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New Stabilization Package for Controlled Rheology Polypropylene Fibers
(Benchmarked against Phenol & Phenol-free Systems)
SPE International Polyolefins Conference 2012
J. Mara 1, H.-J. Kwon 2, J.-D. Kim 2, J. Bayer 3 & K. Keck 2
1 Songwon International Americas; USA 2 Songwon Industrial, South Korea
3 Songwon International, Switzerland
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• Introduction to Auto-oxidation of Polyolefins • Degradation of Polypropylene (PP) • Classification of PP Fibers (by Songwon)
Stabilization Requirements for PP Fibers Stabilization Strategies for PP Fibers Technical Benchmarking vs. Phenol-containing & Phenol-free Systems Summary
Contents
SPE International Polyolefins Conference 2012
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SPE International Polyolefins Conference 2012
OH
H2O
O2
OO*
Peroxy Radical
OOH
Hydroperoxide
*
Alkyl Radical
O*
HO *
Alkoxy Radical
Hydroxy Radical
Polymer
Polymer
Polymer
None Radicalic Products
Oxygen Heat
Shear UV
Metal Ion (Mn+)
Heat UV
Simplified Auto-Oxidation Cycle of Polyolefins
Introduction
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Concepts to Counter Auto-Oxidation of Polyolefins
Free Radical Scavenging
Phenolic Antioxidant + → +
Aminic Antioxidant + → +
Peroxide Decomposition
Phosphite Antioxidant + → +
Thioester Antioxidant
+ → + + → +
OH
B A
C
OO* O*
B A
C
OOH
N H
R
OO* * N R
OOH
P OR
OR
RO
OOH P OR
O
RO
OR
OH
S R R
OOH
S R
O
R
S R
O
R
O
OH
OH
S R
O
R
OOH
Introduction
SPE International Polyolefins Conference
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OH
H2O
O2
OO*
Peroxy Radical
OOH
Hydroperoxide
*
Alkyl Radical
O*
HO *
Alkoxy Radical
Hydroxy Radical
Polymer
Polymer
Polymer
Oxygen Heat
Shear UV
Metal Ion (Mn+)
Heat UV
Radical Scavenging HALS, Amine ?
Radical Scavenging HALS, Amine, AO
Radical Scavenging HALS, Amine, AO
Radical Scavenging
Auto-Oxidation Mechanism Thermo-Oxidation
Peroxide Decomposition
Phosphite, Thioester
SPE International Polyolefins Conference 2012
Introduction
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• PP is an unstable substrate • Industrially unsuitable w/o stabilizers • Undergoes uncontrolled thermo-oxidative degradation w/o stabilizers • Polymerization, processing, & service life conditions can vary …
Degradation of Polypropylene
SPE International Polyolefins Conference 2012
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PP will undergo different Degradation Mechanisms: • Processing/Conversion:
• Concentration [ROO*] < Concentration [R*] • MW decreases; [Mw/Mn] narrows • Disproportioning of Alkyl Radicals (formation of c=c)
• Storage/Service Life: • Concentration [ROO*] >> Concentration [R*] • MW decreases; [Mw/Mn] broadens • Formation of Carbonyl Groups
• Different & Contradicting Stabilizer Reqirements
Degradation of Polypropylene
SPE International Polyolefins Conference 2012
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Classification of Polypropylene Fiber
• PP fiber grades are supplied over a range of MW’s depending upon processing & conversion characteristics as well as required properties of the application.
• Songwon classifies PP fiber grades by the conversion technology & by the presence (or absence) of peroxides for controlled degradation (Controlled Rheology).
• Monofilament & Tape grades have low MFI’s which need to be maintained during compounding & conversion.
• Meltblown & Spunbond grades have MFI’s that must be tailored in a post reactor operation via the use of peroxides (CR grades).
• Bulk continuous filament & Staple grades are available as either reactor grades or CR grades.
