EPA-600/2-77-023J
February 1977 Environmental Protection Technology Series
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-77-023J
February 1977
INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE
CHAPTER 10
PLASTICS AND RESINS INDUSTRY
by
Glynda E. Wilkins
Radian Corporation
Austin, Texas 78766
Contract No. 68-02-1319
Project Officer
Alfred B. Craig
Metals and Inorganic Chemicals Branch
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCALIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory - Cincinnati, U.S. Environmental Protection Agency, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency
or recommendation for use.
n
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"ABLE OF CONTENTS
CHAPTER 10
Paqe
INDUSTRY DESCRIPTION , 1
Raw Materials 6
Products 6
Companies 6
Environmental Impact 11
Bibliography 14
INDUSTRY ANALYSIS 16
Mass Addition Polymerization Processes 17
Process No. 1. Polymerization 20
Process No. 2. Vacuum Stripping 22
Process No. 3. Pelletizing and Bagging 23
Emulsion Addition Polymerization Processer 25
Process No. 4. Polymerization 28
Process No. 5. Dry Product Preparation 33
Suspension Addition Polymerization Processes 35
Process No. 6. Polymerization 38
Process No. 7. Polymer Isolation 42
Process No. 8. Final Product Preparation 45
High-Pressure Mass Polymerization Processes 47
Process No. 9. Polymerization 49
Process No. 10. Separation 51
Process No. 11. Final Product Operation 53
Solution Polymerization Processes 55
Process No. 12. Polymerization 57
Process No. 13. Solvent Recovery 59
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TABLE OF CONTENTS (Continued)
CHAPTER 10
Page
Particle Form Polymerization Processes 61
Process No. 14. Polymerization 63
Process No. 15. Polymer Recovery 66
Polyolefins Polymerization (Ziegler) Processes 68
Process No. 16. Polymerization 70
Process No. 17. Catalyst and Solvent Removal 72
Process No. 18. Production Preparation 74
Phenolic Resin Production Processes 76
Process No. 19. Polymerization (Resols) 78
Process No. 20. Product Preparation (Resols) 80
Process No. 21. Polymerization (Novolaks) 82
Process No. 22. Product Preparation (Novolaks) 84
Amino Resin Production Processes 86
Process No. 23. Polymerization 88
Process No. 24. Alkylation 90
Process No. 25. Preparation 91
Polycarbonate Production Processes 93
Process No. 26. Polymerization 95
Process No. 27. Washing 97
Process No. 28. Precipitation 99
Process No. 29. Drying 100
Process No. 30. Product Preparation 102
Epoxy Resin Production Processes 103
Process No. 31. Polymerization (One Step) 106
Process No. 32. Polymerization (Two Steps) 108
Process No. 33. Washing 110
Process No. 34. Polymer Recovery 112
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TABLE OF CONTENTS (Continued)
CHAPTER 10
Page
Unsaturated Polyester Resin Production Processes 114
Process No. 35. Polymerization 116
Process No. 36. Mixing 118
Alkyd Resin Production Processes 120
Process No. 37. Polymerization 122
Process No. 38. Mixing 124
Poly (Ethylene Terephthalate) Production Process 125
Process No. 39. Ester Exchange or Esterification 127
Process No. 40. Polymerization 129
Process No. 41. Product Formation 131
Nylon 6 Resin Production Processes 132
Process No. 42. Polymerization 134
Process No. 43. Polymer Isolation (Aqueous Extraction) 136
Process No. 44. Polymer Isolation (Vacuum Distillation) 138
Nylon 66 Resin Production Processes 140
Process No. 45. Feed Preparation 142
Process No. 46. Evaporation 144
Process No. 47. Polymerization (Batch) 146
Process No. 48. Resin Product Preparation 148
Process No. 49. Polymerization (Continuous) 150
Process No. 50. Product Preparation 152
Polyurethan Foam Production Processes 153
Process No. 51. Phosgenation 155
Process No. 52. Polymerization (One Shot) 157
Process No. 53. Polymerization (Prepolymer Systems) 160
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TABLE OF CONTENTS (Continued)
CHAPTER 10
Page
Polyamide Resin Production Processes 162
Process No. 54. Dimerization 164
Process No. 55. Condensation 165
Poly (Phenylene Sulfide) Production Processes 166
Process No. 56. Polymerization 168
Process No. 57. Product Preparation 169
Polyacetal Production Processes 170
Process No. 58. Feed Preparation 172
Process No. 59. Polymerization 174
Process No. 60. Final Product Preparation 176
APPENDIX A - Raw Materials 177
APPENDIX B - Products 217
APPENDIX C - Companies and Products 221
VI
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LIST OF FIGURES
CHAPTER 10
Figure No. Page
1 Interrelation of Industries with the Plastics and Resins
Industry 2
2 Progression of Petrochemicals to Plastics 8
3 Mass Addition Polymerization 19
4 Emulsion Addition Polymerization 27
5 Suspension Addition Polymerization 37
6 High Pressure Mass Polymerization 48
7 Solution Polymerization 56
8 Particle Form Polymerization 62
9 Polyolefin Production (Ziegler) 69
10 Phenolic Resin Production 77
11 Ami no Resin Production 87
12 Polycarbonate Production 94
13 Epoxy Resin Production 105
14 Unsaturated Polyester Resin Production 115
15 Alkyd Resin Production 121
16 Poly (Ethylene Terephthalate) Production 126
17 Nyl on 6 Res i n Producti on 133
18 Nylon 66 Resin Production 141
19 Polyurethan Foam Production 154
20 Polyamide Resin Production 163
21 Poly(Phenylene Sulfide) Production 167
22 Polyacetal Production 171
VI 1
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LIST OF TABLES
CHAPTER 10
Table No. Page
1 Operations and Products of the Plastics and Resins Industry. 3
2 Major Raw Materials for the Plastics and Resins Industry.... 7
3 Large Volume Products of the Plastics and Resins Industry... 9
4 Major Plastics Producers 10
5 Major Waste Water Subcategories of the Plastics and Resins
Industry 12
6 Product Classification Waste-Water Characteristics 12
7 Utility Requirements for Polystyrene Production by Mass
Polymerization 18
8 Waste Water Data for Products Made in Mass Addition
Operations 18
9 Production Capacities of Screw Extruders for 0.64 cm (0.25
in) Rod 23
10 Waste-Water Data from Emulsion Polymerization 25
11 Input Materials for Production of Polystyrene by Emulsion
Polymerization 29
12 Cmc Values for Typical Emulsifiers 30
13 Effective pH Range of Emulsifiers 30
14 Waste-Water Data for Suspension Polymerization Products 36
15 Input Materials to Typical Suspension Polymerization Pro-
cesses 39
16 Centrifuge Power Requirements 42
17 Utility Requirements and Waste Streams for Production of
454 kg of Low Density Polyethylene 47
18 Utility Requirements and Waste Generation for Production of
454 kg of High Density Polyethylene 61
19 Ratios of Feed Materials for Various Comonomers of Ethylene. 63
20 Utility Requirements for Ziegler-Type Polyolefins Processes. 68
21 Waste Stream Information for Production of Phenolic Resins.. 76
22 Emission Data for Ami no Resin Production 86
23 Utility Requirements for Polycarbonate Manufacture 93
24 Utility Requirements for Epoxy Resin Production 103
25 Input Materials for a Shell Epoxy Resin Production Process.. 106
26 Input Materials for a One-Stage Epoxy Resin Production
Process 106
vm
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LIST OF TABLES (Continued)
CHAPTER 10
Table No. Page
27 Input Materials for a Two-Step Epoxy Resin Polymerization... 108
28 Utility Requirements for Unsaturated Polyester Resin
Production 114
29 Polyester Resin Feed Materials 116
30 Feed Materials for a Typical Alkyd Resin 122
31 Utility Requirement for Poly(Ethylene Terephthalate) 125
32 Utility Requirements for Making Nylon 6 Resin Chips 132
33 Characteristics of Aqueous Effluent from Nylon 6 Washing
and Distil lation 137
34 Utility Requirements for a Continuous Nylon 66 Operation.... 140
35 Utility Requirements for Producing Toluene Diisocyanate 155
36 Isocyanates Used in Polyurethan Foam Production 157
37 Typical Formulations for Flexible and Rigid Forms 158
38 Utility Requirements for Polyurethan Prepolymer Production.. 160
A-l Raw Materials List 178
A-2 Antioxidants Chart 188
A-3 Antistatic Agents Chart 193
A-4 Flame Retardants Chart 198
A-5 Free Radical Initiator Chart 203
A-6 Colorants Chart 208
A-7 Manufacturers/Suppliers of Materials Listed in Charts 213
B-l Products of the Plastics and Resins Industry 218
C-l-75 Companies and Products (Alphabetically by Product) 222
IX
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ACKNOWLEDGEMENTS
Some of the technical information used in preparing this catalog entry was
supplied to EPA by Monsanto Research Corporation, Dayton Laboratory, under
Contract No. 68-02-1320, Task 17. The contributions of Duane E. Earley are
gratefully acknowledged. Mr. William Medley was Project Leader.
This was prepared for EPA by Radian Corporation under Contract No. 68-02-1319,
Task 52. The author was Glynda E. Wilkins. Contributions by Terry B. Parsons.
Judith D. Whiting, and C. J. Scholin are gratefully acknowledged. Eugene C.
Cavanaugh was the Program Manager.
Helpful review comments from Robert W.
in this chapter.
Leny were received and incorporated
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PLASTICS AND RESINS INDUSTRY
INDUSTRY DESCRIPTION
The Plastics and Resins Industry includes operations which convert mono-
mer or chemical intermediate materials obtained from the Basic Petrochemicals
Industry and the Organic Chemicals Industry into resinous polymer products.
Fabrication is not included, nor is blending or formulation of resin materials.
