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1 | Polyethylene

Polyethylene

It is a polymer of ethylene, CH2-CH2, having the formula (-CH2-CH2-)n, and is

produced at high pressures and temperatures in the presence of any one of several catalysts,

depending on the desired properties for the finished product. Polyethylene is resistant to

water, acids, alkalies, and most solvents. Its many applications include films or sheets forpackaging, shower curtains, unbreakable bottles, pipes, pails, drinking glasses, and insulation

for wire and cable.

Polyethylene is a thermoplastic polymer consisting of long chains of the monomer

ethylene (IUPAC name ethene).

The ethene molecule (known almost universally by its common name ethylene) C2H4 is

CH2=CH2, Two CH2 groups connected by a double bond, thus:

Polyethylene contains the chemical elements carbon and hydrogen. Polyethylene is created

through polymerization of ethene. It can be produced through radical polymerization, anionic

addition polymerization, ion coordination polymerization or cationic addition polymerization.

Classification:-

Polyethylene is classified into several different categories based mostly on its density and

branching.

∑ Ultra high molecular weight polyethylene (UHMWPE)

∑ Ultra low molecular weight polyethylene (ULMWPE or PE-WAX)

∑ High molecular weight polyethylene (HMWPE)

∑ High density polyethylene (HDPE)

∑ High density cross-linked polyethylene (HDXLPE)

∑ Cross-linked polyethylene (PEX or XLPE)

∑ Medium density polyethylene (MDPE)

∑ Linear low density polyethylene (LLDPE)∑ Low density polyethylene (LDPE)

∑ Very low density polyethylene (VLDPE)

The most important polyethylene grades are HDPE, LLDPE and LDPE and here we will

discuss two major clae i.e HDPE & LDPE.

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2 | Polyethylene

ÿHigh-Density Polyethylene (HDPE)

polyethylene high-density (PEHD) is a polyethylene thermoplastic made from

petroleum. It is defined by a density of greater or equal to 0.941 g/cm 3. HDPE has a low

degree of branching and thus stronger intermolecular forces and tensile strength. HDPE can

be produced by chromium/silica catalysts, Ziegler-Natta catalysts or metallocene catalysts.HDPE is the strongest four times that of low density polyethylene, toughest, most chemical

resistant, and least flexible of these four types of polyethylene.HDPE is used in products and

packaging such as milk jugs, detergent bottles, margarine tubs, garbage containers and water

pipes. One third of all toys are manufactured from HDPE.

Schematic diagram:-

Manufacturing Process:-

I. Production of HDPE by addition polymerization with a supported metal oxide catalystrequires:

o temperature ~300oC

o 1 atmosphere pressure (101.3kPa)

o aluminium-based metal oxide catalyst (metallocene catalyst)

The catalyst can be used in a variety of operating modes including fixed-bed,moving-bed, fluid-bed or slurry processes

The ethene (ethylene) monomer is fed with a paraffin or cycloparaffin diluent (diluting

agent).

HDPE is now produced by catalytic polymerisation of ethylene in either slurry

(suspension), solution or gas phase reactors. Alpha-olefin comonomers, such as butene,hexene and octene, may be incorporated at low levels to modify the polymer's properties.Some processes can switch to linear low density polyethylene production ('swing' between

HDPE and LLDPE).

After polymerization the polymer (polythene) is recovered by cooling or by solvent

evaporation.

II. Production of HDPE by coordination polymerization requires:

o temperature 50-75oC

o slight pressure

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3 | Polyethylene

o a coordination catalyst is prepared as a colloidal suspension by reacting analuminium alkyl and titanium chloride (TiCl4) in a solvent such as heptane

(C7H16).

The polymer (polythene) forms as a powder or granules which are insoluble in the

reaction mixture. When the polymerization is completed, the catalyst is destroyed by adding

water or alcohol to the reaction mixture. The polymer (polythene) is then filtered orcentrifuged off, washed and dried.

Properties:-

 Melting Point:- ~135oC

Crystallinity:- Highly crystalline (>90% crystalline). Contains less than 1 side

chain per 200 carbon atoms in the main chain leading to long linear chains that

result in regular packing and high crystallinity.

 Flexibility:- More rigid than LDPE due to higher crystallinity.

Strength:- Strong as a result of regular packing of polymer chains.

 Heat Resistance:- Useful above 100-110oC.

Transparency:- Less transparent than LDPE because it is more crystalline .

 Density:- 0.95-0.97 g/cm3 higher density than LDPE

Chemical Properties:- Chemically inert.

Tensile elongationat rupture (%):- 653

 Molecular weight:- 90 000

Tensile strength (MPa):- 12.4

More Properties:-

∑ Resists abrasion, corrosion, stains and odors.

∑ Low coefficient of friction.High impact strength and durability up to 180°F.

∑ Easy to clean and disinfect.

∑ Good tensile strength and stiffness.

∑ FDA approved for food processing/handling.