0 10 20 30 40 50 60 70 80
Melt Flow MFI 230°C/2.16
Monofilament
Slit Tape
Staple Fiber
Continuous Filament
Spunbond
Meltblown
Typically cracked
- 1500
Can be cracked
Reactor grade
Narrow
Narrow
Normal to narrow
Normal to broad
Normal
Normal
1-Step CR 2-Step CR
SPE International Polyolefins Conference 2012
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Classification of Polypropylene Fibers
SPE International Polyolefins Conference 2012
0 10 20 30 40 50 60 70 80
Melt Flow MFI 230°C/2.16
Reference: E.P. Moore; Polypropylene Handbook; Hanser Publishers (1996)
Monofilament
Slit Tape
Staple Fiber
Continuous Filament
Spunbond
Meltblown - 1500
Reactor grade
Narrow
Narrow
Normal to narrow
Normal to broad
Normal
Normal
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Classification of Polypropylene Fibers
SPE International Polyolefins Conference 2012
0 10 20 30 40 50 60 70 80
Melt Flow MFI 230°C/2.16
Reference: E.P. Moore; Polypropylene Handbook; Hanser Publishers (1996)
Monofilament
Slit Tape
Staple Fiber
Continuous Filament
Spunbond
Meltblown - 1500
Can be cracked
Reactor grade
Narrow
Narrow
Normal to narrow
Normal to broad
Normal
Normal
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Classification of Polypropylene Fibers
SPE International Polyolefins Conference 2012
0 10 20 30 40 50 60 70 80
Melt Flow MFI 230°C/2.16
Reference: E.P. Moore; Polypropylene Handbook; Hanser Publishers (1996)
Monofilament
Slit Tape
Staple Fiber
Continuous Filament
Spunbond
Meltblown
Typically cracked
- 1500
Can be cracked
Reactor grade
Narrow
Narrow
Normal to narrow
Normal to broad
Normal
Normal
1-Step CR 2-Step CR
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Standard Post Reactor Extrusion
SPE International Polyolefins Conference 2012
Stabiliser & Peroxide Addition for CR-PP
W W
Peroxide (mainly liquid)
Stabiliser Single Additive, OPS
or masterfluff
Loss-in-weight feeder
(Individual) additive streams
Polyolefin bulk feed
Polymer main stream
High shear extruder Pelletizing & Storage
Silo or discharge hopper
P
Storage tank
Pump
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Separate Addition during Extrusion
SPE International Polyolefins Conference 2012
Stabiliser & Peroxide Addition for CR-PP
W W
Peroxide (mainly liquid)
Stabiliser Single Additive, OPS
or masterfluff
Loss-in-weight feeder
Stabiliser stream (later)
Polyolefin bulk feed
Polymer main stream
High shear extruder Pelletizing & Storage
Silo or discharge hopper
P
Storage tank
Pump
Peroxide stream (first)
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Stabilization Requirements of PP Fibers
SPE International Polyolefins Conference 2012
• Excellent MW protection during compounding & conversion – Principle reason for addition of processing stabilizer
• No interaction with peroxides (CR grades)
– Peroxide interaction leads to strong antagonism w/processing stabilizer
• Low initial color following compounding • Low color development following conversion • Low gas fade during conversion & storage
– Potentially negatively affected by primary AO
• Adequate storage stability (optional) • Outdoor UV stability (optional)
– Easily adjustable by choice of HAS
• Other (registrations, cost, industrial availability)
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Stabilization Requirements of PP Fibers
• Performance requirements for PP fiber stabilization packages vary with the conversion technology & the need for CR grades.
