DESC:FIELD
The present disclosure relates to a polymer blend composition and a process for preparation thereof.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Atactic: Atactic polymers are polymers in which the side chains are arranged randomly along the backbone chain.
Isotactic: Isotactic polymers are polymers in which the side chains are arranged on one side of the backbone chain.
Syndiotactic: Syndiotactic polymers are polymers in which the side chains are arranged alternatively on both sides of the backbone chain.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Polypropylene sold for commercial purposes invariably contains additives. Additives like antacids and antioxidants are added to ensure proper processing of polypropylene in commercial extruders. Other additives that may be incorporated are dependent on the processing parameters or physical properties desired. Fillers and/or reinforcement agents are added, where the primary goal is “value addition” to polypropylene/recycled plastics.
Fillers are additives in the solid form, used typically to occupy space in the polymer, increase bulk density of the polyemr, thereby lowering the cost of polymer. Such fillers are generally known as inert/extender fillers. Further, certain active fillers may be employed to produce specific improvements in the physical, mechanical or thermal properties of polypropylene. Generally, the active fillers used are inorganic in nature and are selected from various forms of hydrated oxides, glass, metal powder, asbestos, calcium carbonate (CaCO3), wollastonite, talc and mica. Reinforcement agents are a specific type of active fillers used to increase the tensile strength and flexural modulus of polypropylene. Generally, glass fibers are used as a reinforcing agent to reinforce into polypropylene.
However, the incorporation of, and reinforcement with, such fillers may lead to certain disadvantages, one being an economic disadvantage, due to the cost of the filler is excessively high, and the other being a technical disadvantage, due to the improvement made in the properties by reason of the filler is at the expense of other properties, which is often the case.
Therefore, there is felt a need for an alternative polymer blend that mitigates the aforestated drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide a polymer blend composition having better thermal and flexural properties.
Still another object of the present disclosure is to provide a polymer blend composition that is cost efficient and economical.
Yet another object of the present disclosure is to provide a process for the preparation of polymer blend composition.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a polymer blend composition comprising at least one polymer resin, at least one filler and at least one additive. The present disclosure further relates to a process for preparing the polymer blend composition. The process comprises the steps of mixing at least one polymer resin, a pulverized form of at least one filler and at least one additive to obtain a mixture. The mixture is processed by a method selected from twin screw extrudation and compression moulding at a predetermined temperature and a predetermined pressure to obtain the polymer blend composition.
DETAILED DESCRIPTION
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
Polymer is commonly used in combination with other materials such as fillers or reinforcing agents to improve its properties and increase its suitability for specific applications. Addition of filler/reinforcing agent is aimed not only to fill the polymer matrix with small particles, but also to modify the matrix texture as a result of interaction between the polymer molecules with the particles of filler/reinforcing agent during processing. By addition of proper filler, it is then possible to produce modified polymer with improved properties, such as thermal and mechanical properties. Most of fillers such as carbon nanotube, carbon fiber, carbon filament, etc., have high strength. However, these fillers are expensive and complicate the process for making the composite.
