Slide 1

CCB 4423

Polymer Process EngineeringAP Dr Zakaria Man

(SPECIALISATION ELECTIVE)Lecture 1 : Tuesday 12.00 noon -1.00 pmRoom 20-00-05Lecture 2 : Wednesday 9.00 12.00 am Room 21-02-07 Tutorial : Wednesday 11.00 am 12.00 pm Room 21-02-071Chemical Engineering Programme Outcomes (PO)

1. Apply knowledge of mathematics, science and engineering fundamentals and an engineering specialisation to the solution of complex chemical engineering problems.2 .Identify, formulate, research literature and analyse complex chemical engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences and engineering sciences3. Design solutions for complex chemical engineering problems and design systems, components or processes that meet specified needs with appropriate consideration for public health and safety, cultural, societal, and environmental considerations.4 Investigate complex chemical engineering problems using research based knowledge and research methods including design of experiments, analysis and interpretation of data and synthesis of information to provide valid conclusions.5. Use modern engineering and IT tools to evaluate complex chemical engineering activities.6. Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to professional engineering practice.7. Understand the impact of professional engineering solutions in societal and environmental contexts and demonstrate knowledge of and need for sustainable development.8. Apply ethical principles and commit to professional ethics and responsibilities and norms of chemical engineering practice9. Communicate effectively on complex chemical engineering activities with the engineering community and society.10. Function effectively as an individual, and as a member or leader in diverse teams and in multi-disciplinary settings.211. Recognise the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

12. Demonstrate knowledge and understanding of engineering and management principles and apply these to ones own work, as a member and leader in a team, to manage projects and in multidisciplinary environments.3COURSE OUTCOME

At the end of this course, students should be able to:

Describe the polymerization mechanism and polymer structure- property relationship.Describe viscoelastic behavior & rheology properties and relate to products performance.Select suitable thermoplastic material and fabrication technique for specific application.Explain the phase separation behavior of polymer blends and apply the knowledge in polymer recycling and properties modification.Formulate composite material with optimum properties for specific applications.

Polymerisation reactions are included to give an overview of how these apply to a wide range of processes, products and applications4Describe the polymerization mechanism and polymer structure- property relationship (MW, Tm, Tg, density, reaction kinetics)

Describe viscoelastic behavior & rheology properties and relate to products performance (Creep, Stress relaxation, Viscosity)

Select suitable thermoplastic material and fabrication technique for specific application. (Membrane, injection moulding)

Explain the phase separation behavior of polymer blends and apply the knowledge in polymer recycling and properties modification.(Thermodynamic of mixing)

Formulate composite material with optimum properties for specific applications.(fiber/particulate and polymer matrix)5 Synopsis

Students will be exposed to introductory concepts anddefinition of polymeric materials, basic principles of polymermolecular weight, structure of polymer solids, cross-linked polymers and rubber elasticity, viscoelasticity, mechanical/physical properties, rheology, composites, processing technology, environment and product recycling. 6WeekTopic and Area Assesment

1

Introductory Concepts and Definition

Some Definitions, Polymerisation and Functionality Overview of Polymeric Materials Why are Synthetic Polymers Useful? Molecular Architecture, Classification, Thermoplastics, Thermosets and Elastomer, Polymer Nomenclature2Polymerisation

NG/LPG/naphta to monomers, Polymerisation and catalyst systemsAddition and CondensationControl of MW and product quality, grade controlBasic Principles of Polymer Molecular Weight- Importance of MW control- Number average, Mn, Weight average, Mw

3Polyethylene Polymerisation (Case Study)Rector control and Grade change in gas phase PE reactor, Handling of polymer powder and pellets ( + additives)

Project

& Lab Work7WeekTopic and Area Assesment

4Structure, Mechanical Properties and Application-Crystalline and Amorphous Polymer-Thermal Transition, Tm & Glass Transition Temp, Tg - Effect of Polymer Structure on TgMechanical/Physical PropertiesTensile, Impact, permeabilitySelection of polymer in Membrane fabrication for gas separationQuiz 1/Assignment5Mechanical/Physical PropertiesLinear Fracture Mechanics, Elastic-plastic Fracture, Brittle Fracture, Toughening

6Viscoelasticity

Creep, Stress relaxation, ViscoelasticModel, Dynamic properties, Quiz 2/Assignment7Revision, Project Identification & Evaluation, Critical analysis on problem statement and Issues

Test 18WeekTopic and Area Assesment

8Rheology OverviewNewtonian and Non-Newtonian FluidsEffect of MW, Temperature, and Pressure on Viscosity

9 Polymer processing/fabricationUsing injection, extrusion etc.-Product defects, selection of screw etc.

Quiz 3/Assignment10Alloys and BlendCompatibility , Thermodynamic of mixing,Miscibility and Phase separation

11Thermoset Part 1The Sol-Gel TransitionCross-links, Gels and Gelation, reaction kinetics

Submissionof Project Report(Friday 4 pm)9WeekTopic and Area Assesment

12Thermoset-Part ii

Polymer network, Mechanical and physical properties,Processing and fabrication. Example of Application:Surface coating for corrosion protection

13Polymer CompositesFiller and Fiber reinforcementProduct performance and economic evaluation

Test 214New Development /ApplicationFire retardant, Intumescent Polymer, Nanocomposite Material.Biopolymer

10COURSE EVALUATION

Assesments

Marks

Tests

20 %

Lab / Project/Quiz

30 %

Final Exam

50 %

Total

100 %

11Reference;Reference McCrum, N. G.. Principles of Polymer Engineering, 2nd Ed, Oxford University Press, Oxford 1997Main ReferenceKumar, Anil, Fundamental of Polymer Engineering, 2nd Ed, Marcel Dekker, New York, 2003.Sperling, L. H. Introduction to Physical Polymer Science, 4th Ed, John Wiley, New Jersey, 2006Optional Reference12