• An overview of the importance of the various requirements for the different PP fiber grades is given below:
Com
poun
ding
Con
vers
ion
Serv
ice
Life
Mon
ofila
men
tTa
pe
Stap
le (R
eact
or)
(B) C
F (R
eact
or)
Stap
le -
CR
(B) C
F-C
R
Spun
bond
-CR
Mel
tblo
wn-
CR
Remark
Excellent MW Preservation P P
Low Peroxide Interaction P P
Low Initial Colour P P
Low Colour Development P P P
Low Gas Fading P
Low Smoke & Fume P
Good MW Protection- LTTS P
Good MW Protection - UV P
Very important Suitable; usually required Required or not depending on end application
Depending on end application
Only colour critical applications
SPE International Polyolefins Conference 2012
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SPE International Polyolefins Conference 2012 February 26th - February 29th, 2012
Stabilization Strategies for PP Fibers
SPE International Polyolefins Conference 2012
3 Alternatives for PP Fibers
Grade Compounding Fiber Conversion Stabilization Strategy
Reactor MW Preservation MW Preservation Excellent ProcessingStability
1 Step CR Controlled MW Decrease MW Preservation Optimum Balance of Good Processing Stability
vs. Low Peroxide Interaction
2 Step CR Controlled MW Decrease Controlled MW Decrease No or MinimalProcessing Stability
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SPE International Polyolefins Conference 2012
Selection Guide for PP Fiber Grades
Criteria
Classification Songwon Product (ppm)
Exce
llent
MW pr
eserv
ation
Low
perox
ide in
terac
tion
Low
initia
l colo
r
Low
color
deve
lopme
nt
Low
gas f
ading
Low
Fume
& S
moke
Good
MW
prote
ction
-LTTS
Good
MW
prote
ction
-MI
Remarks
Songnox 21B (1500 ~ 2000) ● ○ ○ ○ Not suitable for color sensitive
applications Monofilament & Tape
Songnox 1790 + Songnox 6260 [33:67](1000~1500) ● ○ ● Severe processing condition
Songnox 21B (1500 ~ 2000) ● ○ ○ ○ Not suitable for color sensitive
applications
Songnox 331B (1500 ~ 2000) ● ○ ● ○ ○ ○ Offers improved color
Staple - Reactor Continuous Filament (CF) - Reactor
Songnox 3016 GR (1000 ~ 2000) ● ○ ● ● ● ● ● Offers best color
Songnox 331B (1500 ~ 2000) ● ○ ● ○ ○ ○ Offers improved color Staple - CR
Continuous Filament (CF) - CR Songnox 3016 GR
(500 ~ 1500) ● ○ ● ● ● ● ● Best color, Excellent balance MW preservation & Low peroxide interaction
Songnox 331B (1000 ~ 2000) ● ○ ● ○ ○ ○ Offers improved color
Spundbond Songnox 3016 GR (500 ~ 1500) ● ○ ● ● ● ● ●
Best color, Excellent balance MW preservation & Low peroxide interaction
Meltblown Songnox 3016 GR [1:1] (300 ~ 600) ● ● ● ● ● ○ ○
No peroxide interaction Very good color & gasfading Low Fume & Smoke
● Recommended / Fulfills criterion completely / ○ Can be used [Green: very important / critical (in general), Yellow: very important / critical (selected end application) Gray: important / useful]
• Recommendations are grouped around the conversion technology & corresponding importance of stabilizer requirements as captured in previous slide.
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Songnox 3016 Characteristics • New AO package for color critical applications, including:
– PP Fiber (Bulk Continuous Filament – Reactor & CR; Staple – Reactor & CR; & Spunbond applications)
– Polyolefin Film applications (Not covered today) – Polyolefin Tape applications (Not covered today) – Thin Walled Injection Molding (TWIM) applications (Not covered today)
• Provides an excellent balance between Processing Stability & Low Peroxide
interaction.
