polyolefins and their influence on single use technology
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Engineering Conferences InternationalECI Digital ArchivesSingle-Use Technologies: Bridging Polymer Scienceto Biotechnology Applications Proceedings
Fall 10-19-2015
Polyolefins and their influence on single usetechnology for bioprocessingAmy PlanconSABIC Europe, [email protected]
Marnik VaesSABIC Europe, [email protected]
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Recommended CitationAmy Plancon and Marnik Vaes, "Polyolefins and their influence on single use technology for bioprocessing" in "Single-UseTechnologies: Bridging Polymer Science to Biotechnology Applications", Ekta Mahajan, Genentech, Inc., USA Gary Lye, UniversityCollege London, UK Eds, ECI Symposium Series, (2015). http://dc.engconfintl.org/biopoly/5
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSINGMarnik Vaes & Amy Plancon
Single-Use Technologies: Bridging Polymer Science to Biotechnology Applications18-21 October 2015Leesburg, Virginia USA
CONTENT
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING
No. 2
CONTENT
• INTRODUCTION: CHEMISTRY THAT MATTERS™
• POLYOLEFINSPOLYETHYLENE & POLYPROPYLENE
• KEY PROPERTIES PHYSICAL, MECHANICAL, CHEMICAL & ADDITIVES
• SUMMARYCHEMISTRY THAT MATTERS™ FOR SINGLE USE TECHNOLOGY
INTRODUCTION:CHEMISTRY THAT MATTERS™
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING
No. 4
SABIC IN NUMBERS
1976, our beginning39 years of growth
3rd largest global diversified chemical company* 116th largest public company in the world*
91 B$ total assets50 B$ annual revenue6.2 B$ net income
40,000 employees50 countries5 Strategic Business Units
64 world-class plants worldwide5 key geographies with innovation hubs150 new products each year10,640 global patent filings
* Forbes 2015
No. 5
PRODUCTION HAS MULTIPLIED BY 5 IN 20 YEARS
A high rate of growth…
Pro
duct
ion
(mill
ion
tons
)
…reaching 69.7M metric tons in 2014
Metals
5.869
Fertilizers
6.848
Chemicals
43.354
Polymers
11.673
Performance Chemicals
0.476
Innovative Plastics
1.505
0
10
20
30
40
50
60
70
80
1985 1990 1995 2000 2005 2010 2011 2012 2013 2014
22
13
28
47
6970.5
6
67 68.5 69.7
No. 6
COMPREHENSIVE HEALTHCARE SOLUTIONS
No. 7
WORKING TOGETHER: CHEMISTRY THAT MATTERS™
COST
BUILDING BRIDGES
SUSTAINABILITY & RECYCLING
NO-CHANGE
GUARANTEE
EXTRACTABLES
AND LEACHABLES
SABIC’S IN DEPTH
POLYMER
KNOWLEGE
PATIENTSAFETY
SECURITY OFSUPPLY
SUS PRODUCT
REQUIREMENTS
REGULATORY
Help our customers grow so as to help preserve and improve human life around the world
No. 8
GLOBAL POLYOLEFIN MARKET
98,33%150444
0,95%1459
0,72%1097
2556
Global Healthcare Polyolefin Demand, KT
Global Non-HC PO Global HC Non-medical Global HC Medical
99,50%1091,51
0,50%5,49
Polyolefins in SUS (KT, estimated)
Global HC EP/USP SUS
* Source: BCC Research 2013** SABIC Market Intelligence*** Estimated
HCMedical grade
HCNon-Medical grade
Medical grade
***
***
***
***Healthcare
Medical grade = EP and USP compliant materials
No. 9
Input• LDPE• HDPE• PP• Additives
Process• Injection
molding• Extrusion• Film (blown,
cast)• Printing• Filling• Sterilization
Output (SUS)• Mechanical
• Modulus• Impact• Rupture
• Chemical• Extractables
& leachables
Single U
se Technology
POLYOLEFINS & INFLUENCE ON SUT
CHEMISTRY THAT MATTERS™ for Single Use Technology
POLYOLEFINS:POLYETHYLENE & POLYPROPYLENE
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING
No. 11
FROM OIL TO OLEFINS
CrackersRefineryOil and Gas
EthylenePropylene
No. 12
POLYMERIZATION PROCESS
RadicalsHigh pressure
process
LDPE
Reaction through
Used technology
CatalystLow pressure
process
ULDPE, LLDPE, MDPE, HDPE
Ethylene (C2) C CH
H
H
H
No. 13
POLYETHYLENE (C2) STRUCTURE
LDPE: Branched HDPE: Linear LLDPE: Linear
Chemical structure
Molecular structure
LLDPE contains side chains by co-polymerization of e thylene with monomer (e.g. butane, hexane, etc)
No. 14
POLYPROPYLENE (C3) STRUCTURE
Homopolymer(no ethylene)
Random(<10% ethylene)
Impact Copolymer(>30% ethylene)
Chemical structure
Molecular structure
KEY PROPERTIES: PHYSICALMECHANICALCHEMICAL & ADDITIVES
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING
No. 16
• Polymers have a distribution of chain lengths
• Production technology allows some tailoring of MWD:
• Narrow distribution for film grades
• Broader distribution for injection molding grades
• Melt Flow Index (MFI) is inversely proportional to MW
PHYSICAL PROPERTIES: MOLECULAR WEIGHT DISTRIBUTION (MWD)
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
2,0 3,0 4,0 5,0 6,0 7,0 8,0
LLDPE (C4)
LDPE (Autoclave)
LDPE (Tubular)
Chain lengths range from very short… …to very long
No. 17
PHYSICAL PROPERTIES: DENSITY & CRYSTALLINITY
Plastomers/rubbers ULDPE HDPELDPE/LLDPE
860 970940920890
75%50%40%30%10% 20%
Density (kg/m 3)
Crystallinity
Chain regularity
LDPE has Long Chain Branches and Short Chain Branch es
No. 18
MECHANICAL PROPERTIES
Tensile Modulus • Resistance of materials to tensile force.
