POLYMER INDUSTRY

Introduction
Polymer:
The simplest definition of a polymer is a useful chemical made of many repeating
units. A polymer can be a three-dimensional network, two-dimensional network
or one-dimensional network. Each repeating unit is the “-mer” or basic unit with
“poly-mer” meaning many repeating units. Repeating units are often made of
carbon and hydrogen and sometimes oxygen, nitrogen, sulfur, chlorine, fluorine,
phosphorus, and silicon.
 Example:
Starch, cellulose, and rubber all possess polymeric properties.

Polymer Industry:
Polymer production is one of the most important areas of applied chemistry due
to its significant economic and social impact Natural and synthetic polymers, such
as plastics, elastomers, and some adhesives, are manufactured by the polymer
industry. They range from common materials like polyethylene or PVC up to
highly specialized and pricey materials for purposes like medication release or
spacecraft. Current applications extend from adhesives, coatings, foams, and
packaging materials to textile and industrial fibers, composites, electronic devices,
biomedical devices, optical devices, and precursors for many newly developed
high-tech ceramics.
History:
 Henri Branconnot’s work from the 1830s is the first instance of polymer
science in the contemporary era.
 By using synthetic materials, John Wesley Hyatt created the first polymer in
1869.
 Hyatt discovered a plastic that could be molded into a variety of shapes and
made to resemble natural materials like tortoiseshell, horn, linen, and ivory by
processing cellulose, which is produced from cotton fiber, with camphor.
 Bakelite, the first wholly synthetic material that contains no molecules from
the natural world, was created in 1907 by Leo Baekeland.
 In 1922, Hermann Staudinger proposed that polymers consisted of long chains
of atoms held together by covalent bonds, an idea which did not gain wide
acceptance for over a decade and for which Staudinger was ultimately
awarded the Nobel Prize.
 Major chemical corporations invested in the study and development of new
polymers like celluloid and Bakelite as a result of the success of Hyatt and
Baekeland.
 Wallace Carothers created nylon in 1935 as a synthetic silk.
 Oil embargoes drove consumers and companies to refocus on biodegradable
plastics in the 1970s.
 Today plastics are renowned for their sustainability, strength and design
flexibility, finding unique and innovative applications in sectors ranging from
 healthcare and medicine, consumer technology, automotive, packaging,
aerospace, building and construction and everything in between.
Physical Properties of Polymer
 Flexibility: Polymers have a high range of flexibility. They are ranging from
highly flexible elastomers (e.g., rubber) to rigid plastics (e.g., polyvinyl
chloride).
 Melting and Boiling Points: High melting and boiling points are the
characteristic of polymers. Longer chains polymers have stronger
intermolecular forces, and thus having higher melting and boiling points. 
Hardness: Hard polymers are resistant to hard substances penetrating them.
They are employed in the construction of electronics and can tolerate wear
and tear as well as scratches.
 Density: Polymers can have varying densities. They are ranging from
lowdensity polymers (e.g., polyethylene) to high-density polymers (e.g.,
polypropylene
Chemical Properties of Polymer
 Reactivity and bonding –Properties such as reactivity and bonding are
determined by the strong covalent link and various weak forces between
polymer particles, such as hydrogen bonding. Polymers are chemically robust
in general due to their low reactivity.
 Biodegradability–Decomposers can decompose polymers. Biodegradable
polymers, such as rubber, are biodegradable, but synthetic polymers are not
biodegradable.
 Resistance to Chemicals- Polymers can exhibit different levels of
resistance to chemicals. Some polymers are highly resistant to acids, bases,
solvents, and other chemicals, while others may be more susceptible to
chemical attack.
 Flammability- Polymers have varying flammability characteristics. Some
polymers are highly flammable, while others are flame-retardant or
selfextinguishing.
Development of polymers
Polymer development involves the creation and advancement of various
types of polymers, which are large molecules, composed of repeating subunits.
Polymers can be naturally occurring or synthetically produced. The development of
polymers has undergone significant advancements over time.
In the history cellulose, rubber and proteins which are the natural polymers
were widely used. However, the revolution in this field occurs in 20th century by the
emergence of synthetic polymers. The development of synthetic polymers, such as
polyethylene, polypropylene, and polystyrene, opened new possibilities in
materials science and manufacturing.
Several key processes are involved in polymer development. The main
method for producing polymers is polymerization, where monomers (small
molecules) undergo chemical reactions to form long chains or networks. There are
different polymerization techniques, including addition polymerization,
condensation polymerization, and ring-opening polymerization.
Advancements in polymer development have focused on improving
properties such as strength, flexibility, heat resistance, electrical conductivity, and
biocompatibility. Researchers have explored various polymerization methods,
copolymerization techniques, and the use of additives to achieve desired
properties.
Developed for specific applications specialized polymers have been
developed. For example, polyethylene terephthalate (PET) is used in plastic bottles,
polyvinyl chloride (PVC) in pipes and cables, and polyethylene glycol (PEG) in
pharmaceuticals and cosmetics.
The development of polymer composites, which combine polymers with other
materials like fibers or nanoparticles, has also gained attention. These composites
offer enhanced mechanical properties and functionality for applications in
industries such as aerospace, automotive, and construction.
 Additionally, efforts are being made to develop sustainable and
environmentally friendly polymers. Biodegradable polymers, derived from
renewable resources like plant starches or polylactic acid (PLA), are being explored
as alternatives to conventional plastics.
Overall, the development of polymers has progressed through continuous
research, improved synthesis techniques, and a focus on tailoring properties to
meet diverse application requirements.
Polymer Manufacturing Process:

The following steps are commonly included in the chemical process used in the
industry to produce polymers:
 Production of Monomers:
Polymers can be created from monomers, which are tiny molecules that can
chemically link together. Various techniques, such as petrochemical
refinement or fermentation processes, can be used to produce monomers.
The monomers go through a process called polymerization to create vast
chains of reoccurring units, or polymers. Different methods, such as addition
polymerization, condensation polymerization, or a mix of the two, can lead to
polymerization.
 Initiation: A particular catalyst or initiator is added to the monomers during
the initiation step, which is the first step in the polymerization process. By
starting the creation of reactive species, like free radicals or ions, the initiator
starts the reaction.
 Propagation: The reactive species participate in the propagation phase. The
reactive species produced at initiation react with additional monomers during
the propagation process, resulting in the expansion of the polymer chain. The
cycle repeats until the majority of the monomers are used up or the target
polymer length is reached.
 Termination: The polymerization reaction is stopped at the termination
phase. Several mechanisms, including combination termination—where two
 polymer chains react with one another—or disproportionation termination—
where an active polymer chain reacts with a monomer unit—can cause this.
 Post-processing: The produced polymer may go through purification, drying,
and shaping processes after polymerization. These procedures assist in purging
impurities, modifying the polymer's characteristics, and creating the finished
product.
It is crucial to keep in mind that the precise chemical procedure used to produce
polymers can change depending on the kind of polymer, the intended qualities,
and the business concerned. Additionally, a variety of modifications and additives
may be added before, during, or after the polymerization process to improve the
performance of the polymer or accomplish properties.
The cost of producing polymers:
The cost of producing polymers in the business can vary greatly based on a
number of variables, such as:
1. Raw Materials
2. Energy Prices
3. Scale of Production
4. Process Effectiveness
5. Labour and administrative costs
6. Market circumstances
It's crucial to remember that the price of polymers might differ greatly based on
the particular type of polymer, its intended use, location, and other elements
unique to the business. Without detailed information on the polymer and
production context, it is difficult to estimate an accurate cost.
Storing and transporting polymers:
In the industry, the following factors are often taken into account when storing
and transporting polymers:
 Packaging: Depending on the nature and form of the polymer, bulk
containers like bags, drums, or huge bags are frequently used to pack
polymers. When being stored and transported, the polymer should be
shielded from moisture, contaminates, and physical damage by the packing.
 Storage Requirements: To preserve polymers' quality and stop
degradation, they should be kept in a regulated atmosphere. Temperature,
humidity, and light exposure should all be carefully controlled variables. Some
polymers could need particular storage conditions, such refrigeration or UV
protection.
 Necessary tools: Polymers should be handled and transported carefully to
prevent damage and guarantee their integrity. To avoid spills, contamination,
or moisture exposure, this may entail utilizing the necessary tools, like forklifts
or conveyor systems, and handling materials properly.
Safety precautions:
The following safety precautions are used when handling and working with
polymers in industrial settings:
1. Workers should put on the proper personal protective equipment (PPE),
such as gloves, lab coats, safety goggles, and respiratory protection, as
needed. Depending on the type of polymer and the operation being
performed, different PPE requirements may apply.
2. To prevent and eliminate potentially harmful vapors, gases, or dust
particles produced during the handling or processing of polymers, adequate
ventilation systems should be in place.
3. Hazard Communication: Employers must tell workers in a transparent and
thorough manner about the risks connected to the particular polymers they
are using. Information on safe handling, storage, and emergency measures
should be included in safety data sheets (SDS), which should be easily
accessible.
4. Employees should obtain enough instruction on handling polymers,
including knowledge of the risks, safe work practices, emergency
procedures, and the correct use of equipment. To make sure that people
are aware of and knowledgeable about safety procedures, ongoing
education and refresher training should be offered.