• The interaction with peroxide is significantly reduced compared to Phenol containing systems (i.e., Songnox 321B) & Phenol-free systems, including:
– Irgastab FS 533 (Composition: FS042 + I-168 + C-2020) [1:10:3] – Irgastab FS 102 (Composition: FS042 + I-168 + T-622) [1:2:1]
– Irgastab FS 410 (Composition: FS042 + C-944) [1:1] • Performance data in PP homopolymer (gas phase) / MFI(230 C/2.16 kg) ~4 to 6
[dg/min] follows…
SPE International Polyolefins Conference 2012
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Substrate: PP homopolymer (gasphase) MFI 230/2.16 ~ 4 to 6 [dg/min] Compounding: N2, 190 – 215oC, TS Criterion: MFI after compounding
Stabilisation: 500 ppm Ca-stearate + 1000 ppm stabiliser Additivation: 490 ppm PO-4 [2,5-Bis(t.-butylperoxy)-2,5-dimethylhexane]
Stabilizer Interaction with Peroxide in CR-PP
4 8 12 16 20 24 28 32
MFI (g/10min) 2.16kg/230oC
No additive
Songnox 3016 GR
Songnox 321B
Irgastab FS 102
Irgastab FS 410
Irgastab FS 533
SPE International Polyolefins Conference 2012
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Substrate: PP homopolymer (gasphase) MFI 230/2.16 ~ 4 to 6 [dg/min] Compounding: N2, 190 – 215oC, TS Exposure: 5hr at 60oC under 5% NOx gas (KS K 0454)
Stabilisation: 500 ppm Ca-stearate + 1000 ppm stabiliser Additivation: 490 ppm PO-4 [2,5-Bis(t.-butylperoxy)-2,5-dimethylhexane] Criterion: Delta YI
Low Gas Fading in CR-PP
Songnox 3016 GR
Songnox 321B
Irgastab FS 102
Irgastab FS 410
0 5 10 15 20 25 30
Delta Yellowness Index
Irgastab FS 533
SPE International Polyolefins Conference 2012
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Substrate: PP homopolymer (gasphase) MFI 230/2.16 ~ 4 to 6 [dg/min] Compounding: N2, 190 – 215oC, TS
Stabilisation: 500 ppm Ca-stearate + 1000 ppm stabiliser Additivation: 490 ppm PO-4 [2,5-Bis(t.-butylperoxy)-2,5-dimethylhexane] Criterion: YI after compounding
Low Initial Color in CR-PP
-4.0 -3.8 -3.6 -3.4 -3.2 -3.0
Yellowness Index E 313
Songnox 3016 GR
Songnox 321B
Irgastab FS 102
Irgastab FS 410
Irgastab FS 533
SPE International Polyolefins Conference 2012
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Substrate: PP homopolymer (gasphase) MFI 230/2.16 ~ 4 to 6 [dg/min] Compounding: N2, 190 – 215oC, TS
Stabilisation: 500 ppm Ca-stearate + 1000 ppm stabiliser Additivation: 490 ppm PO-4 [2,5-Bis(t.-butylperoxy)-2,5-dimethylhexane] Criterion: YI after multiple extursion Pass 1 ~ 5
Low Color Development during Processing
-3.0 -2.0 -1.0 0.0 1.0 2.0 3.0
Yellowness Index E 313
Pass 5
Pass 3
Pass 1
Songnox 3016 GR
Songnox 321B
Irgastab FS 102
Irgastab FS 410
Irgastab FS 533
SPE International Polyolefins Conference 2012
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Stabilisation of Controlled Rheology Polypropylene Methodology
Radar chart Relative scale: 5 Best (outside)
4 3 Intermediate 2 1 Worst (inside, center)
SPE International Polyolefins Conference 2012
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1
2
3
4
5Excellent Processing Stability
Low Peroxide Interaction
Low Initial Colour
Low Colour Development (Processing)
Low Gas fading
Easy Adjustment LTTS / UV
Stabilisation of Controlled Rheology Polypropylene
SPE International Polyolefins Conference 2012
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1
2
3
4
5Excellent Processing Stability
Low Peroxide Interaction
Low Initial Colour
Low Colour Development (Processing)
Low Gas fading
Easy Adjustment LTTS / UV
Stabilisation of Controlled Rheology Polypropylene Unstabilised Controlled Rheology PP
SPE International Polyolefins Conference 2012
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Formulation:
Stabilisation Strategy:
Positioning:
General Phenol Stabilizer System A
A [Songnox 317B] Composition: 3 parts SN1680 + 1 part SN1076
[Phenolic AO + Phosphite] synergism Standard phenolic AO Standard phosphite Partially optimised composition & ratio
Standard AO package from IM or extrusion
SPE International Polyolefins Conference 2012
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Stabilisation of Controlled Rheology Polypropylene
A [Songnox 317B] 1000 ppm
SPE International Polyolefins Conference 2012