Petroleum coke, abbreviated as coke or pet coke, is a final carbon-rich solid material derived from oil refining, and is one type of the group of fuels referred to as coke. Pet coke is the coke that, in particular, derives from a final cracking process; a thermo-based chemical engineering process that splits long chain hydrocarbons of petroleum into shorter chains which takes place in coker units. Disposal of pet coke must be done in a precise and safe manner. Dust emanating from pet coke can be hazardous to human health. Dust particles have size less than 10 µm can lodge themselves in the respiratory tract of humans and this may have serious health effects. Also, pet coke has a high sulphur content which presents an environmental hazard at the time of combustion of pet coke. Therefore, there is a need for safe disposal as well as further utilization of the pet coke.
Further, zeolites are hydrated aluminosilicate mineral with a relatively open, three-dimensional crystal structure having water molecules trapped within. Synthetic zeolites have also been designed for specific purposes. Importantly, zeolites are used as catalysts in the petrochemical industry, where they are used in catalytic crackers to break large hydrocarbon molecules into gasoline, diesel, kerosene, waxes and all kinds of other byproducts of petroleum. However, there is always formation and retention of heavy by-products, particularly coke, which causes catalyst deactivation. This deactivation is due to the poisoning of the acid sites and/or pore blockage. It is important to ensure proper handling and adequate disposal of the deactivated zeolites.
At present, there are no polymer blends that incorporate calcined pet coke and/or deactivated zeolite therein.
The present disclosure therefore, provides a polymer blend composition that utilizes cost effective materials as fillers and provides better thermal and flexural properties.
In a first aspect, the present disclosure provides a polymer blend composition comprising at least one polymer resin, at least one filler and at least one additive.
The polymer resin is at least one selected from the group consisting of polypropylene (PP) and recycled plastics based on PP, polyethylene (PE), polypropylene random co-polymer (PP-RCP), acrylonitrile butadiene styrene (ABS), low density polyethylene (LDPE), high impact polystyrene (HIPS), nylon plastics and polycarbonate (PC).
In an exemplary embodiment of the present disclosure, the polymer resin is polypropylene. The properties of the polypropylene resin used are given below in Table 1.
TABLE 1: Properties of Polypropylene Resin
Property Typical Value
MFI, g/10 min, ASTM D 1238-B 12.0
Xylene solubility, %, ASTM D 5492 3.20
In accordance with an embodiment of the present disclosure, the polypropylene resin is selected from the group consisting of atactic polypropylene, isotactic polypropylene and syndiotactic polypropylene.
In another exemplary embodiment of the present disclosure, the polymer resin is recycled plastics based on PP, PP-RCP, ABS, and LDPE.
The filler is at least one selected from calcined pet coke and deactivated zeolite.
In an exemplary embodiment of the present disclosure, the filler is calcined pet coke in a pulverized form. The properties of the pulverized pet coke used are given below in Table 2.
TABLE 2: Properties of Calcined Pet Coke
Density 1330Kg/m3
Sulfur content 7.5%
Carbon content 92.30%
Particle size distribution Diameter on cumulative %
(1)10.00 (%)- 18.9133 (µm)
(2)50.00 (%)- 310.9392 (µm)
(3)90.00 (%)- 712.5994 (µm)
(4)30.00 (%)- 153.6578 (µm)
(5)40.00 (%)- 232.3935 (µm)
(6)60.00 (%)- 386.3794 (µm)
(7)70.00 (%)- 464.1223 (µm)
(8)80.00 (%)- 560.2008 (µm)
(10)95.00 (%)- 864.7938 (µm)