Figure 1 is a simplified diagram showing the interrelation of closely related
industries to the plastics and resins industry. There are eighteen operations
treated in this report which were deemed significant in characterizing the in-
dustry: Mass Addition Polymerization, Emulsion Addition Polymerization, Sus-
pension Addition Polymerization, High Pressure Mass Polymerization, Solution
Polymerization, Particle Form Polymerization, Polyolefin Production (Ziegler),
Phenolic Resin Production, Ami no Resin Production, Polycarbonate Production,
Epoxy Resin Production, Unsaturated Polyester Resin Production, Alkyd Resin
Production, Poly(ethylene terephthalate) Production, Nylon 6 Resin Production,
Nylon 66 Resin Production, Polyurethan Foam Production, Polyamide Resin Pro-
duction, Poly (phenylene sulfide) Production, and Polyacetal Production. Each
of these operations is represented by a flow sheet indicating processing se-
quence, waste streams, raw materials, and products. Table 1, a listing of
products and the operations and processes in which the/ are made, is included
as an aid to finding particular products considered in this treatment.
The 1972 Census of Manufacturers lists 323 establishments involved in
Plastics and Resins manufacture employing 54,800 people. A 1974 estimate in-
cluded in an EPA document indicates 300 producers operating over 400 plants.
The 1974 employment figure is almost certainly proportionally higher also.
The total production of plastics and resins for 1974 was 10 Tg (22 billion
Ib), a 20 percent decrease from 1974 production levels. Because the Plastics
and Resins Industry is sensitive to domestic economic conditions, and because
the industry is linked to oil-derived raw materials, a feedstock shortage and
a resulting slump have been encountered. It is difficult to accurately des-
cribe significant growth trends within the industry. Many economists expect
feedstock shortages to continue but to become less intense. An industry econ-
omist predicts a recovery from the slump with a 7 to 9 percent average growth
rate through 1980 due to increased prices in competitive materials.
Geographic locations are dictated by two factors: markets and raw
materials. Producers of large volume resins such as poly(vinyl chloride),
polystyrene, and the polyolefins which are generally produced in large con-
tinuous operations are usually located near petrochemical complexes on the
Gulf Coast because of their dependence on large quantities of raw materials.
The producers of small amounts of resins for particular end uses are usually
more market oriented and as a result are likely to bo located in large popu-
lation areas.
The 1972 Census of Manufacturers indicates that the bulk of the electri-
cal power consumed in this industry is purchased. In 1971, 6358.4 GWh were
purchased, while 411.9 GWh were generated for use within the plastics and
resins industry. The total energy consumed for heat and power, including fuel
and electrical consumption, was 45.7 TWh equivalents in 1971.
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Table 1. OPERATIONS AND PRODUCTS OF THE PLASTICS AND RESINS INDUSTRY
Operation
Mass Addition
Polymerization
Emulsion Addition
Polymerization
Products
Process
Numbers
Polystyrene 1,2,3
Acryloni trile-butadiene-
styrene
Styrene-acrylonitrile
Methyl methacrylate
Ally! resins
Latices 4, 5
Polystyrene
AeryIonitrile-butadiene-
styrene
Styrene-acrylonitrile
Poly(vinyl chloride)
Poly(vinyl acetate)
Poly(vinylidene chloride)
Polyalkyl acrylates and
copolymers
Polyalkyl rnethacrylates and
copolymers
Po1y(vinyl esters) and copolymers
Polyacrylonitrile
Polybutadiene
Polychloroprene
Polyisoprene
a-Methyl styrene copolymers
Isobutylerie copolymers
Solids
Poly(vinyl chloride)
plastisol resins
Styrene-acrylonitrile graft
polyblends with synthetic
rubbers
Teflon (polytetrafluoro ethylene)
Kel-F (polytrifluorochloro-
ethylene)
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Table 1 (Continued). OPERATIONS AND PRODUCTS OF THE PLASTICS AND RESINS INDUSTRY
Operation
Products
Process
Numbers
Suspension Addition Poly-
merization Processes
High Pressure Mass Poly-
merization
Solution Polymerization
Particle Form Poly-
merization (Poly-
ethylene)
Polyolefins Polymer-
ization (Ziegler)
Polymethacrylic esters and
copolymers 6, 7, 8
Polyacrylic esters and
copolymers
Polystyrene
Rubber-modified polystyrene
Poly(vinylidene chloride)-vinyl
chloride copolymers
Poly(vinyl chloride) and
copolymers
Poly(vinyl acetate)
Styrene acrylonitrile
Rubber-modified styrene-
acrylonitrile copolymers
(ie. ABS and others)
Polydivinyl benzene and
copolymers
Polytri fluorochloroethylene
Low density polyethylene 9, 10, 11
Styrene polymers and
copolymers 12, 13
a-Methylstyrene copolymers
Polyacrylic acid
Polymethacrylic acid
Polyacrylamide
Poly(vinyl pyrrolidone) and
copolymers
Polyethylene 14, 15
Ethylene-olefin copolymers
High density polyethylene 16, 17, 18
Polypropylene
Polybutene
(Various copolymers)
4
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Table 1 (Continued). OPERATIONS AND PRODUCTS OF THE PLASTICS AND RESINS INDUSTRY
Operation
Products
Process
Numbers
Phenolic Resin Production
Amino Resin Production
Polycarbonate Production
Epoxy Resin Production
Unsaturated Polyester
Resin Production
Alkyd Resin Production
Polyethylene Terephth-
alate Production
Nylon 6 Production
Nylon 66 Production
Polyurethan Foam
Production
Polyamide Resin
Production
Poly (phenylene sulfide)
Production
Polyacetal Production
Resols
Novolaks
Amino Resins
Polycarbonates (linear
thermoplastic polyesters)
Epoxy resins
Polyester resins (Mixtures
of unsaturated polyester
resin and vinyl-type
monomers)
Alkyd Resins
Polyethylene terephthalate
Nylon 6
Nylon 66
Polyurethan foam
Polyamide resins
Poly (phenylene sulfide)
Polyacetal resins
19, 20, 21, 22
23, 24, 25
26, 27, 28,
29, 30
31, 23, 33, 34
35, 36
37, 38
39, 40, 41
42, 43, 44
45, 46, 47, 48,
49, 50
51 , 52, 53
54, 55
56, 57
58, 59, 60
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Raw Materials
Major feed materials for this industry are obtained from the basic petro-
chemicals industry and from the industrial organic chemicals industry. The
progression of materials from petrochemicals to plastics is illustrated in
Figure 2 for eight high-volume production resins.
In addition to hydrocarbon feedstocks the industry employs many additives
such as fillers, pigments, fire retardants, and plasticizers to produce a final
resin product. A raw materials list was compiled from the process descriptions
in this chapter and may be found in Appendix A, Table A-l. While there are
omissions due to incomplete coverage of the industry, the list is thought to be
representative of the substances in common use for making plastics and resins.
Extensive lists of antioxidants, antistatic agents, flame retardants, free
radical initiators, and colorants are also included in Appendix A along with a
list of their manufacturers and suppliers. A list of plasticizers may be found
in the product list of the Synthetic Plasticizers Industry (Chapter 13).
The 1972 Census of Manufacturers lists materials consumed by the plastics
and resins industry. Those raw materials deemed important enough for report-
ing by the Bureau of Census are listed in Table 2.
Products
The plastics and resins industry as defined in this treatment produces
solid materials to be molded, cast, or extruded by fabricators and solutions,
pastes, and emulsions for coatings and adhesives. There are almost limitless
numbers of possible products made with different formulations and additives.
The largest consumers of plastics and resins products are the building and
construction industries and the packaging industries. They consume about 45
percent of the resins production.
There are two general types of polymeric materials produced in this
industry: thermosetting and thermoplastic resins. Thermoplastics, materials
whose shape and form are reversible by the application of heat, accounted for
about 85 percent of the plastics production in 1975. Thermosetting materials,
those whose form is not reversible when set by heat, accounted for the remain-
der. Table 3 lists the largest volume production materials with production
data for 1974 and 1975. These products approximate 90 percent of the total
plastics industry production. A complete product list is included in Appendix
B.
Companies
The industry is composed of an estimated 300 plastics producers. Although
an analysis of the large producers was prevented by lack of capacity and pro-
duction data, Table 4 lists twenty-four companies termed major producers in
one source of information.
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Table 2. MAJOR RAW MATERIALS FOR THE PLASTICS AND RESINS INDUSTRY
Raw Materials
1972 Consumption
acrylates and methacrylates, monomers
acrylonitrile
alcohols (except ethyl)
carbon black
cellulose acetate
extender oils (petroleum derived)
formaldehyde (37%)
glycerin
liquid refinery and petroleum gases
butadiene
ethylene
other (isoprene, propylene,
isobutylene, etc.)
melamine
phenol
phthalic anhydride
plasticizers
rubber processing chemicals
(accelerators, antioxidants,
blowing agents, inhibitors,
peptizers, etc.)
soap and detergents
sodium hydroxide
styrene
sulfuric acid (100%)
thermoplastic resins
thermosetting resins
urea
vinyl acetate monomer
vinyl chloride monomer
woodpulp (excluding wood flour)
358.4 Gg (789.5 x 106 Ib)
124.4 Gg (274.1 x 106 Ib)
1.86 hm3 (490.4 x 106 gal)
Not reported
Not reported
Not reported
618.4 Gg (1362.2 x 106 Ib)
11.8 Gg (26.1 x 106 Ib)
156.4 Gg (344.6 x 106 Ib)
1.978 Tg (4,356.7 x 10(l Ib)
530.5 Gg (1168.5 x 10'' Ib)
23.0 Gg (50.7 x 10f' Ib)
285.7 Gg (629.2 x 106 Ib)
103.1 Gg (227.2 x 106 Ib)
93.5 Gg (205.9 x 106 Ib)
Not reported
18.1 Gg (39.9 x 1C6 Ib)
3.54 Gg (3.9 x 106 tons)
1.417 Tg (3122.2 x 106 Ib)
81 Gg (90 x 103 tons)
242.8 Gg (534.9 x 10'' Ib)
17.2 Gg (37.9 x 10'' Ib)
157.5 Gg (346.9 x 10h Ib)
193.1 Gg (425.3 x 106 Ib)
1.176 Tg (2591.4 x 106 Ib)
40.0 Gg (44.1 x 103 tons)
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Table 4. MAJOR PLASTICS PRODUCERS
Allied Chemical
Borden
Borg-Warner (Marbon)
Celanese
Dart
Diamond-Shamrock
Dow
Du Pont
Eastman Kodak
Ethyl
Foster Grant
B. F. Goodrich
Gulf
Hercules
Koppers
Monsanto
National Distillers
Phillips Petroleum
Shell
Standard Oil (Indiana)9
Standard Oil (New Jersey)
Tenneco
Union Carbide
Uniroyal
Amoco, subsidiary
Now Exxon
Source: Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0266, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
1976 Di rectory of _ Chemi caJ__P_rpducejrs_
10
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The list in Table 4 includes mostly oil companies integrated toward end
products and chemical companies integrated back to raw materials as well as
forward to end products. Many of the installations produce monomer, polymer,
and fabricated end products at the same site. An estimated one-third of
fabricated plastic items are manufactured by the resin producers, a fact which
indicates the degree of forward integration within the industry. A complete
list of companies is included in Appendix C with locations and capacities
when available.