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Formulation:
Stabilisation Strategy:
Positioning:
General Phenol Stabilizer System B
B [Songnox-321B] Composition: 2 parts SN1680 + 1 part SN3114
[Phenolic AO + Phosphite] synergism Phenolic AO with reduced color formation Partially optimised composition & ratio
Improved processing stability
SPE International Polyolefins Conference 2012
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Stabilisation of Controlled Rheology Polypropylene
A [Songnox 317B] 1000 ppm B [Songnox 321B] 1000 ppm
SPE International Polyolefins Conference 2012
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Formulation:
Stabilisation Strategy:
Positioning:
Phenol-Free Stabiliser System C
C [Hydroxylamine + HAS / FS 410]
Elimination of phenolic AO (color source) Processing stability based only on hydroxylamine No synergistic effect Conversion independant of service life
Hyperactive processing stabiliser
SPE International Polyolefins Conference 2012
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Stabilisation of Controlled Rheology Polypropylene
A [Songnox 317B] 1000 ppmB [Songnox 321B] 1000 ppm C [FS 410] 1000 ppm
SPE International Polyolefins Conference 2012
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Formulation:
Stabilisation Strategy:
Positioning:
Phenol-Free Stabiliser System D,E
D [Hydroxylamine + Phosphite + HAS / FS 102] E [Low hydroxylamine + Phosphite + HAS / FS 533]
Elimination of phenolic AO (colour source) ‘‘Kinetic’’ balance Processing vs. Peroxide Synergistic effect Conversion independant of Service Life
C System formulated with low level of hyperactive
processing stabiliser
SPE International Polyolefins Conference 2012
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Stabilisation of Controlled Rheology Polypropylene
A [Songnox 317B] 1000 ppm B [Songnox 321B] 1000 ppm C [FS 410] 1000 ppm D [FS 102] 1000 ppm E [FS 533] 1000 ppm
SPE International Polyolefins Conference 2012
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Formulation:
Stabilisation Strategy:
Positioning:
New Color Critical Stabiliser System
F [Songnox 3016 GR]
Elimination of phenolic AO (colour source) ‘‘Kinetic’’ balance Processing vs. Peroxide Synergistic effect Conversion independant of Service Life
No hyperactive processing stabiliser
SPE International Polyolefins Conference 2012
![Page 35: Powerpoint - New Stabilization Package for Controlled ...€¦ · General Phenol Stabilizer System A A [Songnox 317B] Composition: 3 parts SN1680 + 1 part SN1076 [Phenolic AO + Phosphite]](https://reader033.vdocuments.site/reader033/viewer/2022060608/605f5a672d95175ef01cb647/html5/thumbnails/35.jpg)
Stabilisation of Controlled Rheology Polypropylene
A [Songnox 317B] 1000 ppm B [Songnox 321B] 1000 ppm C [FS 410] 1000 ppm D [FS 102] 1000 ppm E [FS 533] 1000 ppm F [Songnox 3016] 1000 ppm
SPE International Polyolefins Conference 2012
![Page 36: Powerpoint - New Stabilization Package for Controlled ...€¦ · General Phenol Stabilizer System A A [Songnox 317B] Composition: 3 parts SN1680 + 1 part SN1076 [Phenolic AO + Phosphite]](https://reader033.vdocuments.site/reader033/viewer/2022060608/605f5a672d95175ef01cb647/html5/thumbnails/36.jpg)
SPE International Polyolefins Conference 2012
Summary
• PP in general must be stabilized during compounding, processing, storage, and service life.
• The stabilization of CR-PP during compounding and conversion is rather complex.
• While efficient protection of the PP is easily achievable via stabilizers with high molar activity & reaction kinetics, peroxides may also be added in order to degrade the PP in a controlled manner, yielding grades with lower MW & narrower MWD’s.
• In this work, we introduced a powerful new AO package for CR-PP that provides excellent balance between processing stability, color suppression, and low peroxide interaction.
• While the scope of today’s presentation was limited to CR-PP fiber applications, the technology is also applicable to other applications such as TWIM where low peroxide interaction and low color development are critical.
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SPE International Polyolefins Conference 2012