Plastics
Plastic is a plastic material that can be formed, through the application of heat and pressure. Thanks to this property of plasticity, often combined with other special properties such as low density, electrical conductivity, transparency and toughness, plastics can be made into a wide variety of products. Some such products include strong and lightweight beverage bottles made of polyethylene terephthalate (PET), flexible garden hoses made of polyvinyl chloride (PVC), insulating food containers made of foamed polystyrene and shatterproof windows made of polymethyl methacrylate.
The relatively inexpensive production cost of plastic is one reason why it is so hugely popular. Plastic products are also popular with businesses, for example, plastic packaging for product agents, plastic bags at local retailers and the use of plastic for new products. Plastic is everywhere, the downside of this is that there is a very large amount of plastic litter. Much of this plastic litter ends up in the ocean, among other things, which has a huge impact on the environment.
Recycling of plastics
With consumer awareness comes a much greater focus on recycling plastic. Because of the enormous consumption and production of plastic, a lot of plastic litter is also created indirectly. Many plastic products are made for single use, given the new environmental trends, manufacturers are increasingly working to reduce the waste of raw materials. By recycling different types of plastic with each other, you give plastic products a new life. With this way of producing new plastic from previously used plastic, the impact on the environment is reduced a lot.
Mixing elements for Plastics
Versatile Propeller Mixer for Plastics Production
The Propeller is a workhorse in plastics production, keeping monomers, catalysts, and suspension polymers in uniform suspension inside polymerization reactors. Its axial flow prevents settling and ensures consistent distribution of every component throughout the batch. Energy-efficient and reliable, it adapts to the viscosity changes typical of plastics production without loss of performance.
Gas Inducing Mixer for Plastics Production Reactions
The Gas Inducing Mixer draws gas directly from the headspace back into the liquid phase, boosting gas-liquid mass transfer in plastics production. It is perfectly suited for reactions where oxygen, nitrogen, or process gases must interact efficiently with monomers, catalysts, and suspension polymers. By recirculating gas internally, it raises reaction rates while reducing the need for external sparging systems.
High-Flow Hydrofoil for Plastics Production
The Hydrofoil generates high-volume axial flow, making it a powerful solution for large polymerization reactors in plastics production. It prevents thermal stratification and keeps monomers, catalysts, and suspension polymers in steady motion with minimal turbulence. The optimized blade profile turns drive power into fluid motion efficiently, supporting consistent homogenization at industrial scale.
Reinforced Hydrofoil Pin for Demanding Plastics Production
The Hydrofoil Pin combines proven hydrofoil performance with reinforced pins for tougher substrates encountered in plastics production. Its structural design handles high-viscosity and high-solids zones where standard impellers might struggle, particularly when heat removal and gel formation becomes critical. It delivers reliable mixing where monomers, catalysts, and suspension polymers are demanding to handle.
Reliable Axial Flow Turbine for Plastics Production
The Axial Flow Turbine is a dependable all-rounder for plastics production, ensuring even distribution of heat and additives throughout polymerization reactors. It prevents stagnant zones and keeps monomers, catalysts, and suspension polymers in consistent motion across the vessel. Its cost-effective, robust design makes it a go-to choice for stable, continuous operation in plastics production.
Heavy-Duty Welded Turbine for Plastics Production
Built for maximum durability in continuous plastics production, this welded turbine eliminates bolted connections for superior mechanical integrity. Its smooth profile resists buildup of monomers, catalysts, and suspension polymers and simplifies cleaning and maintenance in polymerization reactors. It is the preferred choice for industrial-scale plastics production that demand long service intervals and high reliability.
Axial Flow Turbine Pin for Challenging Plastics Production
Adapted for plastics production involving fibrous materials or high solids content, this turbine uses reinforced pins to cut through heat removal and gel formation. It maintains an effective mixing zone even when the composition of monomers, catalysts, and suspension polymers varies from batch to batch. An essential element for facilities handling inconsistent or demanding substrates in plastics production.
Double Acting Axial Flow Turbine for Plastics Production
The Double Acting Axial Flow Turbine (MTE) generates both upward and downward flow, doubling mixing intensity in polymerization reactors during plastics production. It eliminates dead zones in vessels with a wide height-to-diameter ratio and ensures complete tank turnover of monomers, catalysts, and suspension polymers. Ideal for operations that demand extra mixing capacity from a single impeller without adding power.
Radial Flow Turbine for Intensive Plastics Production Mixing
The Radial Flow Turbine delivers powerful radial agitation, making it well-suited to plastics production that need high shear and turbulence. It ensures thorough homogenization of monomers, catalysts, and suspension polymers and prevents phase separation in viscous or reactive systems. A proven choice where intensive mixing drives consistent reaction performance across the vessel.
Counterflow Turbine for Complex Plastics Production Homogenization
The Counterflow Turbine creates opposing flow patterns that deliver superior homogenization in plastics production. It prevents the formation of dead zones in polymerization reactors and fully mixes monomers, catalysts, and suspension polymers, even in high-viscosity regimes. Essential when consistent results require an unusually thorough blend of every component.