Environmental Impact
Gaseous emissions of hydrocarbon materials are encountered throughout
this industry. Some of these organic compounds are toxic materials, notably
vinyl chloride, toluene diisocyanate, phosgene, and pyridine. Great concern
has been generated for the welfare of workers subjected to exposure to these
substances, and maximum allowable concentration levels are being reassessed.
Another point of concern regarding hydrocarbon emissions is the reaction of
these substances in the atmosphere to form constituents of photochemical smog.
Hydrocarbons vary in their degree of reactivity in atmospheric oxidation
reactions depending on their chemical structure. Olefins are the most reactive
followed by aromatics, paraffins, and naphthenes. The industry uses very
large quantities of olefins and makes extensive use of aromatics and paraffins.
Solid wastes generated by this industry are landfilled or incinerated by
the resin producers who generally maintain their own disposal systems. The
waste originating from off-spec and excess product as well as from captured
particulates and fines is recycled when possible. A quantity of 2.6 Tg/yr
(5.8 billion Ibs/yr) of plastic waste is recycled, while 0.77 Tg/yr (1.7 bill-
ion Ibs/yr) end up as waste. This is compared to 3.8 Tg/yr (8.3 billion Ibs/yr)
of non-industrial plastic waste generated for which recycle technology is lack-
ing. To put the solid waste problem in perspective, the total solid waste gen-
erated in one year in the U. S. is about 272 Tg (300 million tons).
Incineration of plastics may cause some emissions of gaseous pollutants
depending on the chemical composition of the polymer materials. Some of the
problems of this nature which have been encountered are HC1 production from
poly(vinyl chloride) incineration; NOx production from burning nylon resins;
and thick, dense smoke evolution when polystyrene is burned in an air atmos-
phere.
Liquid waste streams, generally aqueous, are also encountered throughout
the industry. Much of the wastewater orginates from processing in which the
process streams are in direct contact with water. Waste water may also be
formed during the course of a chemical reaction; it may arise from cleaning
process vessels, area housekeeping, utility boiler and cooling water blowdown,
and other sources such as laboratories. The contaminants encountered in the
waste water include organic reactants, monomers, oligomers, polymers, and salts.
EPA studies to suggest guidelines for effluent limitations for the indus-
try established four major subcategories with respect to waste water character-
istics. These subcategories are presented in Table 5.
11
-------
Table 5. MAJOR WASTE-WATER SUBCATEGORIES OF THE PLASTICS AND RESINS INDUSTRY
Major
Subcategory
I
II
III
IV
Raw
Waste load-
BOD5 Valued
low
high
low or high
low or high
Achievable
BOD5 Value
<20 mg/liter
<20 mg/liter
30 - 75 mg/liter
>75 mg/liter
a
'10 kg/Mg product is low; >kg/Mg product is high.
Products found in each category are listed in Table 6, although all of the
products are not treated in this report.
Table 6. PRODUCT CLASSIFICATION BY WASTE-WATER CHARACTERISTICS
Category Products
I ethylene vinyl acetate, polytetrafluoroethylene,
polypropylene fiber, poly(vinylidene chloride),
poly(vinyl chloride), poly(vinyl acetate), poly-
styrene, polyethylene, polypropylene
II acrylic resins, cellulose derivatives, ABS/SAN,
cellophane, rayon
HI alkyd resins, unsaturated polyesters, cellulose
nitrate, polyamides, saturated polyesters,
poly(vinyl butyral), poly(vinyl ethers), silicones,
nylon 66, nylon 6, and cellulose acetates
IV nitrile barrier resins, spandex fibers, acrylics
12
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The extensive heating and cooling requirements necessitate elaborate cooling
tower, refrigeration, and steam generation facilities. The waste water
streams from these points are generally combined to be sent to the water
treatment plants. Cooling tower and boiler blowdown streams may contain
toxic anti-corrosion chemicals such as chromium compounds and anti-fouling
agents.
Specific emissions problems for resin products are indicated in the
process descriptions. A qualitative description of potential pollution
sources is attempted when quantitative data were not available in the con-
sulted literature.
Integration of industries makes it difficult to assess waste streams
from a particular plant. The waste stream compositions and loading ultimately
depend on such things as the other processes within the plant and waste
management practices. Waste streams may be combined or segregated and one
waste treatment facility may serve a large number of operations at one site.
13
-------
Bibliography
1V Anderson, Earl V. Industry Steps Up Efforts to Recycle Plastics Wastes.
Chemical and Engineering News, 5_3(38) :16-17, Sept. 22, 1975.
2. Booz-Allen Applied Research, Inc. A Study of Hazardous Waste Materials,
Hazardous Effects and Disposal Methods, Vol II. PB-221 466. Bethesda,
Md., 1973.
3. Bradley, R. F. et al. Classification of Industries, Descriptions and
Product Lists, SRI Project ECD-3423. Menlo Park, California, Stanford
Research Institute, December 1974.
4. C&EN's Top 50 Chemical Products and Producers. Chemical and Engineering
News, 54^19) :33-39, May 3, 1976.
5. Environmental Protection Agency, Effluent Guidelines Division. Develop-
ment Document for Effluent Limitations Guidelines and New Source Perform-
ance Standards for the Synthetic Polymers Segment of the Plastics and
Synthetic Materials Manufacturing Point Source Category. EPA 440/1-75/
036-b. Washington, D. C., Jan. 1975.
6. Environmental Protection Agency, (Office of Air and Water Programs, Eff-
luent Guidelines Div.) Development Document for Effluent Limitations
Guidelines and New Performance Standards for the Synthetic Resins Segment
of the Plastics and Synthetic Materials Manufacturing Point Source Cate-
gory. EPA 440/1-74-010-a. Washington, D. C., 1974.
7. Environmental Protection Agency, Office of Air Quality Planning and
Standards. Control of Photochemical Oxidants. Technical Basis and
Implications of Recent Findings. EPA-450/2-75-005. Research Triangle
Park, N.C., July 1975.
8. Federal Energy Administration (Office of Economic Impact). Report to
Congress on Petrochemicals. Public Law 93-275, Section 23, (no date:
circa 1974).
9. Federal Energy Administration, Office of Policy and Analysis. The Analy-
sis of the Economic Environment for the Report to Congress on Petrochemi-
cals, 1974-75. Washington, GPO, 1975.
10. Hedley, W. H., et al. Potential Pollutants from Petrochemical Processes,
Final Report. Contract 68-02-0226, Task 9, MRC-DA-406. Dayton, Ohio,
Monsanto Research Corp. Dayton Lab., Dec. 1973.
11. Makela, Robert G. and Joseph F. Malina, Jr. Solid Wastes in the Petro-
chemical Industry. EHE-72-14, CRWR-92. Austin, Tx., Center for Research
in Water Resources, University of Texas at Austin, Aug. 1972.
12. 1974-1975 Modern Plastics Encyclopedia. Sidney Gross, ed. McGraw-Hill,
N.Y., 1974.
14
-------
13. Plastic Resins Output Seen at 22 Billion Ib, Down 19.5%. The Oil and
Gas J_. Jan. 19, 1976, p. 37.
14. Plastics to Maintain Their Competitive Edge. Chemical and Engineering
News, 53(45):12-14, Nov. 10, 1975.
15. Sittig, Marshall. Pollution Control in the Plastics and Rubber Industry.
Park Ridge, N.J., Noyes Data Corp., 1975.
16. Stephens, E. R. and W. E. Scott. Relative Reactivity of Various Hydro-
carbons in Polluted Atmospheres. CA 59:8038f. Proc. Am. Petrol. Inst.,
Sect III 42, 665-70 (1962).
17. U. S. Bureau of Census. Census of Manufacturers, 1972. Industries
Series: Plastics Materials, Synthetic Rubber, and Man-made Fibers.
MC72(2)-28B. Washington, GPO, 1974.
15
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INDUSTRY ANALYSIS
This chapter provides an overview of the plastics and resins industry
through a summary of information from the open literature describing indus-
trial practice. Because of the wide range and complexity of the industry,
this treatment necessarily describes only the more important processes and
products. This type of summary eliminates many of the complexities and
variations in processing, resulting in a somewhat simplified picture of the
industry.
The major emphasis is on industrial processing practices, and description
of the often complex subject of polymer chemistry was beyond the scope of this
treatment.
Blending procedures as a part of the industrial processing are de-empha-
sized, causing some apparent inconsistencies in the process descriptions. It
is recognized that, especially in the case of the solid molding powder pro-
ducts of this industry, various additives may be blended with the product
before it is packaged for sales or storage. When these practices were in-
dicated in the literature sources, they are mentioned in the process descrip-
tions; however, chemical processing is stressed. Appendix A contains lists
of various types of additives used in formulating various plastic products.
Information used in this chapter was found in books, encyclopedias, trade
journal articles, and EPA documents. It is thought that inconsistencies
encountered in these sources result mainly from the wide variation in process-
ing methods within the industry and from the lag of technical literature be-
hind technological advances. Confusion also results from data presented with-
out specification of the processing method used.
Data deficiencies encountered in the preparation of the Industry Descrip-
tion include a lack of capacity and/or production data by company or location.
An attempt was made to retrieve this information using statistics published by
SIC codes. A compilation for companies categorized in SIC code 2821 provided
production data for about half of the plastics producers listed in the 1976
Directory of Chemical Producers. This is thought to be a result of categori-
zation of fabricators and resin producers in separate SIC codes. The exten-
sive integration of plastics producers and fabricators appears to create
difficulties in differentiating between the two types of companies. As a
result, information based on SIC categories such as that provided by the
Bureau of Census and the International Trade Commission may be inadequate,
but it is used for lack of better data.
