

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pFormosa Plastics

Corp. pNan Ya Plastics

Corp. pFormosa Chemicals & Fiber

Corp. pFormosa Petrochemical

Corp.

FPG FPC was founded on October 30, 1954. The

capital was 125,000 USD.

The Kaohsiung Plastic Factory is the development source of the Formosa Plastics Group. After sixty years of effort, has developed including in the petrochemical, oil refining, plastics, fibers, electronics, machinery, steel, medical, biotechnology, and other one hundred affiliates.

In 2015,the total assets are 102 billions USD. The sales are 60 billions USD. The total number of employees are 110,677 people.

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Taipei

Taichung

Kaohsiung

Formosa Plastics Corporation

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The business and products are including PVC powder, VCM,caustic soda, hydrochloric acid, plastics modifier, high densitypolyethylene, ethylene vinyl acetate Copolymer / lowdensity polyethylene, linear low density polyethylene,polypropylene and other products.

Item Products Productivity (1000 tons/year)

Plastics Division

PVC (Southeast Asia) 1,700

MBS 19.7PA 15.5

Sodium hydroxide 1,700

Polyolefin Division

HDPE 566EVA LDPE 240

LLDPE 244

Polypropylene Division

PP 8505

Productivity

Introduction of Formosa Processing Aids (PA)

1. The Development History of Formosa PA 2. The Principle and Function of PA3. The Applications of Formosa PA

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1. The Development History of Formosa PA

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※ Formosa PA Production began in 1996，at that time the capacity is 3,500 tons per year.

※We have invested a lot of resources in 2007, the capacity could raise to 15,500 tons per year.

※We also have a strong R & D team, so the new product P‐220、P‐251、P‐1000 success production in 2013.


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※ Formosa PA products currently have seven brands, covering all types of processing customer needs, including different molecular weight of the product, such asP‐101, P‐201, P‐220, P‐251, P‐301 , P‐302 and P‐1000.


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2. The Principle and Function of PA10

PVC granule formationPVC granule formation

2st particle(1~10μm)

VCM polymerization1st particle(10~20nm)

PVC granule(100~200μm)

Aggregation(10~100nm)

Skin caused bysuspension agent(0.2~1μm )

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Advantages Drawback inexpensive price use broadly in many field. Chemical resistance Oil resistance Non Flammability High transparency

Bad heat stability <170

Poor processability(Surface rough & dull) Poor impact resistance

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The nature defects of PVCThe nature defects of PVC

C C

H

Cl

H

H

C

H

Cl

C

H

H

PVC

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PA is the copolymer, composed of MMA (Methyl methacrylate)and BA (Butyl acrylate),in a Core-Shell structure.

The PA has a variety of compositions and can be designed to the products of multiple properties.

MMA/BA

MMA/BA

The structure of PAThe structure of PA

Acrylate Copolymers

Excellent compatibility with PVC

A polymer with high molecular weight, long and soft chain in molecular structure.

C C C

OOR

C

C（）

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The properties of PAThe properties of PA

1) A good lubricant2) Improving PVC fusion3) Improvement of melting strength of

PVC

Three major Function of processing aids:

A good lubricant that can prevent the melt plastics adhere to the metal surface and reduce the dosage of external lubricant without the scale forming at die.

1) A good lubricant1) A good lubricant

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Improving heat delivery in molecular and increasing the shear stress in processing by additives of PA.

2) improving PVC fusion2) improving PVC fusion

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3) Improvement of melting strength of PVC3) Improvement of melting strength of PVC

PVC Chain PA Chain Entanglement

PA have long and soft polymer chain, which has the property of elasticity and extensibility.

PA can help PVC molecular bind together to improve melting strength.

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The Summary functions of PAThe Summary functions of PA Enhancing fusion property, melting strength,

elongation, elasticity. Preventing intermediate products droopy, and

stabilizing the size in processing. Improving product gloss, reducing air spot

formation, and getting good appearance of products.