∑ Easily extruded or pressed.

∑ Vacuum formable.

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4 | Polyethylene

End Uses:-

∑ The rigid nature of HDPE allows manufacturers to use it for food product and

chemical containers. Other uses for HDPE include trays, cutting boards, pipe fittings

and tanks.

One of the largest uses for HDPE is wood plastic composites and composite wood,

with recycled polymers leading the way.

∑ Chemical-resistant piping systems.

∑ HDPE mortars are preferred to steel or PVC tubes because they are more durable and

more importantly they are much safer compared to steel or PVC.

∑ For the manufacturing of freezer bags, water pipes, wire and cable insulation,

extrusion coating.

∑ Chemical Resistant Tanks and Containers.

∑ Food Storage Containers.

∑ Laboratory Equipment.

∑ Disposable Thermoformed Products.

ÿ Low-Density Polyethylene (LDPE)

LDPE is a thermoplastic made from petroleum. LDPE is defined by a density

range of 0.910 - 0.940 g/cc. This results in a lower tensile strength and increased ductility.

LDPE is used for both rigid containers and plastic film applications such as plastic bags and

film wrap. It was the first grade of polyethylene, produced in 1933 by Imperial Chemical

Industries (ICI) using a high pressure process via free radical polymerization. Its manufactureemploys the same method today.

Schematic diagram:-

Manufacturing Processp:-

Production of LDPE by addition polymerization requires:

o temperature range of 100-300oC

o very high pressure 1500-3000 atmospheres

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5 | Polyethylene

o oxygen or an organic peroxide such as dibutyl peroxide, benzoyl peroxide or

diethyl peroxide as initiator.

An initiator is a substance which is added in small quantities and is decomposed by

light or heat to produce a free radical (R .). A free radical is formed when a covalent bond is

broken and a bonding electron is left on each part of the broken molecule. Since the O-O

covalent bond is weak, free radicals are easily formed from oxygen or peroxides.

Benzene or chlorobenzene used as the solvent since both polymer (polythene) and

monomer (ethene) dissolve in these compounds at the temperature and pressure used.

Water or other liquids may be added to dissipate the heat of reaction as the polymerization

reaction is highly exothermic.

CH2=CH2

ethene+

R.

initiator-----> .CH2-CH2-R

CH2=CH2 + .CH2-CH2-R -----> .CH2-CH2-CH2-CH2-R

Process continues to form polythene (polyethylene) [-CH2-CH2-]n

Properties:-

 Melting Point :- ~115oC

Tensile strength (MPa):- 26.5

Crystallinity:- Low crystallinity (50-60% crystalline). Main chain contains many side

chains of 2-4 carbon atoms leading to irregular packing and low crystallinity

(amorphous).

 Flexibility:- More flexible than HDPE due to lower crystallinity.

Strength:- Not as strong as HDPE due to irregular packing of polymer chains.

 Heat Resistance:- Retains toughness & pliabilty over a wide temperature range,

but density drops off dramatically above room temperature.

Transparency:- Good transparency, since it is more amorphous (has non-

crystalline regions) than HDPE.

 Density:- 0.91-0.94 g/cm

3

, lower density than HDPE.

Chemical Properties:- Chemically inert. Insolvent at room temperature in most

solvents. Good resistance to acids and alkalis. Exposure to light and oxygen

results in loss of strength and loss of tear resistance.

Tensile elongation at rupture (%):- 906

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6 | Polyethylene

More Properties:-

∑ It is not reactive at room temperatures, except by strong oxidizing agents, and some

solvents cause swelling.

∑ LDPE has more branching (on about 2% of the carbon atoms) than HDPE,  so its

intermolecular forces (instantaneous-dipole induced-dipole attraction) are weaker.

∑ Its tensile strength is lower.

∑ Its resilience is higher.

∑ Since its molecules are less tightly packed and less crystalline because of the side

branches, its density is lower.

∑ Good toughness at a variety of temperatures.

∑ Good formability and pliability.

∑ Exceptional resistance to stress cracking.

End Uses:-

∑ LDPE is widely used for manufacturing various containers, dispensing bottles, wash

bottles, tubing, plastic bags for computer components, and various molded laboratory

equipment. Its most common use is in plastic bags.

∑ Food Storage Containers.

∑ Laboratory Equipment.

∑ Disposable Thermoformed Products.

∑ Corrosion Resistant Work Surfaces.

∑ Sandwich bags, cling wrap, car covers, squeeze bottles, liners for tanks and ponds,

moisture barriers in construction

Difference b/w HDPE & LDPE:-

 LDPE is softer, more flexable and melts at lower temperatures than HDPE. LDPE is

used for things like sandwich bangs.

 HDPE is harder, has a higher chemical resistance and can withstand higher

temperatures. (120 Degrees Celsius for short periods and 110 Degrees Celcuis continiously)

 It is used for things like Plastic bins.