Data are given in metric units as specified by the ASTM Metric Practice
Guide. Preferred base units and rules for rounding numbers converted from
one system of units to another are described therein. Gas volumes given in
standard cubic feet are assumed to be 60°F volumes and are converted to
cubic meters at 0°C.
Each operation is accompanied by a flow sheet indicating input materials,
processes (numbered rectangles), and product and by-product streams (large
circles). Solid, liquid, and gaseous waste streams are indicated by small
squares, triangles, and circles, respectively, attached to the numbered pro-
cess rectangles. Process descriptions follow the flow sheets on which they
are presented.
16
-------
MASS ADDITION POLYMERIZATION PROCESSES
A number of important resins (plastics) are manufactured by mass polymer-
ization, a system in which the purified monomer is allowed to polymerize under
controlled conditions of temperature and reaction rate. The Mass Addition
Polymerization Operation is concerned only with those monomers which dissolve
their polymers and excludes those from which the polymer precipitates.
Mass polymerization is the method most frequently used in the laboratory
to study new monomers and their copolymers; no extra variables are introduced
with the addition of other substances, and the problem of heat removal is
trivial. However, industrial operations on a larger scale must contend with
large heats of reaction which must be removed, as the resulting high tempera-
tures would cause the polymer product to break down. The high viscosity of
the polymer often makes heat transfer difficult. Another problem encountered
is the autoacceleration or gd effect encountered is some polymer systems, es-
pecially in methyl methacrylate. This effect is seen as a marked deviation
from first order kinetics with an attendant increase in reaction rate and
molecular weight.
Resins produced by this operation include polystyrene, ABS (acrylonitrile-
butadiene-styrene), SAN (styrene-acrylonitrile), PVC (poly[vinyl chloride]),
methyl methacrylate, and ally! resins. Polystyrene and its copolymers are the
primary resins commercially manufactured by a pure mass polymerization process.
Methyl methacrylate and ally! resins (ally! casting resin syrups) are produced
commercially by mass polymerization on a small scale for specialty items.
There are three processes involved in this operation. The polymer is
formed from the monomer in the Polymerization Process (No. 1). The Vacuum
Stripping Process (No. 2) removes the impurities from the product, and the
Palletizing and Bagging Process (No. 3) cuts and packages the polymer products.
The sequence of processing is illustrated diagrammatically on Figure 3.
Utility requirements were largely unavailable in the literature consulted.
Some requirements are listed for polystyrene production by the mass addition
method. Since the basis is mass of product, the values include requirements
for all three of the processes. For this reason the utility requirements are
listed in Table 7.
A product-specific treatment of waste water from the plastics and resins
industry defines waste water loading and raw waste loads for a few products
made by this operation. They are presented here in Table 8, since they in-
clude waste from the entire plant.
17
-------
Table 7. UTILITY REQUIREMENTS FOR POLYSTYRENE PRODUCTION BY
MASS POLYMERIZATION3
Power 340 kWh
Steam (500 kPa) 400 kg
Process Water 2.5m3
a Based on 900 kg production (1 ton)
Source: Polystyrene—Mitsui Toatsu Chem., Inc. Hydrocarbon
Processing, 50_:202, November 1971.
Table 8. WASTE WATER DATA FOR PRODUCTS MADE IN MASS ADDITION
OPERATIONS
Waste Water Raw Waste Load
Loading (kg/Mg product)
Product
Poly(vinyl chloride)
ABS/SAN
Polystyrene
(m3/Mg Product)
2.5-41.72
1.67-24.03
0-141.8
BOD5
0.1-48
2-20.7
0-2.2
COD
0.2-100
5-33.5
0-6.0
SS
1-30
0-30
0-8.4
Source: Environmental Protection Agency, Effluent Guidelines
Division. Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards
for the Synthetic Polymers Segment of the Plastics and
Synthetic Materials Manufacturing Point Source Category.
EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
Environmental Protection Agency, (Office of Air and
Water Programs, Effluent Guidelines Div.) Development
Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Resins
Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a.
Washington, D. C., 1974.
18
-------
ADDITIVES
POLYMERIZATION
LSQtHO
O QAtioua EMISSIONS
Q 8OUO (MISSIONS
& UQUIO EMISSIONS
VACUUM
STRIPPING
/ PURE \
I POLYMER )
PELLETIZING
AND
BAGGING
FIGURE 3. MASS ADDITION POLYMERIZATION
19
-------
MASS ADDITION POLYMERIZATION PROCESS NO. 1
Polymerization
1. Function - This process produces polymeric materials from a purified
monomer material in a continuous or multistage batch operation. After remov-
al by distillation or washing of inhibitors used to protect the monomers from
autopolymerization in storage, small amounts of catalysts and modifiers are
added which will initiate the reaction, control its rate, and influence the
molecular weight of the polymer. These substances are not easily recoverable
and the residues remain in the product.
The monomer is brought to reaction temperature by indirect heating in
a stirred, jacketed kettle. Temperature control is accomplished through cir-
culating heat transfer fluid and heat exchange equipment. When the reaction
is completed, the polymer is sent to a vacuum stripper.
2. Input Materials - Input materials include the monomer required for the
specific product; styrene, acrylonitrile, butadiene, vinyl chloride, methyl -
acrylate, or allyl esters of aromatic acids. For polystyrene about 1.1 kg
of styrene is required per kg of polystyrene.
For polystyrene approximately 0.03 kg of additives (catalysts and modi-
fiers) are required per kg of product.
About 0.004 kg of inert solvents (viscosity reducers) are required to
produce 1 kg of polystyrene.
It is thought that conversion is limited to 50 to 60 percent in PVC pro-
duction.
3. Operating Parameters - Equipment used includes stirred, jacketed resin
reaction kettles and heat exchangers.
Conditions are different for each polymer product. The temperature for
making polystyrene is initially 90°C and is raised to 150° or possibly 200°C.
4. Utilities - See Table 7.
5. Waste Streams - Possible liquid waste streams are inhibitor-wash waste,
oil leaks in the heat exchange equipment, and water from washdown of spills.
Excess or substandard product is produced as a solid waste stream.
Fugitive gaseous emissions of volatile monomer material may also be
produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
20
-------
References -
(1) Bishop, Richard B. Find Polystyrene Plant Costs. Hydrocarbon Pro-
cessing, 51:137-140, November 1972.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthetic
Resins Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 258-259.
(4) Matthews, George. Vinyl and Allied Polymers. Vol. 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Hiffe Books, 1972.
(5) Polystyrene-Ato Chimie. Hydrocarbon Processing, 54_:198, November
1975.
(6) Polystyrene-Mitsui Toatsu Chem., Inc. Hydrocarbon Processing, 50:
202, November 1971.
21
-------
MASS ADDITION POLYMERIZATION PROCESS NO. 2
Vacuum Stripping
1. Function - The molten polymer from the reaction kettle is pumped by means
of vented twin screw extruders to a vacuum stripper (devolatilizer) to remove
unreacted monomer and small amounts of contaminants and by-products. Vapors
from the vacuum stripper pass through an oil-cooled tar condenser. The condens-
er vent is connected to a steam jet ejector; steam and volatile hydrocarbons
condense in a water-cooled surface condenser. Phase separation is accomplished
by decanting. The oils are recovered, and contaminated condensate goes to the
process sewer. Tars and oligomer form a solid waste stream. The isolated
molten polymer is extruded from the bottom of the stripper.
2. Input Materials - Molten polymer from the reactor is the input material.
3. Operating Parameters - The vacuum stripper operates at 3.1 kPa (29 in Hg)
4- Utilities - See Table 7.
5. Waste Streams - Possible sources of liquid waste are contaminated condensate
and condenser leaks.
Fugitive gaseous emmissions are possible from the stripper (valves, condens-
ers, vents, seals, etc.). Emissions may also result in the form of light ends
from the decanter.
Solid waste in the form of tars and oligomers also results from the phase
separation.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02.
7. References -
(1) Bishop, Richard B. Find Polystyrene Plant Costs. Hydrocarbon
Processing, 51_: 137-140, November 1972.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Oiv.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthetic
Resins Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N. Y.,
Van Nostrand Reinhold, 1974, p. 258-259.
(4) Polystyrene--Ato Chimie. Hydrocarbon Processing, 54:198, November
1975.
(5) Polystyrene—Mitsui Toatsu Chem., Inc. Hydrocarbon Processing,
50:202, November 1971.
22
-------
MASS ADDITION POLYMERIZATION
PROCESS NO. 3
Palletizing and Bagging
1. Function - Ribbons of pure molten polymer are extruded from the bottom
of the stripper through a water bath. The polymer strands are then cut into
granules or pellets and the finished product is packaged.
2. Input Materials - Purified polymer from the stripper and cooling water
are input materials to this process.
3. Operating Parameters - The extrusion temperature range is 150° to 180°C
for poly(vinyl chloride) and 190° to 260°C for polystyrene. Table 9 presents
production capacities for various sizes of screw extruders processing poly
(vinyl chloride).
Table 9. PRODUCTION CAPACITIES OF SCREW EXTRUDERS FOR 0.64 cm
(0.25 in) RODa
Diameter
cm
5
6.4
8.3
8.9
11.4
15
of Screw
in
2
2.5
3.25
3.5
4.5
6.0
Productive
kg/hr
10-20~
20-30
34-57
43-68
68-90
110-140
Capacity
Ib/hr
30-50
40-75
75-125
95-150
150-200
250-350
apolyvinyl chloride, sp. gr. 1.35
4. Utilities - See Table 7.
5. Waste Streams - An aqueous waste stream containing polymer fines may result
from pelleting procedures.
Solid waste in the form of particulates, fines, and chunks may
result from pelleting and bagging. Particulates may also be emitted if
pneumatic conveying systems are employed.
6. EPA Source Classification Code - Polyprod. General 3-018-01-02
7. References -
(1) Bishop, Richard B. Find Polystyrene Plant Costs. Hydrocarbon
Processing, 51:137-140, November 1972.