Improving the foaming product surface quality, and reducing the crack by foaming.

A good lubricant that can form a thin membrane between metal surface and resin to provide good lubricity.

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3. The Applications ofFormosa PA

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50 times

The appearance of powder into spherical particles, uniform size, so they have good mobility.The appearance of powder into spherical particles, uniform size, so they have good mobility.

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150 times

Formosa PA Powder characteristics

Lubricant type

General gelation type

High dispersing typeHigh dispersing type

Outline diagram of Formosa PA products and molecular weight

Outline diagram of Formosa PA products and molecular weight

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High Molecularweight

Item Molecular weight type

Suitable resinApplications

CPVC ABS PVC PMMA

P‐101 Lubrication type ○ ○ Exterior lubricant: preventing resin adhering to metal surfaceP‐1000

Ultra High efficiency

Lubrication type○ ○ ○ ○

P‐201 General type ○ Rigid sheetSemi‐rigid sheetExtrusion, injectionBlow moldingSecondary processing

General type(reducing plate‐out） ○

P‐220

Fast fusion type ○ ○For soft, Semi‐rigid, rigid, injection molding, and shrink film.

P‐251

P‐301High efficiencydispersion type ○ ○

Rigid sheetSemi‐rigid sheetProfile extrusion, injection moldingProduct with high fillingVacuum formingFoaming molding

P‐302Ultra High efficiency

dispersion type○ ○

low

high

Classification and application of FPC PA Classification and application of FPC PA

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1) Ultra High efficiency lubrication: P‐10002) for calender molding: P‐220

(reducing plate‐out )3) Fast fusion type ： P‐2514) High molecular weight： P‐302

The application of four special products

Lubricant for extrusion, injection andcalendering processes

1) Ultra High efficiency lubrication: P‐1000

Traditional lubricant or PE wax

Resin surface

Wax vaporLose lubricant

Thermoplastic resin

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Combining region:high affinity with thermoplastic resin & promote melting

P‐1000It has two feature

Lubricant region：low affinity with thermoplastic resin & improving the releasability.

P‐1000 has good stability in high temperature to prevent volatilization.

high temperature

So P‐1000 can form a thin membrane between metal surface and resin to provide good lubricity.

1) Ultra High efficiency lubrication: P‐1000

Slag easily form at the die when using traditional lubricant.

FPC P‐1000 can keep die clean after a long period of running.

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PA for reducing plate‐out condition

2) for calender molding: P‐220

Additives easily plate‐out on the roller when using traditional lubricant.

FPC P‐220 can keep roller surface clean and prevent additives migrating out after a long period of running.

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Fast fusion, less fish eye, high transparency, high tensile and elongation。

P-251（FPC）

Competitor M

S-60

P-201（FPC）

Item Fusion time (sec)

Fusion torque(Nm)

Final torque (Nm)

S‐60 142 69.6 39.5P‐251 42 73.5 39.6Competitor M 64 74.5 40.0P‐201 82 76.0 40.2

3) Fast fusion type ：P‐251

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4) High molecular weight： P‐302

a. High filler product poor dispersion

b.P‐302 has a large shear force, can improve the dispersion

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Fillers are concentrated together

Use different types of Formosa PA to solve the problems

when processing Enhancing fusion、improving melting flowability of resin.P‐201、P‐251

Reducing the surface roughness of products. P‐201、P‐251 Improving the surface gloss of products. P‐201、P‐251

P‐220

P‐201、P‐301P‐301、P‐302

P‐302

P‐1000、P‐101

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Applications of PA

P‐101+ABS Audio shell

P-201 credit cardP-201 IC Tube31

P‐101+ABS Car Application

Applications of PA

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P‐201 Rigid FILMP‐220 Specifically Rigid FILM(reduce the small molecular to migrate‐out )

P‐1000 high temp. CPVC Pipe (SPA)

P-251 shrink film

P-301 Rigid foam board P-301 Window frames

P-302 Floor tiles

Applications of PA

33P-302 High foam board

Specification of Formosa PA

ItemVolatile Bulk

density density Appear-ance feature & Application

% g/ml g/ml

P-101 ≦1.0 0.4以上 1.3~1.4 White Power

A low molecular PA with good lubricity, which can prevent the melt plastics adhere to the metal surface and provide high transparency to the products.