Cumulative % at diameter
(1)20.00 (µm)- 10.701(%)
(2)38.00 (µm)- 16.323(%)
(3)53.00 (µm)- 18.336(%)
(4)75.00 (µm)- 20.794(%)
(5)90.00 (µm)- 22.441(%)
(6)106.0 (µm)- 24.279(%)
(7)125.0 (µm)- 26.516(%)
(8)212.0 (µm)- 37.448(%)
Moisture <10PPM
Total volatile matter NIL
Ash Content <0.5 %
In another exemplary embodiment of the present disclosure, the filler is deactivated zeolite in a pulverized form. The properties of pulverized deactivated zeolite used are given below in Table 3.
Table 3: Properties of Deactivated Zeolite
Density 0.90g/cc (average)
Particle size distribution Cumulative % at diameter
(1)20.00 (µm)- 0.701(%)
(2)38.00 (µm)- 9.961(%)
(3)53.00 (µm)- 24.741(%)
(4)75.00 (µm)- 49.424(%)
(5)90.00 (µm)- 63.863(%)
(6)106.0 (µm)- 74.882(%)
(7)125.0 (µm)- 83.402(%)
(8)212.0 (µm)- 97.214(%)
Diameter on cumulative %
(1)10.00 (%)- 38.0522 (µm)
(2)50.00 (%)- 75.5464 (µm)
(3)90.00 (%)- 148.8665 (µm)
(4)30.00 (%)- 57.6861 (µm)
(5)40.00 (%)- 66.5089 (µm)
(6)60.00 (%)- 85.6092 (µm)
(7)70.00 (%)- 98.1203 (µm)
(8)80.00 (%)- 115.9189 (µm)
(10)95.00 (%)- 183.1523 (µm)
Composition SiO2: 28.5%
AL2O3: 64.5%
Fe2O3: 2.3%
MgO: 0.8%
Rest: Other metal oxides
Total volatile matter NIL
In an embodiment of the present disclosure, the pulverized filler have a particle size in the range of 10 µm to 900 µm. The pulverized filler have particle size distribution as illustrated in the tables 2 and 3.
The additive is at least one selected from an antioxidant and a processing aid.
In an embodiment of the present disclosure, the antioxidant is at least one selected from pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate] (commercially available as AO-1010) and tris(2,4-di-tert-butylphenyl)phosphite (commercially available as Phosphite 168). In an exemplary embodiment, the antioxidant is pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate] (commercially available as AO-1010). In another exemplary embodiment, the antioxidant is tris(2,4-di-tert-butylphenyl)phosphite (commercially available as Phosphite 168).
In an embodiment of the present disclosure, calcium stearate is used as the processing aid.
In an embodiment of the present disclosure, a ratio of the polymer resin to the filler is in range of 1:1 to 9:1. In an exemplary embodiment of the present disclosure, the ratio of the polymer resin to the filler is 2.3:1.
In an embodiment of the present disclosure, the polymer blend composition comprises 30% to 95% by weight of polypropylene resin with respect to the total weight of the composition, 4% to 60% by weight of at least one filler with respect to the total weight of the composition and 0.1% to 1% by weight of at least one additive with respect to the total weight of the composition.
In a second aspect, the present disclosure provides a process for preparing the polymer blend composition.
The process comprises the step of mixing at least one polymer resin, a pulverized form of at least one filler and at least one additive to obtain a mixture.
The mixture is processed by a method selected from twin screw extrudation and compression moulding at a predetermined temperature and at a predetermined pressure to obtain the polymer blend composition.
In an embodiment of the present disclosure, the predetermined temperature is in the range of 220 °C to 250 °C.
In an embodiment of the present disclosure, the predetermined pressure is in the range of 500 psi to 900 psi.
In an exemplary embodiment of the present disclosure, the predetermined temperature is 230 °C and the predetermined pressure is 600 psi.
In an embodiment of the present disclosure, the processing of the mixture is carried out by twin screw extrudation when the amount of filler is in the range of 4% to 20% by weight with respect to the total weight of the composition.
In another embodiment of the present disclosure, the processing of the mixture is carried out by compression moulding when the amount of filler is in the range of 21% to 60% by weight with respect to the total weight of the composition.
In an embodiment of the present disclosure, the predetermined screw speed is in the range of 300 to 500 rpm. In an exemplary embodiment of the present disclosure, the predetermined screw speed is 400 rpm.
The polymer blend of the present disclosure incorporates waste materials and/or by-products like calcined pet coke and deactivated zeolite as fillers and thereby helps in overcoming the environmental limitations of pet coke burning and ensuring safe disposal of deactivated zeolites.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Experiment 1: Preparation of the polymer blend composition comprising polypropylene + Calcined Petcoke + an additive