23
-------
(2) Chemical Engineers' Handbook, 4th Ed., Robert H. Perry, ed. N. Y.,
McGraw-Hill, 1963.
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N. Y.,
Van Nostrand Reinhold, 1974, p. 258-59.
(5) Polystyrene--Ato Chimie. Hydrocarbon Processing, 54kl98, November
1975.
(6) Polystyrene--Mitsui Toatsu Chem., Inc. Hydrocarbon Processing,
50:202, November 1971.
24
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EMULSION ADDITION POLYMERIZATION PROCESSES
Emulsion polymerization is a two-phase polymerization system. It is
characterized and differentiated from suspension polymerization by the lo-
cation of the initiator in the aqueous phase and by the size of the particles
produced (lOnm-lym).
The polymer product is usually marketed in the latex form (for paints,
adhesives, paper coatings, etc.) but may be sold as a dry resin. Latex
materials produced in this operation include polystyrene, ABS (acrylonitrile-
butadiene-styrene), SAN (styrene-acrylonitrile), PVC (poly[vinyl chloride]),
PVA (polyivinyl acetate]), poly(vinylidene chloride), poly(alkyl acrylates) and
and copolymers, poly(alkyl methacrylates) and copolymers, poly(vinyl esters) and
copolymers, polyacrylonitrile, polybutadiene, polychloroprene, polyisoprene,
a-methylstyrene copolymers, and isobutylene copolymers.
Some of the solid products of this operation include poly(vinyl chloride)
plastisol resins, styrene-acrylonitrile graft polyblends with synthetic
rubbers, teflon (polytetrafluoroethylene), and Kel-F (polytrifluorochloroethy-
lene).
Advantages offered by emulsion polymerization are the ability to form
a high molecular weight product at a high reaction rate, the ease of heat
transfer, and the lower viscosity of the emulsion compared to a polymer
solution. This type of polymerization produces very finely divided particles
which can be of very uniform size distribution. A disadvantage for some
applications is the contamination of the product with emulsifiers and other
chemical additives.
A product specific treatment of plastics and resins manufacture presented
some waste water data for several products made by this operation. Because
the data include waste water from the entire operation, they are included here
in Table 10.
Table 10. WASTE-WATER DATA FROM EMULSION POLYMERIZATION
Product
Waste-Water Loading
(m3/Mg product)
Raw Waste Load
(kg/Mg product)
BOD5 COD ~
Poly(vinyl chloride)
ABS/SAN
Poly(vinyl acetate)
Fluorocarbon polymers
Poly(vinyl idene chloride)
2.5-41.72
1.67-24.03
0-25.03
18.4-152.7
4.2a
0.1-48
2-20.7
0-2
0-6. 6a
Oa
0.2-100
5-33.5
0-3
4.4-44a
8a
1-30
0-30
0-2
2.2-6
0.2a
.6a
Estimated
Source: See next page
25
-------
Source: Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the
Synthetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a. Washing-
ton, D. C., 1974.
Two processes are described: 4) Polymerization which results in a latex
product and 5) Dry Product Preparation, producing a dry resin through coagu-
lation and drying methods. Figure 4 is a process flow chart included as an
aid in understanding the processing methods.
26
-------
LI01NO
IMISSIONS
Q SOLID IMISaiONS
A LIQUID SMISSIONS
POLYMERIZATION
4
TO SALES
DRY PRODUCT
PREPARATION
TO SALES
FIGURE 4. EMULSION ADDITION POLYMERIZATION
27
-------
EMULSION ADDITION POLYMERIZATION
PROCESS NO. 4
Polymerization
1. Function - In this process a latex polymer product is produced from an
emulsion feedstock of monomer in a continuous liquid phase, usually water.
After removal of inhibitors from the monomer material by washing, an
emulsion is made by addition of monomer and emulsifier to deionized or
distilled water. The reaction is initiated by formation of micelles, aggre-
gates of emulsifier molecules. The critical micelle concentration (cmc)
is the concentration below which micelles will not form and is characteristic
of a specific emulsifier. The emulsifying agent must be added in concentra-
tions exceeding the cmc.
If a batch cycle is used, the emulsion of monomer is introduced into a
stirred, jacketed reactor containing an emulsified solution of various
chemical additives such as catalysts, initiators, and chain transfer agents.
Reactors may be equipped with reflux condensers if the polymer does not
have heavy fouling tendencies. Turbine agitators are often employed, but
large-diameter, slow-speed impellers are used in some emulsion systems which
are sensitive to coagulation due to shearing. Double mechanical seals are
commonly used in the agitator, and lubricants are chosen carefully, as some
leakage into the reactor always results.
The reactor temperature is controlled by circulating water or steam
through the jacket. Additional methods of heat removal are continuous
addition of cold monomer, reflux condensing, and side-stream cooling through
heat exchange. It is not possible to use refluxing and heat exchange with all
polymers because of temperature sensitivity and fouling tendencies. However,
if a reflux condenser is used, volatilized monomer and water are recirculated
to the reactor.
When the reaction is completed, the polymer is drawn off through a screen
to remove oversize particles which are landfilled. The remaining monomer
is then removed by flashing, usually in a vertical tank, and steam stripping
in single or multiple stages.
Continuous operations may utilize tubular reactors, a series of agitated
reactors, or towers.
2. Input Materials - Input materials include monomers, initiators, emulsifiers,
chain transfer agents, redox catalysts, and stabilizers. Examples are given
below.
Monomers - include styrene, acrylonitrile, butadiene, vinyl chloride,
vinylidene chloride, tetrafluoroethylene, trifluorochloroethylene, vinyl
acetate, alkyl acrylates, alky! methacrylates, chloroprene, isoprene,
a-methylstyrene, and isobutylene.
Initiators - usually water soluble peroxidic compounds such as hydrogen
peroxide, urea peroxide, potassium persulfate, sodium perborate, ammonium
peroxysulfate, and cumene hydroperoxide.
28
-------
Emulsifiers - include soaps of long-chain alcohols, salts of aliphatic
and aromatic sulfonic acids, aliphatic amines and their salts.
Modifier or chain transfer agent - mercaptans, halogenated aliphatic
hydrocarbons, or hydrocarbons with an active hydrogen such as cumene.
Redox catalyst - water soluble, inorganic reducing agent, commonly
chelated iron.
Stabilizers and buffering agents may be added to protect the emulsion
from breaking. These include casein, glue, albumin, starch, methyl cellulose,
poly (vinyl alcohol), phosphates, carbonates, and other additives.
Also added are small amounts of oxygen scavengers such as sodium dith-
ionite.
Table 11 illustrates typical emulsion polymerization "recipes." The lower
limit of emulsifer concentration is indicated by the cmc values in Table 12
for various emulsifiers.
Table 11. INPUT MATERIALS FOR PRODUCTION OF POLYSTYRENE AND
POLY (VINYL CHLORIDE) BY EMULSION POLYMERIZATION
METHODS.
Polymer
Chemical
Parts by Weight
polystyrene
poly (vinyl chloride)
sytrene
sodium oleate
potassium persulfate
water
vinyl chloride
fatty sulphonate
fatty alcohol
lauroyl peroxide
water
100
6
0.3
150
40-50
0.4-0.6
0.4-0.6
0.4-0.5
100
29
-------
Table 12. CMC VALUES FOR TYPICAL EMULSIFIERSa
Emulsifier Cmc (moles/?,)
potassium caprylate 0.393
potassium caprate 0.105
potassium laurate 0.026
potassium myristate 0.0059-0.0072
potassium palmitate 0.003
potassium stearate 0.0008
potassium oleate 0.001
sodium decyl sulfonate 0.04
sodium dodecyl sulfonate 0.0098
sodium tetradecyl sulfonate 0.0027
sodium decyl sulfateb 0.023
sodium dodecyl sulfateb 0.0057
potassium dehydroabietate 0.025-0.03
sodium rosenate <0.01
d50°, in pure water
btemperature not specified
3. Operating Parameters- The polystyrene polymerization reaction presented
in Table 11 takes place at 70°C. One source of information indicates typical
reaction times of 18 to 30 hours at temperatures of 45° to 75°C. With the use
of redox catalysts the reaction may proceed at very low temperatures (0°C) and
may require much shorter reaction times.
The pressure in the reactor may begin at 0.5-1.5 MPa (5-15 atm) for PVC
polymerization; it decreases as the reaction proceeds. Reaction times may
be as short as six hours.
Typical reactor volumes are from 20 to 100 m'! (5000 to 30,000 gal).
Reactors are usually glass-lined or stainless steel.
Table 13 indicates effective pH ranges for various types of emulsifiers.
Overall heat transfer coefficients of emulsion systems are usually 340
W/m2°C (40-60 Btu/hrft2°F) for turbine agitated reactors. Agitation heat
input is about 5 percent of the total for emulsion polymerization systems.
Shear sensitive latices may require pump type agitation.
30
-------
Table 13. EFFECTIVE pH RANGE OF EMULSIFIERS
Emulsifier pH Range
Ci2-C18 soaps 9-11
ammonium or ami no soaps 8-9
alkyl sulfates and alkyl sulfonates wide pH range
salts of amines, quartenary ammonium
salts of long-chain substituted cyclic
amines acid pH
Non ionic emulsifiers, such as
polyalcohols and esters insensitive to pH
4. Utilities - Agitation requires 0.6-2W/m3 (3-10hp/1000 gal).
5- Waste Streams - Fugitive gaseous emissions of volatile monomer may
occur at leaks in equipment, vents, valves, and rupture discs.
A solid waste stream results from the oversize latex screenings; these
are landfilled.
Water used to wash the inhibitors from the monomers prior to reaction
forms a wastewater stream. Additional liquid waste may result from leaks
in processing equipment.
Cleaning of reactors is accomplished by mechanical removal of solid
deposits or by washing down the sides of the reactor with solvent or high-
pressure steam. The literature contained no information concerning the
disposition of this waste stream.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Basel, L. and J. Papp. Polymerization Procedures, Industrial
In: Encyclopedia of Polymer Science & Technology, Vol 11. H.F.
Mark, ed. N.Y., Wiley, 1969, p. 280-304.
(2) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed.
N.Y., Wiley, 1971.