P-1000 ≦1.0 0.4以上 1.3~1.4 White Power

A mid-low molecular PA with superior lubricity, which can prevent the melt plastics adhering to the metal surface and reduce the usage of external lubricant without the scale forming at die.

P-201 ≦1.0 0.4以上 1.3~1.4 White Power A general type, which can enhance the PVC fusion in processing.

P-220 ≦1.0 0.4以上 1.3~1.4 White Power

It can reduce plate-out to rolls. It not only possess the functions of enhance plastics fusion but also reduce the small molecular to migrate-out.

P-251 ≦1.0 0.4以上 1.3~1.4 White Power

It can accelerate PVC fusion, reduce fish-eye, increase transparency, and enlarge tensile strength and elongation. It can apply to shrink film and rigid products.

P-301 ≦1.0 0.4以上 1.3~1.4 White Power

A high molecular PA which can enhance additives dispersing and assist foaming. It can apply to foaming products, high filler contained products, extruding and injection-molding processes.

P-302 ≦1.0 0.4以上 1.3~1.4 White Power

A ultra high molecular PA which can enhance additives dispersing and assist fine-cell foaming and increase toughness. It can apply to foaming products which need high foaming ratio, to the products that need high amount of filler, and to the product with vacuum forming process. 34

Dis

pers

ant t

ype

P-101

FPC Kaneka

Dow MITSUBISHIfusion

type

lubr

ican

t typ

eM.W.

high

low

P-1000

P-201

P-220

P-251

P-301

P-302

PA-101

PA-20

PA-30

PA-40

PA-600

K -175

K -130

K -400P

K -440

P -710

L -1000

P -560J

P -551A

P -530A

Contrast of commercial productsLG

P -910

P -930

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1. The Development History of Formosa MBS

2. The Principle of MBS

3. The Applications of Formosa MBS36

Introduction of Formosa Impact Modifier (MBS)


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※ The factory began production in Linyuan Plant in May 1989 and 2,562 tons per year.

※ Our factory completed the removal of the bottleneck project in June 2007, so the capacity was increased to 19,700 tons per year..

※We have a strong R & D team, so we continue to develop the application of different products, such as M‐31, M‐41, M‐48, M‐51, M‐61 and so on.


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2. The Principle of MBS39

◎Impact strength is very importance for PVC rigid processing especially at the low temperature.

◎It will enhance the PVC rigid product impact strength when you add the impact modifier which contain elastomer. The idea impact modifier is MBS ,and MBS is compatible with PVC very well.

(1).The meaning of MBS for PVC

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(2).Structure and composition of MBS

Core(SBR rubber)

‐Butadiene‐Styrenecopolymer‐Lower glass transition temperature‐The impact energy absorbing unit

Shell(Graft components)

‐MMA‐Styrene copolymer‐Higher glass transition temperature‐Good compatibility with PVC‐Good dispersion


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(3) Observed by TEM (Transmission Electron Microscope)

When MBS was added to PVC, MBS was evenly distributed in PVC.


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(4)The function of MBS2. The Principle of MBS

When MBS is added to the substrate, the MBS becomes an energy absorption center, and a silver grain is formed to prevent the formation of cracks, so as to achieve toughening effect.

• silver grain

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When MBS substrate is subjected to stress, MBS is used as the center to form micro‐shear deformation band at 45 degree angle to consume energy and to achieve shock‐absorbing effect.