A. Preparation of the polymer blend composition by twin screw extrudation method.
Comparative example 1: Polypropylene 99.8% + additive 0.2%
998 g of Polypropylene (99.8%) and 2 g calcium stearate were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 220 °C and at a pressure of 600 psi to obtain an extrudate of polypropylene.
Example 2: Polypropylene 89.8% + Calcined Petcoke 10% + additive 0.2%
898 g of Polypropylene (89.8%), 100 g of calcined petcoke (10%), in pulverized form and 2 g of calcium stearate were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 230 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 3: Polypropylene 79.8% + Calcined Petcoke 20% + 0.2% additive
798 g of Polypropylene (80%), 200 g of calcined petcoke (10%), in pulverized form and 2 g of calcium stearate were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 700 rpm, at 225 °C and at a pressure of 600 psi to obtain the polymer blend.
B. Preparation of the polymer blend composition by compression moulding method.
Example 4: Polypropylene 69.8% + Calcined Petcoke 30% + 0.2% additive
698 g of Polypropylene (69.8%) and 300 g of calcined petcoke (30%), in pulverized form and 2 g of phosphite 168 (tris(2,4-di-tert-butylphenyl)phosphate) were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 230 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 5: Polypropylene 59.8% + Calcined Petcoke 40% + 0.2% additive
598 g of Polypropylene (59.8%), 400 g of calcined petcoke (40%), in pulverized form and 2 g of calcium stearate (5%) were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 240 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 6: Polypropylene 49.8% + Calcined Petcoke 50% + 0.2% additive
498 g of Polypropylene (49.8%), 500 g of calcined petcoke (50%), in pulverized form and 2 g of AO-1010 (pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate]) were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 240 °C and at a pressure of 700 psi to obtain the polymer blend.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with calcined petcoke filled polypropylene.
The blends prepared in Examples 1 to 6 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 4 and 5.
TABLE 4: Mechanical Properties of Polymer Blend with Calcined Petcoke as Filler
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile Properties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
1 0 1550 35.2 34.8 25.7 23.6 750
2 10 1650 29.8 33.0 25.0 21.5 150
3 20 1750 26.7 30.4 22.8 20.7 140
4 30 1870 23.5 27.0 20.1 19.2 130
5 40 2020 20.2 22.5 16.8 17.3 120
6 50 2150 18.7 18.5 12.5 16.8 110
From table 4, it is observed that Flexural Modulus, at 1% Sec increases with increase in filler %. However, tensile properties decreases with increase in filler %.
Stiffness (or rigidity) is a property of polymers that is described by flexural modulus or bending modulus of elasticity. Flexural Modulus denotes the ability of a material to bend. It is a measure of materials stiffness/resistance to bend when a force is applied perpendicular to the long edge of a sample and also known as the three points bend test. But tensile property test involves the mechanical stretching of the plastic. The filler content may increases the number of weak sites in the plastic and leads to the early failure of the materials to bend at low energy. In the polymer blends of the present disclosure, the fillers imparted more rigidity and hence there is an increase in the flexural properties. But, due to more number of weaker sites in the polymer blends, mechanical strength decreased.
TABLE 5: Thermal Properties of Polymer Blend with Calcined Petcoke as Filler
Example
Filler % Vicat Softening Point (10N) ,°C
ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C
ASTM D 648 Melting Point
By DSC
1 0 153.0 98.2 166.3
2 10 154.5 105.1 167.2
3 20 156.1 108.3 167.9
4 30 157.2 112.3 168.8
5 40 158.5 116.8 169.3
6 50 159.3 122.0 170.3
It is evident from the results shown in Tables 4 and 5, that the polymer blend exhibits improved mechanical and thermal properties in proportion to the percentage of calcined petcoke present in the polymer blend.
Experiment 2: Preparation of the polymer blend composition comprising polypropylene + deactivated zeolite + an additive
A. Preparation of the polymer blend composition by twin screw extrudation method.
Example 7: Polypropylene 99% + 1% additive (Comparative example)
990 g of Polypropylene (98%) and 10 g of phosphite 168 (1%) were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400, at 220 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 8: Polypropylene 89.8% + deactivated zeolite 10% + 0.2% additive