(3) Duck, Edward W. Emulsion Polymerization. In: Encyclopedia of
Polymer Science and Technology, Vol. 6. H.F. Mark, ed. N.Y.,
Wiley, 1966, p. 801-59.
(4) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a. Wash-
ington, D.C., 1974.
31
-------
(5) Hahn, A. V. The Petrochemical Industry - Market and Economics.
N.Y., McGraw-Hill, 1970, p 299-300.
(6) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 260.
(7) Lenz, Robert. Polymerization, Mechanisms and Processes. In: Kirk-
Othmer Encyclopedia of Chemical Technology, Vol 16. Anthony Standen,
ed. N.Y., Wiley, 1968, p. 219-42.
(8) Matthews, George. Vinyl and Allied Polymers. Vol 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Iliffe Books, 1972.
(9) Oringer, Kenneth. Current Practice in Polymer-Recovery Operations.
Chemical Engineering, 7_9:29-106, 20 March 1972.
(10) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houndry Div.,
March 1974.
(11) Schlegel, Walter F., Design and Scaleup of Polymerization Reactors.
Chemical Engineering, 79_:88-95, 20 March 1972.
(12) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
32
-------
EMULSION ADDITION POLYMERIZATION
PROCESS NO. 5
Dry Product Preparation
1. Function - In this process a dry resin product is formed from the latex
material resulting from emulsion polymerization. Coagulation is accomplished
by the addition of a chemical substance to break the emulsion, by freezing,
by agitation, by ultrasonic vibration, or by forcing the latex through jets
(shearing).
The coagulated polymer which contains 40 to 65 percent water must then
be dried. Product specifications are usually 0.1 to 1.0% water (wet basis).
Drying may be accomplished by milling on heated rollers or in spray, rotary,
or flash driers.
Spraying the latex into a heated gas chamber is an often used method
which accomplishes coagulation and drying in one step. The polymer is then
compressed into pellets for sale as a finished dry product.
2. Input Materials - Latex formed by emulsion polymerization and chemical
additives to break the emulsion (acids, electrolytes, flocculating agents)
are input materials to this process.
3- Operating Parameters - None were available in the sources consulted for
this study.
4- Utilities - None were available in the sources consulted for this study.
5. Waste Streams - Gaseous emissions of monomer or other low boiling compounds
may result in the drying section of the plant. Waste water also results
from the dryers, and it may be contaminated with various chemicals: monomer,
initiators, modifiers, emulsion breakers, etc. Dusting in the driers has the
potential for producing particulate emissions if the dust collecting methods
are inadequate.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Basel, L, and J, Papp. Polymerization Procedures, Industrial. In;
Encyclopedia of Polymer Science & Technology, Vol 11, H. F. Mark,
ed. N.Y., Wiley, 1969, p. 280-304,
(2) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y.,
Wiley, 1971.
(3)
(4)
Duck, Edward W.
Polymer Science
Wiley, 1966, p.
Emulsion Polymerization. In:
and Technology, Vol, 6. H. F.
801-59.
Encyclopedia of
Mark', ed. N.Y, .
Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
33
-------
(5) Hahn, A. V. The Petrochemical Industry - Market and Economics.
N.Y., McGraw-Hill, 1970, p. 299-300.
(6) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 260.
(7) Lenz, Robert. Polymerization Mechanisms and Processes. In: Kirk-
Othmer Encyclopedia of Chemical Tehcnology, Vol 16. Anthony Standen,
ed. N.Y., Wiley, 1968, p. 219-42.
(8) Matthews, George. Vinyl and Allied Polymers, Vol 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Iliffe Books, 1972.
(9) Oringer, Kenneth. Current Practice in Polymer-Recovery Operations.
Chemical Tehcnology, Vol 16. Anthony Standen, ed. N.Y., Wiley,
1968.
(10) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
34
-------
SUSPENSION ADDITION POLYMERIZATION PROCESSES
Suspension polymerization is similar to emulsion polymerization in that
the monomer is dispersed rather than dissolved in the continuous phase. It
differs from emulsion polymerization in the location of the initiator in the
monomer phase and in the size of the polymer particles produced (5Q-2000y).
Although reaction times required are longer than in an emulsion polymerization,
the product is obtained in the form of spherical beads rather than in the
latex form. This fact makes possible the recovery of a polymer product of
higher purity than in the emulsion process in which coagulation of latex
results in inclusion of chemical additives. The suspension polymerization
product is easily washed and dried to form the final dry product. Other
.advantages of this process include good heat transfer and low viscosity due
to the suspension of particles in the continuous phase.
Polymers produced by a commercial suspension process include poly
(methacrylic esters) and copolymers, polyacrylic esters and copolymers,
polystyrene, rubber-modified polystyrene, poly(vinylidene chloride)-vinyl
chloride copolymers, poly(vinyl chloride) (PVC) and copolymers, PVA (poly
[vinyl acetate]), SAN (styrene-acrylonitrile copolymers), rubber-modified
styrene-acrylonitrile copolymers, i.e., ABS and others, poly(divinylbenzene)
and copolymers, and poly(chlorotrifluoroethylene) and copolymers. Of these
polymers poly (vinyl chloride) is produced in the largest quantities; this is
the major method for PVC production.
Figure 5 shows that there are three processes presented in this opera-
tion: 6) Polymerization, 7) Polymer Isolation, and 8) Final Product Prepar-
ation. These processes accomplish the transformation of a monomer into a
dry polymer product.
A product-specific treatment of this industry presents waste-water data
for several products made by this operation. The data are included in Table
14, as they pertain to the whole operation.
35
-------
Table 14. WASTE-WATER DATA FOR SUSPENSION POLYMERIZATION PRODUCTS
Product
Waste-water Loading
(m3/Mg) product
BOD.
Raw Waste Loads
(kg/Mg product)
COD
SS
Poly (vinyl chloride)
ABS/SAN
Poly (vinylidene chloride)
Polystyrene
Poly (vinyl acetate)
2.5-41.72
1.67-24.03
4.2a
0-141.8
0-25.03
0.1-48
2-20.7
Oa
0-2.2
0-2
0.2-100
5-33.5
8a
0-6.0
0-3
1-30
0-30
0.2a
0-8.4
0-2
Estimated
Source: Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Materials Manufacturing Point Source Category. EPA 440/1-
74-010-a. Washington, D. C., 1974.
36
-------
OOAS80US EMISSIONS
Q 3OUO EMISSIONS
& UQUIO IMIS8ION8
CATALYSTS
POLYMER ISOLATION
DRIED
POLYMER
BEADS
FINAL PRODUCT
PREPARATION
FIGURE 5, SUSPENSION ADDITION POLYMERIZATION
37
-------
SUSPENSION ADDITION POLYMERIZATION PROCESS NO. 6
Polymerization
1. Function - Liquid monomer is transformed into solid globules of polymer
product in this process.
In a typical batch process the atmosphere in the reaction kettle is purged
with an inert gas prior to charging a suspension agent along with distilled or
deionized water. The monomer may be prepared by washing with water to remove
protective inhibitors. Initiator is added to the monomer, and the resulting
solution is added to the reactor. Continuous agitation and temperature control
are applied until the reaction is completed.
Agitation is of utmost importance in this process as it is a controlling
factor in particle sizing. Turbine, anchor, and paddle agitators have been
used; baffles have also been used as an aid to agitation. To ensure thorough
agitation, the agitator equipped with double mechanical seals is commonly
located near the bottom. Lubricants must be chosen very carefully, as a small
amount of leakage at the seals always results.
Temperature control is achieved primarily through the use of steam/water
jackets on the reactors. A few polymers may be cooled with reflux cooling and
by circulation through a heat exchanger, but fouling and temperature sensitivities
prohibit this practice for many polymers. If reflux cooling is utilized, the
vaporized monomer and water vapor are returned to the reactor.
Residual monomer is flashed in single or multiple stages, usually in vertical
flash tanks. This procedure is usually followed by steam or vacuum stripping.
Commercial processes are generally of the batch cycle type, but a series
of reactors is sometimes employed in continuous processing methods.
2. Input Materials - Monomers may include the following: methacrylic acid esters,
acrylic acid esters, styrene, vinylidene chloride, vinyl chloride, vinyl acetate,
acrylonitrile, butadiene, divinylbenzene, tetrafluoroethylene, and chlorotri-
fluoroethylene. Suspension agents such as (tri)calcium phosphate (hydroxy
apatite), barium sulfate, aluminum hydroxide, bentonite clay, calcium oxalate,
gelatin, poly(vinyl pyrrolidone), poly(vinyl alcohol), carboxymethylcellulose,
hydroxyethylcellulose, polyacrylic acid, polymethacrylic acid, acrylic-methacrylic
acid, and ester copolymers have been used.
Initiators are monomer-soluble catalysts, in many cases organic peroxides.
Some initiators which have been used are benzoyl peroxide, diacylperoxides,
lauroyl peroxide, diisopropylperoxy dicarbonate, and t-butylperoxypivalate.
Stabilizers which have been used include poly(vinyl alcohol), tragacantn
gum, salts of styrene-maleic anhydride copolymers, vinyl acetate-maleic
anhydride copolymers and salts, starch, gelatin, and methy!cellulose. Purified
(distilled or deionized) water is also required.
The ratio of water to monomer varies from 1:1 to 4:1. Input materials to
typical suspension polymerization processes are listed in Table 15.
38
-------
Table 15. INPUT MATERIALS TO TYPICAL SUSPENSION POLYMERIZATION PROCESSES
Component
Water
Peroxide initiator
Stabilizers
Styrene
200
0.1
0.1
Parts per 100 Parts
Methyl Methacrylate
350
0.5
0.01 - 1
of Monomer
Vinyl Chloride
150 - 350
0.1 - 0.5
0.01 - 1
3. Operating Parameters - Poly(vinyl acetate) is processed in a reactor capable
of withstanding 300 kPa (50 psi). The reaction temperature is about 70°C. Agi-
tators used are generally of the anchor or paddle type. Reflux cooling is fre-
quently employed.
Poly(vinyl chloride) reactors are rated at a minimum of 1 MPa (200 psi).