Flex Modulus• Resistance of materials to flexural force
Izod Impact• Resistance of materials to impact at
several temperatures
No. 19
MECHANICAL PROPERTIES: IMPACT STRENGTH
Impact strength is influenced by melt index and den sity
No. 20
CHEMICAL PROPERTIES: TYPES OF ADDITIVES
Modifiers
• Impact Modifiers• Nucleating
agents/clarifiers• Organic
Peroxides• Plasticizers
Property Extenders
• Antioxidants• Antistatic agents• Heat stabilizers• Light stabilizers
Processing Aids
• Anti-blocking agents
• Lubricants/mold release
• Slip agents
Additives are used to improve processing of polymer s and to enhance their properties
Improves film toughness
• Inhibits gels• Increases
gamma stability
• Facilitates bag opening
• Minimizes blocking
No. 21
Energy
Metal Ions
CHEMICAL PROPERTIES: OXIDATION & POLYMER DEGRADATION
• Mechanical stress
• Heat• Light
• Catalytical residue
• Impurities • Co-additives
PeracidsPeroxides
Alcohols Ketones
AcidsAldehydes
AUTO-OXIDATION
No. 22
CHEMICAL PROPERTIES: OXIDATION & ANTIOXIDANTS
Polymerization
Extrusion
StorageInjection molding
Irradiation
Why do we use antioxidants?
Auto-oxidation ALWAYS takes place
No. 23
CHEMICAL PROPERTIES: DEGRADATION CHEMISTRY
Various Oxidation Products
Chain Scission Property deterioration
Chain scission produces small chains that degrade m echanical properties
No. 24
CHEMICAL PROPERTIES: ANTIOXIDANTS & DEGRADATION
Primary (Phenolic)
Secondary (Phosphite)
Antioxidants are used in most polymer resins to pre vent oxidative degradation
Oxidative degradation can lead to gels and black sp ecs in PE film
No. 25
CHEMICAL PROPERTIES: EXTRACTABLES & LEACHABLES
Solvent BP GC-MSUPLC-HRMS(+ & - APCI)
Headspace
Ethanol 78 °C ➼ ➼
DCM 40 °C ➼ ➼
Hexane 69 °C ➼ ➼
Water pH 2, 7, 9 100 °C ➼ ➼
Neat “150 °C” ➼
Degradation products can impact E&L
CHEMISTRY THAT MATTERS™: ensure “what comes out” will work in SUT
SUMMARY:CHEMISTRY THAT MATTERS™ FOR SINGLE USE TECHNOLOGY
POLYOLEFINS AND THEIR INFLUENCE ON SINGLE-USE TECHNOLOGY FOR BIOPROCESSING
No. 27
PROCESS• Sterilization (gamma), etc.• Extrusion• Injection molding
END APPLICATION• Properties (chemical/ E&L,
mechanical)
POLYMER• Additives• Physical properties
CHEMISTRY THAT MATTERS™ FOR SUT
WORKING TOGETHER TO FIND SMART NEW SOLUTIONS
No. 28
No. 29
THANK YOU
No. 30
LEGAL DISCLAIMER
The products and services of SABIC are sold and rendered subject to SABIC’s standard terms & conditions of sale (GTCS), which are available free of charge upon request, by post or digital. Standard terms & conditions other than the GTCS are dismissed and do not apply. Although any information or recommendation contained herein is given in good faith, SABIC makes no warranty or guarantee, express or implied, (i) that the results or specifications described herein will be obtained under end-use conditions, or (ii) as to the effectiveness or safety of any design incorporating SABIC’s products, services or recommendations.
This presentation or document does not contain any calculation, estimate or other warranty or representation that customers and third parties may rely on. Customers and third parties are responsible for making their own determination as to the suitability of SABIC’s products, services or recommendations for the customers’ particular intended use through appropriate end-use testing and analysis, and compliance with applicable laws and regulations.
Except as provided in SABIC’S GTCS, SABIC shall not be responsible for any loss or damage resulting from any use of its information, products or services described herein and SABIC assumes no liability whatsoever in this respects.
Nothing in any document or oral statement shall be deemed to alter or waive any provision of SABIC’s GTCS or this Disclaimer, unless it is specifically agreed to in a writing signed by SABIC.
No statement by SABIC concerning a possible use of any SABIC product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of SABIC or as a recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right.