898 g of Polypropylene (90%), 100 g of deactivated zeolite (10%), in pulverized form and 2 g of AO-1010 were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 225 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 9: Polypropylene 79.8% + deactivated zeolite 20% + 0.2% additive
798 g of Polypropylene (79.8%) and 200 g of deactivated zeolite (20%), in pulverized form and 2 g of calcium stearate were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 500 rpm, at 230 °C and at a pressure of 600 psi to obtain the polymer blend.
B. Preparation of the polymer blend composition by compression moulding method.
Example 10: Polypropylene 69.8% + deactivated zeolite 30% + 0.2% additive
698 g of Polypropylene (69.8%), 300 g of deactivated zeolite (30%), in pulverized form and 1 g each of calcium stearate and AO-1010 were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 240 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 11: Polypropylene 59.8% + deactivated zeolite 40% + 0.2% additive
598 g of Polypropylene (59.8%) and 400 g of deactivated zeolite (40%), in pulverized form and 2 g of calcium stearate were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 250 °C and at a pressure of 500 psi to obtain the polymer blend.
Example 12: Polypropylene 49.8% + deactivated zeolite 50% + 0.2% additive
498 g of Polypropylene (49.8%) and 500 g of deactivated zeolite (50%), in pulverized form and 2 g of phosphite 168 were mixed to obtain a mixture. The mixture was subjected to the compression moulding at 250 °C and at a pressure of 600 psi to obtain the polymer blend.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with deactivated zeolite filled polypropylene.
The blends prepared in Examples 7 to 12 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 6 and 7.
TABLE 6: Mechanical Properties of Polymer Blend with Deactivated Zeolite as Filler
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile Properties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
7 0 1550 35.2 34.8 25.7 23.6 750
8 10 1620 30.9 32.7 24.1 22.4 160
9 20 1690 27.8 30.1 22.2 21.1 150
10 30 1820 24.7 26.8 19.5 20.2 140
11 40 1910 21.6 22.3 16.1 18.8 130
12 50 2080 19.8 19.2 13.7 17.8 120
TABLE 7: Thermal Properties of Polymer Blend with Deactivated Zeolite as Filler
Example
Filler % Vicat Softening Point (10N) ,°C
ASTM D 1525 Heat Deflection Temperature (0.455MPa), °C
ASTM D 648 Melting Point
By DSC
7 0 153.0 98.2 166.3
8 10 153.8 107.5 167.5
9 20 155.4 123.8 168.1
10 30 156.2 127.6 168.8
11 40 157.3 131.2 169.0
12 50 158.2 135.3 169.5
It is evident from the results shown in Tables 6 and 7, that the polymer blend exhibits improved mechanical and thermal properties in proportion to the percentage of deactivated zeolite present in the polymer blend.
Experiment 3: Preparation of the polymer blend composition comprising PP raffia based recycled plastic + calcined petcoke + an additive by twin screw extrudation method
Example 13: PP raffia based recycled plastic 99.8% + 0.2% additive (Comparative example)
998 g of PP raffia based recycled plastic (99.8%) and 2 g of calcium stearate (0.2%) were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 240 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 14: PP raffia based recycled plastic 94.8% + Calcined Petcoke 5% + 0.2% additive
948 g of PP raffia based recycled plastic (94.8%) and 50 g of calcined petcoke (5%), in pulverized form and 1 g each of AO-1010 and phosphate 168 were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 240 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 15: PP raffia based recycled plastic 89.8% + Calcined Petcoke 10% + 0.2% additive
898 g of PP raffia based recycled plastic (89.8%), 100 g of calcined petcoke (10%), in pulverized form and 2 g of AO-1010 were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 500, at 240 °C and at a pressure of 600 psi to obtain the polymer blend.
Example 16: PP raffia based recycled plastic 79.8% + Calcined Petcoke 20% + 0.2% additive
798 g of PP raffia based recycled plastic (79.8%) and 200 g of calcined petcoke (20%), in pulverized form and 2 g of calcium stearate were mixed to obtain a mixture. The mixture was fed into the twin screw extruder with a screw speed of 400 rpm, at 240 °C and at a pressure of 700 psi to obtain the polymer blend.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with calcinated petcoke filled PP raffia based recycled plastic
The blends prepared in Examples 13 to 16 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 8 and 9.
TABLE 8: Mechanical properties of calcinated petcoke Filled PP raffia based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa

ASTM D 790-B Izod Impact Strength, N, J/m

ASTM D 256 Tensile Properties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
13 0 1450 32.2 32.8 23.7 22.6 150
14 5 1640 27.1 31.0 22.0 20.1 110
15 10 1800 25.3 28.4 21.6 18.1 90
16 20 1900 21.4 26.0 18.2 17.2 70
TABLE 9: Thermal properties of calcinated petcoke PP recycled raffia waste
Example
Filler % Vicat Softening Point (10N) ,°C
ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C
ASTM D 648 Melting Point
By DSC
13 0 153.1 96.2 166.0
14 5 153.6 103.1 166.2
15 10 155.8 110.3 166.8
16 20 157.2 112.0 167.4
Experiment 4: Preparation of the polymer blend composition comprising PP raffia based recycled plastic + deactivated zeolite + an additive by twin screw extrudation method
Example 17-20: Same experimental procedure was followed as described in Examples 13-16 respectively, except that the deactivated zeolite was used.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with deactivated zeolite Filled PP raffia based recycled plastic
The blends prepared in Examples 17 to 20 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 10 and 11.
TABLE 10: Mechanical properties of deactivated zeolite Filled PP raffia based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa

ASTM D 790-B Izod Impact Strength, N, J/m

ASTM D 256 Tensile Properties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
17 0 1450 32.2 32.8 23.7 22.6 150
18 5 1600 28.9 30.4 22.1 21.3 110
19 10 1660 27.6 28.1 20.3 20.1 60
20 20 1740 23.7 24.7 17.6 19.6 40
TABLE 11: Thermal properties of deactivated zeolite Filled PP raffia based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C

ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C

ASTM D 648 Melting Point

By DSC
17 0 153.1 96.2 166.0
18 5 154.3 100.4 166.8
19 10 154.8 118.2 166.8
20 20 154.7 122.3 170.1
Experiment 5: Preparation of the polymer blend composition comprising PP-RCP based recycled plastic + calcined petcoke + an additive by twin screw extrudation method
Examples 21-24: Same experimental procedures were followed as described in Examples 13-16 respectively, except that the PP-RCP based recycled plastic was used.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with calcinated petcoke Filled PP-RCP based recycled plastic
The blends prepared in Examples 21 to 24 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 12 and 13.
TABLE 12: Mechanical properties of calcinated petcoke filled PP-RCP based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m ASTM D 256 Tensile Proparties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
21 0 1440 31.2 30.1 24.7 24.5 80
22 5 1540 28.1 26.4 20.0 18.4 65
23 10 1680 27.1 23.4 16.1 16.2 30
24 20 1750 20.2 20.1 14.2 14.8 <10
TABLE 13: Thermal properties of calcinated petcoke filled PP-RCP based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C
ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C
ASTM D 648 Melting Point
By DSC
21 0 150.0 86.2 166.3
22 5 152.6 94.1 167.2
23 10 153.8 98.1 167.8
24 20 155.2 102.4 167.8
Experiment 6: Preparation of the polymer blend composition comprising PP-RCP based recycled plastic + deactivated zeolite + an additive by twin screw extrudation method
Examples 25-28: Same experimental procedures were followed as described in Examples 17-20 respectively, except that the PP-RCP based recycled plastic was used.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with deactivated zeolite filled PP-RCP based recycled plastic
The blends prepared in Examples 25 to 28 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 14 and 15.
TABLE 14: Mechanical properties of deactivated zeolite filled PP-RCP based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile Proparties, ASTM D-638, Type 1 specimen, 50mm/min
Tensile Strength, (UTS), MPa Tensile Strength at Yield, MPa Tensile Strength at Break, MPa Tensile Elongation at Break, %
25 0 1440 31.2 30.1 24.7 24.5 80
26 5 1550 27.5 30.4 22.1 21.3 55
27 10 1650 26.2 28.1 20.3 20.1 30
28 20 1700 22.1 24.7 17.6 19.6 20
TABLE 15: Thermal properties of deactivated zeolite filled Filled PP-RCP based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C

ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C

ASTM D 648 Melting Point

By DSC
25 0 150.0 86.2 166.3
26 5 153.3 96.4 166.2
27 10 153.8 98.2 166.7
28 20 154.0 108.3 168.1
Experiment 7: Preparation of the polymer blend composition comprising LDPE based recycled plastic + calcined petcoke + an additive by twin screw extrudation method
Examples 29-32: Same experimental procedures were followed as described in Examples 13-16 respectively, except that the LDPE based recycled plastic was used and the temperature was set at 200 °C.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with calcinated petcoke Filled LDPE based recycled plastic
The blends prepared in Examples 29 to 32 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 16 and 17.
Table 16: Mechanical properties of calcinated petcoke filled LDPE based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile strength, UTS, MPa, ASTM D-638, Type 1 specimen, 50mm/min
29 0 350 16 12
30 5 560 11 7
31 10 620 <10 5
32 20 750 <10 4
Table 17: Thermal properties of calcinated petcoke filled LDPE based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C

ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C

ASTM D 648 Melting Point

By DSC
29 0 92 52 118
30 5 92.5 53 119.1
31 10 92.8 56 119.5
32 20 93.1 58 119.8
Experiment 8: Preparation of the polymer blend composition comprising LDPE based recycled plastic + deactivated zeolite + an additive by twin screw extrudation method
Examples 33-36: Same experimental procedures were followed as described in Examples 17-20 respectively, except that the LDPE based recycled plastic was used.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with deactivated zeolite filled LDPE based recycled plastic
The blends prepared in Examples 33 to 36 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 18 and 19.
Table 18: Mechanical properties of deactivated zeolite with Recycled LDPE
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile strength, UTS, MPa, ASTM D-638, Type 1 specimen, 50mm/min
33 0 350 16 12
34 5 520 12 8
35 10 630 10 6
36 20 820 <10 4
Table 19: Thermal properties of deactivated zeolite filled LDPE based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C

ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C

ASTM D 648 Melting Point

By DSC
33 0 92.0 52 118
34 5 92.0 52 118.2
35 10 92.6 54 118.5
36 20 93.0 58 118.9
Experiment 9: Preparation of the polymer blend composition comprising ABS based recycled plastic + calcined petcoke + an additive by twin screw extrudation method
Examples 37-40: Same experimental procedures were followed as described in Examples 13-16 respectively, except that the ABS based recycled plastic was used and the temperature was set at 220 °C.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with calcinated petcoke filled ABS based recycled plastic
The blends prepared in Examples 37 to 40 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 20 and 21.
Table 20: Mechanical properties of calcinated petcoke filled ABS based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile strength, UTS, MPa, ASTM D-638, Type 1 specimen, 50mm/min
37 0 1900 120 56
38 5 1980 118 48
39 10 2080 96 36
40 20 2340 83 28
Table 21: Thermal properties of calcinated petcoke filled ABS based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C

ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C

ASTM D 648 Melting Point

By DSC
37 0 101.2 89 218.1
38 5 102.1 92 218.3
39 10 102.5 94 219.0
40 20 102.8 98 219.3
Experiment 10: Preparation of the polymer blend composition comprising ABS based recycled plastic + deactivated zeolite + an additive by twin screw extrudation method
Examples 41-44: Same experimental procedures were followed as described in Examples 17-20 respectively, except that the PP-RCP based recycled plastic was used and the temperature was set at 225 °C.
Analysis Study: Determination of the mechanical and thermal properties of polymer blend with deactivated zeolite filled ABS based recycled plastic
The blends prepared in Examples 41 to 44 were subjected to standard test methods to determine their mechanical and thermal properties as tabulated in Tables 22 and 23.
Table 22: Mechanical properties of deactivated zeolite filled ABS based recycled plastic
Example
Filler % Flexural Modulus, at 1% Sec, Mpa
ASTM D 790-B Izod Impact Strength, N, J/m
ASTM D 256 Tensile strength, UTS, MPa, ASTM D-638, Type 1 specimen, 50mm/min
41 0 1900 120 56
42 5 2120 114 53
43 10 2220 108 47
44 20 2350 96 40
Table 23: Thermal properties of deactivated zeolite filled ABS based recycled plastic
Example
Filler % Vicat Softening Point (10N) ,°C
ASTM D 1525 Heat Deflection Temperature (0.455 MPa), °C
ASTM D 648 Melting Point
By DSC
41 0 101.2 89 218.1
42 5 100.2 89 218.6
43 10 100.8 91 218.6
44 20 100.8 95 219.1
In the similar manner, the blends of recycled IM grade PP, recycled Polycarbonate, recycled HIPS and recycled nylon plastics are prepared at their respective processing temperatures and characterized. As per the experimental results there is an increase in the flexural properties of the polymer blends of the present disclosure. Thermal properties of the polymer blends are improved when compared with the corresponding virgin plastics. Hence, in the present disclosure various types of recycled/shredded plastics in appropriate proportions are blended with petcoke or de-activated zeolits (5 to 20%). This is an effective method to manage the recycled plastics in a useful approach and in an economical way.
Basically, the invention as disclosed in the present invention attempts to add value to the pet coke and used/deactivated zeolites. Experimental data shows the properties of the newly prepared blends are comparable with commercially available blends like, PP filled with glass fibre, carbon fibre/black filled, talc filled, and calcium carbonate filled composites. These polymer blends of the present disclosure are capable of resisting corrosion, good flexural/fatigue and less maintenance requirements. The usage of the polymer blends of the present disclosure are typically associated with;
• Strength and light-weight
• Dimensional stability, stiffness and stability for durable performance
• Corrosion resistance
• Lighter weight to reduce operating costs and improve efficiency
• Sound baffling for a less noisy operating environment
• Design flexibility for use in complex shapes
They can be substituted with these commercially available blends. Specifically these blends can find places in the following applications;
• Tiles and roof structures: The experimental results indicate that PP-Petcoke/Zeolite polymer blend of the present disclosure can be used as low cost construction material which could be used as a cheaper substitute to clay bricks, interlocks, roof tiles, floor tiles, shade/seperation structures and various other such building materials. The developed polymer blend of the present disclosure is strong, water proof and is not vulnerable to insect destruction.