This pressure exceeds the vapor pressure of vinyl chloride at the reaction tem-
perature by 300 kPa (50 psi). Relief valves generally have an orifice area of
0.00020 m2/m3 (0.0012 in2/gal) of reactor capacity. Reaction temperature is
50°C (122°F). The required coolant temperature at the maximum conversion rate
for a 14 m3 (3700 gallon) reactor is 5°C (41°F), necessitating the use of re-
frigerated water. Total reaction time is 12 hours per batch. The same reactor
has an overall heat transfer coefficient of 312 W/m2K (55 Btu/hr ft2 °F).
One source indicates that for polymerization of styrene in a 19 m3 (5000 gal)
reactor equipped with internal cooling baffles, the lowest coolant temperature
required is 49°C (120°F). This allows the use of cooling tower water to control
the temperature. Another source of information specifies temperature and re-
action times for polystyrene: 6 hours at 90°C, then 8 hours at 13C)°C.
The size of the polymer beads is determined by agitation rates and ef-
ficiencies, amounts of stabilizers and catalysts, temperature, and pH. Usual
temperatures range from 40°C to 90°C. Typical reactor volumes are 20 to 100 m3
(5000 to 30,000 gal). Reactors are usually glass-lined steel or stainless
steel. Heat input from agitation is usually 5 percent or less of the total
heat input.
4. U t i1it ies - Agitation power input is commonly 1 kW/m (6 to 7 hp/1000 gal).
5. Waste Streams - A liquid waste stream results from water-washing to remove
inhibitors from monomer feedstocks.
Fugitive gaseous emissions of volatile monomer materials may occur at vents,
valves, flanges, seals and at leaks in equipment. In the production of PVC
0.0009 kg of vinyl chloride are emitted in this way per kg of PVC produced.
39
-------
Cleaning of reactors is accomplished by mechanical methods or by washing
with solvent or high-pressure steam. Although no information was found concern-
ing the disposition of this material, a solid and/or liquid waste steam is
assumed.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Basel, L. and J. Papp. Polymerization Procedures, Industrial, In:
Encyclopedia of Polymer Science & Technology, Vol 11. H. F. Mark,
ed. N.Y., Wiley, 1969, p. 280-304.
(2) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed.
N.Y., Wiley, 1971.
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Farber, Elliott. Suspension Polymerization. In: Encyclopedia of
Polymer Science and Technology, Vol 18. H. F. Mark. ed. N.Y.,
Wiley, 1970, p. 552-71.
(5) Hahn, A. V. The Petrochemical Industry - Market and Economics.
N.Y., McGraw-Hill, 1970, p. 299.
(6) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 263.
(7) Lenz, Robert. Polymerization Mechanisms and Processes. In: Kirk-
Othmer Encyclopedia of Chemical Technology, Vol. 16. Anthony Standen,
ed. N.Y., Wiley, 1968, p. 219-42.
(8) Matthews, George. Vinyl and Allied Polymers. Vol 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Iliffe Books, 1972.
(9) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(10) Polystyrene--Cosden Technology, Inc. Hydrocarbon Processing, 5£:199,
November 1975.
40
-------
(11) Polyvinylchloride--Ato Chimie. Hydrocarbon Processing, 54:200,
November 1975.
(12) Schlegel, Walter F. Design and Scaleup of Polymerization Reactors.
Chemical Engineering, 79_:88-95, 20 March 1972.
(13) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
41
-------
SUSPENSION ADDITION POLYMERIZATION
PROCESS NO. 7
Polymer Isolation
1. Function - The solid and liquid phases of the polymer slurry are separated
in this process by centrifugation and/or filtration. Large-scale processes com-
monly use drum-type belt filters, horizontal belt filters, perforate basket cen-
trifuges, solid-bowl centrifuges, and pusher centrifuges to remove about 90
percent of the water. Rotary driers are most often used to provide a moisture
content of 0.1 to 1 percent (wet basis). Other types of driers may also be used.
Fluid-bed driers find an application in this process for drying polystyrene beads,
2. Input Materials - A slurry of polymer beads is the input to this process.
Direct drying with air requires 0.2 to 0,3 m3/min (8 to 10 ft3/min) of air to
remove 0.5 kg (1 Ib) of water.
3. Operating Parameters - Rotary driers usually operate at 5 to 15 percent of
their total volume. Air velocities usually range from 2 to 20 Mg/hr m2(400 to
4000 Ib/hr ft2). The peripheral speed of operation is 9 to 30 m/min (30 to 100
ft/min). The slope of the shell varies from 0 to .08 cm/m (0 to 1 in./ft).
Typical residence times are 5 to 20 min. The cylinder length may be 4 to 10
times its diameter; 4 meter (12 foot) diameters are typical of large polymer
operations.
Piping for transport of the beads within the plant is of stainless steel
to prevent contamination of the product.
4- Utilities - Estimated power requirements for centrifuges handling concen-
trated slurries are summarized in Table 16.
Table 16. CENTRIFUGE POWER REQUIREMENTS
Centrifuge type
(kWh/kg)
Power required
(kWh/ton)
helical conveyor centrifuge
up to 61 cm (24 in.)
helical conveyor centrifuge
larger than 61 cm (24 in.)
automatic batch centrifugal
reciprocating conveyor
centrifugal
oscillating-screen
centrifugal
batch centrifugal
0.013 - 0.017
0.002 - 0.01
0.004 - 0.007
0.002 - 0.004
0.0002- 0.0003
0.006 - 0.03
12 - 15
2 - 10
4 - 6
2-4
0.2 - 0.3
5 - 25
42
-------
The total horsepower required for rotary driers (including fans, drier
drive, and conveyors) is estimated at (0.5 to 1) D2 where D is the diameter in
feet.
Power requirements for fluid-bed dryers are about 0.081 kWh/kg (0.037
kWh/lb) of water removed.
5. Waste Streams - Gaseous emissions of water vapor and low boiling compounds
may result from the dryer. Fugitive emissions from this part of the plant
amount to 0.0112 kg of hydrocarbon per kg of polymer produced in PVC plants.
Liquid waste streams containing water, monomer, and chemical additives
result from centrifugation, filtration and drying operations.
Rotary driers have the potential for causing dusting. Dust collectors are
necessary to recover the product. A plant utilizing cyclones for dust col-
lectors will suffer product losses of 1 percent of its capacity. Assuming an
annual capacity of 23 Gg (50 million Ib), a loss of 230 Mg (500,000 Ib) would
result. It is clearly evident that this method of dust collection is not
adequate. An average of particulate emissions from PVC plants based on EPA
questionnaires is 0.0020 kg of particulates per kg of PVC produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed.
N.Y., Wiley, 1971.
(2) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y.,
McGraw-Hill, 1963.
(3) Environmental Protection Agency, (office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Farber, Elliott. Suspension Polymerization. In: Encyclopedia of
Polymer Science and Technology, Vol 18. H. F. Mark, ed. N.Y.,
Wiley, 1970, p. 552-71.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 263.
(6) Matthews, George. Vinyl and Allied Polymers. Vol 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Iliffe Books, 1972.
(7) Oringer, Kenneth. Current Practice in Polyer-Recovery Operations
Chemical Engineering, 79:29-106, 20 March 1972
43
-------
(8) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974
(9) Polystyrene--Cosden Technology, Inc. Hydrocarbon Processing, £4:199,
November 1975.
(10) Polyvinylchloride--Ato Chimie. Hydrocarbon Processing, 5_4:200,
November 1975.
(11) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
44
-------
SUSPENSION ADDITION POLYMERIZATION PROCESS NO. 8
Final Product Preparation
1. Function - The dried polymer beads from Process No. 7 are mixed with
various chemical additives such as colorants, plasticizers, and stabilizers.
The mixture is melted and thoroughly mixed in a Banbury mixer or in an
extruder. The plastic material then enters an extruder, usually of the
screw type. Devolatilization is accomplished by passing the hot polymer
through an evacuated zone of the extruder to reduce the concentration of
volatiles to 0.5 percent or lower. The extruded plastic is cooled and
pelletized, commonly with a multiknife pelletizer. The product is then
bagged or packaged for sales.
2. Input Materials - Polymer beads and additives to alter the characteristics
of the polymer product are input materials to this process.
3. Operating Parameters - Pressure inside Banbury mixers is commonly 0.10 to
0.14 MPa (15-20 psi).
Extrusion temperature ranges are 150 to 180°C (300 to 350°F) for poly
(vinyl chloride), 190 to 260°C (375-500°F) for polystyrene, and 150-180°C
(300-350°F) for vinylidene chloride resins.
Table 9 in Process No. 3 presents production capacities for various
sizes of screw extruders processing poly(vinyl chloride).
4- Utilities - A No. 11 Banbury mixer operating at 20 rpm and processing
0.25 mYlO min (9 ft3/10 min) consumes 190 kW (250 hp). If the same mixer
operates at 40 rpm to process 0.25 m3/5 min (9 ft3/5 min) the power required
is 370 kW (500 hp).
5. Waste Streams - Particulates may be emitted form the pelletizing and
bagging steps. This source also has the potential for creating a solid
waste stream resulting from spills in materials handling. If pneumatic
conveyor systems are utilized, additional particulate emissions may occur.
Particulates emitted from this section of a PVC plant amount to 0.0007 kg
per kg of PVC product.
The devolatilization procedure has the potential for gaseous emissions
of toxic monomer materials. Extrusion of polymer materials is often
accompanied by cooling through direct contact with water. This type of
quenching produces a waste-water stream containing polymer fines.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y.,
McGraw-Hill, 1963.
(2) Farber, Elliott. Suspension Polymerization. In: Encyclopedia of
Polymer Science and Technology, Vol 18. H. F. Mark, ed. N.Y.,
Wiley, 1970, p. 552-71.
45
-------
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 263.
(4) Latinen, G. A. Devolatilization of Viscous Polymer Systems. Poly-
merization and Polycondensation Processes. In: Advances in Chemistry
Series No. 34. Robert F. Gould, ed. Washington, D. C., ACS, 1962.
(5) Matthews, George. Vinyl and Allied Polymers. Vol 2. Vinyl Chloride
and Vinyl Acetate Polymers. London, Iliffe Books, 1972.
(6) Oringer, Kenneth. Current Practice in Polymer-Recovery Operations.
Chemical Engineering, 79^:29-106, 20 March 1972.
(7) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(8) Polystyrene—Cosden Technology, Inc. Hydrocarbon Processing, 54:199,
November 1975.