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• Shear yield stress

When the substrate is added with MBS, the MBS becomes an energy absorption center and the core begins to be hollow. When the external force is released, the nucleus is constantly deformed into a void and becomes a whitening appearance.

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• Cavitation

3. The Applications of Formosa MBS

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High

Low

M-61

M-31

M-41

M-48

M-51Low

Whitening Grade

General Grade

Opaque Grade

Transparent OpaqueTransparency

Stress WhiteningImpact Strength

Haze

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Application of MBS ◎ superior ○ well

Applicatioin M‐31 M‐41 M‐48 M‐51 M‐61B

uild

ing

Mat

eria

ls Pipe/Conduit ◎

Fittings ◎

Interior Trim ◎ ◎ ◎

Rigid Foam ◎

Pack

ing

Clear film/sheet ◎ ○ ○ ◎

Opaque film/sheet ◎

Clear Bottles ◎ ◎

Opaque Bottles ◎

IC Tube ○ ○ ○ ◎

Vacuum forming ◎ ○ ○ ◎ ◎

Con

sum

able Credit Card ◎ ◎ ◎

Sanitary Ware ◎ ◎ ◎

Semi‐Rigid ○ ◎ ◎ ◎ ○

Tapes‐Embossing ◎ 48

Grade：M‐31，M‐61feature：high transparency and low whitenessApplication：Vacuum forming、Folding product

Applications of MBS

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Grade：M‐41，M‐48feature：transparency and high impact strengthApplication：packing cases、credit card 、 albums

Applications of MBS

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Grade：M‐51feature：opaque and high impact strengthApplication：Christmas tree leaves、fitting、rigid sheet 、decorations、 foaming plate

Applications of MBS

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Specification of MBS

GradeVolatile matter

Bulk density

Tensile strength

Elongation at

breakAppear‐ance feature & Application

% g/ml kg/cm2 %

M‐31 ≦1.0 0.3以上 539 338White Power

It can enhance the PVC fusion, and it with good transparency and stress whitening. It is adapted for calender film/sheet、IC‐tube and vacuum forming.

M‐41 ≦1.0 0.3以上 570 379White Power

high impact strength、good transparency、oil resistance. . It is adapted for transparency film、sheet、transparency bottle、credit card and vacuum forming.

M‐48 ≦1.0 0.3以上 585 385White Power

It has high impact strength、good transparency、low odor. It is adapted for transparency film、sheet、transparency bottle、credit card and vacuum forming.

M‐51 ≦1.0 0.3以上 590 358White Power

It has high impact strength at low temperature、good melting strength. It is adapted for rigid foaming、opaque film/sheet、credit card and vacuum forming.

M‐61 ≦1.0 0.3以上 541 335White Power

It has excellent transparency、low haze、low stresswhitening、odorless. . It is adapted for ultra‐transparency film/sheet、IC‐tube and vacuum forming.

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M‐61

M‐31

M‐41

M‐51

B‐513

B‐610

B‐620

B‐564

BTA‐707

BTA‐717

BTA‐730

BTA‐751

C‐320

C‐303H

C‐223

MB‐872

MB‐885

MB‐838A

FPC Kaneka Dow Arkema LG

MB‐802

C‐859 M‐564

Wanda

M‐71

RK‐852

RK‐875

RK‐853

Rike

RK‐616

BTA‐731

BTA‐736S

BTA‐780S

B‐521

B‐625

M‐511

M‐730

M‐872

B‐907

B‐917

M‐66

M‐48

contraststab

le

Opaque

Transparent

LowImpact Strength

HighImpact Strength

HIGH IM

PACT

OPA

QUE

GEN

ERAL

TRAN

SPAR

ENT

LOW W

HITEN

ING

HIGH TRA

NSPAR

ENT

LOW W

HITEN

ING

IMPA

CT

OPA

QUE

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Thank you for your attention

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hsu‐chihyen (george yen) formosa plastics corporation ... pam 2016 presentations u… · and...

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