• Marine engineering applications: Watercraft, submersibles, offshore structures, and other marine structural components are exposed to relevant environmental challenges. Therefore, polymer blend of the present disclosure exhibit good properties for such applications. Additionally, being lightweight and corrosion resistance, the polymer blend of the present disclosure meet design requirements and perform with better reliability.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a polymer blend composition which:
- has better thermal and flexural properties;
- is economical and environmental friendly; and
- has high strength with light weight.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A polymer blend composition comprising:
a) at least one polymer resin;
b) at least one filler; and
c) at least one additive.
2. The polymer blend composition as claimed in claim 1, wherein said polymer resin is at laeast one selected from the group consisting of polypropylene (PP) and recycled plastics based on PP, polyethylene (PE), polypropylene random co-polymer (PP-RCP), acrylonitrile butadiene styrene (ABS), low density polyethylene (LDPE), high impact polystyrene (HIPS), nylon plastics and polycarbonate (PC).
3. The polymer blend composition as claimed in claim 1, wherein said filler is at least one selected from calcined pet coke and deactivated zeolite.
4. The polymer blend composition as claimed in claim 1, wherein said additive is at least one selected from an antioxidant and a processing aid.
5. The polymer blend composition as claimed in claim 4, wherein said antioxidant is at least one selected from pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate], tris(2,4-di-tert-butylphenyl)phosphite; and said processing aid is calcium stearate.
6. The polymer blend composition as claimed in claim 1, wherein a ratio of said polymer resin to said filler is in range of 1:1 to 9:1.
7. The polymer blend composition as claimed in claim 1, comprising;
a) 30% to 95% by weight of polypropylene resin with respect to the total weight of the composition;
b) 4% to 60% by weight of at least one filler with respect to the total weight of the composition; and
c) 0.1% to 1% by weight of at least one additive with respect to the total weight of the composition.
8. A process for preparing the polymer blend composition, said process comprising the following steps:
i. mixing at least one polymer resin, pulverized form of at least one filler and at least one additive to obtain a mixture; and
ii. processing said mixture by a method selected from twin screw extrudation and compression moulding at a predetermined temperature and a predetermined pressure to obtain the polymer blend composition.
9. The process as claimed in claim 8, wherein said polymer resin is at least one selected from the group consisting of polypropylene (PP) and recycled plastics based on PP, polyethylene (PE), polypropylene random co-polymer (PP-RCP), acrylonitrile butadiene styrene (ABS), low density polyethylene (LDPE), high impact polystyrene (HIPS), nylon plastics and polycarbonate (PC).
10. The process as claimed in claim 8, wherein said filler is at least one selected from the group consisting of calcined pet coke and deactivated zeolite.
11. The process as claimed in claim 8, wherein said pulverized filler have a particle size in the range of 10 µm to 900 µm.
12. The process as claimed in claim 8, wherein said additive is at least one selected from an antioxidant and a processing aid.
13. The process as claimed in claim 12, wherein said antioxidant is at least one selected from pentaerythritol tetrakis[3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate], tris(2,4-di-tert-butylphenyl)phosphite and combination thereof and said processing aid is calcium stearate.
14. The process as claimed in claim 8, wherein said predetermined temperature is in the range of 200 °C to 250 °C.
15. The process as claimed in claim 8, wherein said predetermined pressure is in the range of 500 psi to 900 psi.
16. The process as claimed in claim 8, wherein said processing of said mixture is carried out by twin screw extrudation metho when amount of said filler is in the range of 4% to 20% by weight with respect to the total weight of the composition.
17. The process as claimed in claim 16, wherein said twin screw extrudation is carried out at a screw speed in the range of 300 to 500 rpm.
18. The process as claimed in claim 8, wherein said processing of said mixture is carried out by compression moulding method when amount of said filler is in the range of 21% to 60% by weight with respect to the total weight of the composition.