Rushton Turbine for Intensive Plastics Production Dispersion
The Rushton Turbine is the industry standard for high-shear gas-liquid work in plastics production. It excels at dispersing gases, catalysts, and additives into monomers, catalysts, and suspension polymers inside polymerization reactors, maximizing mass transfer at every stage. The preferred choice when intensive reaction conditions and high power input are needed.
Concave Turbine for Efficient Plastics Production Gas Mixing
The Concave Turbine is an advanced evolution of the Rushton design, delivering improved gas handling in plastics production. Its concave blades prevent gas flooding in polymerization reactors and ensure stable power draw, even at high gas rates with monomers, catalysts, and suspension polymers. Ideal where reliable gas-liquid interaction is critical to process outcome.
Counter Rotating Mixer for Complex Plastics Production
For high-viscosity stages of plastics production, the Counter Rotating Mixer provides intensive homogenization through two impellers turning in opposite directions. It eliminates dead zones in polymerization reactors and creates a highly turbulent environment that fully blends monomers, catalysts, and suspension polymers. The ultimate solution for thick, challenging batches where standard impellers fall short.
Dispersion Turbine for Plastics Production Emulsions
The Dispersion Turbine provides the high-shear mixing required to create stable dispersions and emulsions in plastics production. It breaks down agglomerates and ensures fine particle distribution of monomers, catalysts, and suspension polymers throughout polymerization reactors. A key element in producing plastics production with consistent texture and reliable end-use performance.
Petrochemical Applications
The market development of plastic
The global plastics market was valued at $593.00 billion in 2021. Of this, the market is only expected to grow further in the coming years. This is because the demand for quantity of plastic continues to rise, the growth in demand for plastic is mainly due to increasing plastic consumption in construction, automotive and electronic energy.
Recycling of plastics
Polymers, also known as plastics, are being produced in large industrial volumes. Each manufacturer has its own specific process conditions, though the principle is always the same.
The most known and commercially worldwide produced plastics are Polyethylene (PE) and Polypropylene (PP).
Depending on the production process either High Density PE or Low Density PE can be produced. For the production of polyethylene the process steps can be described as follow:
- Distillation
- Cracking
- Polymerization
- Blending
Atmospheric Distillation
In the first step of this process, crude oil will be heated and guided to a distillation column were the lighter fraction (propene, butane) evaporates. The middle fractions (such as naphtha, kerosene, gasoil) are being taken away for further treatment in other refinery units. The Nafta will be the feed for the next process step.
Cracking
The Nafta is now treated with steam up to temperatures of 875 °C. Nafta will be “cracked” into small size molecules, unsaturated hydrocarbons, such as Ethene, Propene and Butene. These gasses are been separated from each other and the Ethene is guided to a polymerization reactor.
Polymerization
By means of polymerization, polyethene is created in a reactor. This can be done via (free-radical) polymerization at extreme high pressure and high temperature. It has an open structure and is called Low Density polyethylene LDPE. This polymer is soft, transparent en not very strong. Finaly for customers used as bottles, plastic bags etc.
Finally the polyethylene molecules are kept in a residence time pot, to terminate the polymerization reaction. Jongia has designed and manufactured mixers for this type of process and reactors. Reactors/mixers having a design Temperature of 100C and a design Pressure of 5000 kPa. Viscosities generally in the range from 600 – 3500 cP.
The purpose of the mixers is to mix the residence time pots and the slurry feed tanks. Jongia has selected a HDM type for this process, with a coaxial gearbox and flexible coupling between drive en motor. Together with a magnetic coupling (design pressure 50 Barg) this mixer is highly effective as well as efficient.
The mixer type HDM is designed for heavy duty industrial applications. Due to the 2 (or even 3) bearing sections, the HDM type can have relatively long shafts, without bottom bearing. Due to the flexible coupling and double bearing sections, the radial and axial loads are completely absorbed.
References:
LyondellBasell, Sabic, DSM, Ineos, Dow Chemicals, Lanxess
Frequently Asked Questions
What are the main properties of plastics?
Plastics are known for their plasticity, which allows them to be molded with heat and pressure. They also have unique properties such as low density, electrical conductivity, transparency, and toughness, making them suitable for a wide variety of products like beverage bottles and garden hoses.
Why is plastic so widely used?
The relatively low production cost of plastic contributes to its popularity. Businesses often favor plastic for packaging, bags, and various products due to its versatility and affordability, which has resulted in its significant presence across many industries.
What are the environmental concerns related to plastic?
A major concern with plastic is its extensive littering, much of which ends up in oceans, harming wildlife and ecosystems. The widespread use of single-use plastics exacerbates this issue, leading to increased waste and environmental impact.
How does plastic recycling work?
Recycling involves reprocessing used plastics into new products, reducing the need for raw materials. This practice decreases environmental impact by minimizing waste and energy consumption associated with creating new plastic from virgin materials, thus giving plastics a new life.
What is the current market trend for plastics?
In 2021, the global plastics market was valued at $593 billion and is expected to continue growing. The demand for plastic is primarily driven by increased consumption in sectors such as construction, automotive, and electronics, indicating robust market development.
Petrochemical Industry Contacts
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