(9) Polyvinylchloride--Ato Chimie. Hydrocarbon Processing, 54-:200,
November 1975.
46
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HIGH-PRESSURE MASS POLYMERIZATION PROCESSES
The only major commercial product made in this operation is low density
polyethylene, characterized by a density of less than 0.94 9/cm with a usual
range of densities between 0.915 to 0.935 g/cm3. The process is a mass addi-
tion process performed at very high pressures to accomplish the difficult
polymerization of ethylene.
Data for utilities and waste streams are available for the entire opera-
tion and are presented in Table 17.
Table 17. UTILITY REQUIREMENTS AND WASTE STREAMS FOR PRODUCTION
OF 454 kg OF LOW DENSITY POLYETHYLENE
Utilities
electricity 580 kWh
natural gas 130 m3 (5000 scf)
diesel 0.08 dm3 (0.02 gal)
gasoline 0.20 dm3 (0.05 gal)
water 0.992 m3 (262 gal)
Waste Streams
solid 4.1 kg (9.0 Ib)
particulates 0.59 kg (1.3 Ib)
hydrocarbons 1.4 kg (3.0 Ig)
waste water
BOD 0.10 kg (0.23 Ib)
COD 0.28 kg (0.61 Ib)
suspended solids 0.13 kg (0.28 Ib)
Source: Sittig, Marshall. Pollution Control in the Plastics and
Rubber Industry. Park Ridge, N.J., Noyes Data Corp.,
1975.
There are three processes described in this operation: 1) Polymerization,
2) Separation, and 3) Final Product Preparation. Figure 6 is a process flow-
chart which illustrates the processing sequence.
47
-------
/ \ /INITIATORSV
(ETHYLENE ANO
\ /
V,
POLYMERIZATION
9
HOINO
OQAMOU8 IMISSION3
Q aouo EMISSIONS
A UOU« EMISSIONS
SEPARATION
10
AIR
I WATER
-D.
FINAL
PRODUCT
PREPARATION
11
TO SALES
D
TO DISPOSAL
FIGURE 6. HIGH PRESURE MASS POLYMERIZATION
48
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HIGH-PRESSURE MASS POLYMERIZATION PROCESS NO. 9
Polymerization
1- Function - In this process ethylene polymerizes under very high pressures
to form low density polyethylene. Continuous operations are generally em-
ployed. Feed ethylene is compressed in multistage compressors to the highest
practical pressure. After the first compression step, initiators and modi-
fiers are added. Recycle ethylene joins the feedstock ethylene in the compres-
sion section.
The polymerization takes place in very high pressure kettle reactors
or in tubular reactors. There may be a preheating step before the polymer-
ization begins; some tubular reactors have temperature zones: preheat, reac-
tion and cooling. Temperature control is accomplished through the use of
cooling water and/or steam in jacketed kettles or jacketed tubes in the reac-
tor. The reactors are generally equipped with relief vents and rupture discs.
The ethylene-polyethylene mixture leaves the reactor through a pressure
control valve and is next treated in Process No. 10, Separation.
2. Input Materials - A polyethylene process licensed by Gulf Oil Chemicals
Co. requires 0.917 Mg (2020 Ibs) of ethylene, up to 1.8 kg (4 Ibs) of
initiator, and up to 1.4 kg (3 Ibs) of antioxidant for producing 0.9 Mg
(one ton) of pelletized polyethylene. Initiators for this process include
air, oxygen, and organic peroxides. Chain transfer agents may be ketones,
aldehydes, alkanes, olefins, alcohols, chlorinated compounds, or hydrogen.
3- Operating Parameters - Pressures used in the reactors are generally
proprietary, but reported pressures are 0.1 to 0.3 GPa (15,000 to 45,000
psi). Reaction temperatures of up to 350°C have been reported.
First stage compression is reported to be from 2 to 31 MPa (300 to
4500 psi).
The literature describes a stainless steel tubular reactor with lengths
of 30m (100 ft) and diameters of less than 2.5cm (1 inch). The preheat
section of the tubular reactor raises the temperature to 100 to 200°C. Con-
versions in the tubular reactor are reported as 15 to 25 percent. This low
conversion rate means that the recycle ethylene comprises 75 to 85 percent
of the feedstream. Processes employing stirred kettle reactors have slightly
higher conversions.
4- Utilities - See Table 17.
5- J^J_t§_!tre_ams. - Fugitive emissions of ethylene are minimized in the pro-
cessing area"because of fire and explosion hazards. The system is essen-
tially closed, and particular attention is paid to controlling fugitive
emissions at compressor seals, valves, and vents. Double mechanical seals
with a purging system may be employed to remove ethylene vapors a safe
distance to be vented or flared. An estimated 0.001 kg of hydrocarbon gases
per kg of polyethylene produced is emitted to the atmosphere as a purge
stream from the compressors. Start-up and emergency vents are normally
connected to smokeless flares.
49
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6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the
Synthetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a. Washing-
ton, D. C., 1974.
(2) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 259.
(3) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(4) Polyethylene (LD)--Gulf Oil Chems. Co. Hydrocarbon Processing,
54_:184, November 1975.
(5) Raff, R. A. V. Ethylene Polymers. In: Encyclopedia of Polymer
Science and Technology, Vol 6. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 275-332.
(6) Shreve, R. N. Chemical Process Industries, 3rd Ed. N.Y.,
McGraw-Hill, 1967.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
50
-------
HIGH-PRESSURE MASS POLYMERIZATION PROCESS NO. 10
Separation
1. Function - The liquid and gas phases of the reactor product are separated
in flash tanks by pressure reduction. The gaseous phase is ethylene which is
recycled; the solid phase is polyethylene which is processed further (Process
No. 11). Separation usually takes place in two or more stages. Succeeding
separators operate at successively lower pressures.
Ethylene gas is taken off at each stage of separation and is passed
through a cooler to remove waxes and oils. The polyethylene is removed from
the final separator by means of gear pumps, screw pumps, or extruders.
2. Input Materials - The feed to this process is the polymer-monomer mixture
from the reactor.
3. Operating Parameters - The separators operate at pressures ranging from
atmospheric to 30MPa (300 bars). No mention of operating temperature was
found in the references consulted for this study.
Coolers may operate at 20 to 150°C.
4. Utilities - See Table 17.
5. Waste Streams - The tars, waxes, and oils collected in the coolers are
waste materials. Disposal methods are incineration or landfill ing.
Light ends from the recycle ethylene stream are vented or flared a safe
distance from the processing area.
Fugitive emissions occur in this process; an estimated rate of emission
is 0.010 kg of hydrocarbon gases per kg of polyethylene produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthe-
tic Resins Segment of the Plastics and Synthetic Materials Manufac-
turing Point Source Category. EPA 440/1-74-010-a. Washington, D.C.,
1974.
(2) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Rieqel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 259.
(3) Makela, Robert G. and Joseph F. Malina, Jr. Solid Wastes in the
Petrochemical Industry. EHE-72-14, CRWR-92. Austin, Tx., Center
for Research in Water Resources, University of Texas at Austin, Aug.
1972.
51
-------
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houdry Div.,
March 1974.
(5) Polyethylene (LD)--Gulf Oil Chems. Co. Hydrocarbon Processing,
54_:184, November 1975.
(6) Shreve, R. N. Chemical Process Industries, 3rd Ed. N.Y.,
McGraw-Hill, 1967.
(7) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(8) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
52
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HIGH-PRESSURE MASS POLYMERIZATION PROCESS NO. 11
Final Product Preparation
1. Function - The polyethylene material is extruded generally in a screw-
type extruder equipped with one or more devolatilization chambers. The
strands of polymer are usually cooled in a water bath, chopped into pellets
by a pelletizer, and then screened. The cooling water is recycled.
The screened pellets are dried. The specific type of drier was not
specified in the literature consulted for this study. The polyethylene
pellets are generally conveyed by air to various storage and processing
points.
2. Input Materials - Molten polyethylene, makeup cooling water, and air
for conveying the pellets are input materials to this process.
3. Operating Parameters - Large extruders can process nearly O.SMg (1000
Ib) of polymer per hour at linear velocities of 2.5 m/sec (500 ft/min).
4. Utilities - See Table 17.
5. Haste Streams - A waste-water stream containing polymer fines may be
generated in this process, depending on the operations of the plant. If
recycle of polymer cooling water is practiced, a blowdown or purge stream
results.
The drying step may generate particulate emissions and a waste-water
stream depending on the type in use. No reference to the type of drier
used for low density polyethylene was made in the literature consulted for
this study.
Vents from the air conveying systems are sources of residual ethylene
and particulate emissions. Recommended methods for particulate control are
cyclones and bag filters used together. An estimated 0.0003 kg of particu-
lates and 0.005 kg of hydrocarbons are emitted in materials handling per
kg of polyethylene produced.
Off-grade and scrap polyethylene form a solid waste stream which is
disposed of by incineration or landfilling.
Vents from pellet storage bins also have the potential for atmospheric
hydrocarbon emissions. One plant operator responding to an EPA question-
naire reported 0.0039 kg of ethylene emitted from the top of pellet storage
bins per kg of polyethylene produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed.
N.Y., Wiley, 1971.
53
-------
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent
Limitations Guidelines and New Source Performance Standards for the
Synthetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 259.
(4) Polyethylene (LD)--Gulf Oil Chems. Co. Hydrocarbon Processing, 54:184,
November 1975.
(5) Raff, R. A. V. Ethylene Polymers. In: Encyclopedia of Polymer
Science and Technology, Vol 6. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 275-332.
(6) Shreve, R. N. Chemical Process Industries, 3rd Ed. N.Y., McGraw-
Hill, 1967.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
54
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SOLUTION POLYMERIZATION PROCESSES
Solution polymerization is an operation in which a solvent is added to
the reaction mixture which dissolves the monomer, the polymer, and the initiat-
ing agent. The viscosity of the resultant solution is lower than that of a
bulk polymerization reaction mixture. The lower viscosity allows better heat
transfer and easier agitation. One of the disadvantages of this processing
method is the necessity for solvent recovery. Another is the slower reaction
rates due to dilution by the solvent.
Polymerizations using water as a solvent are included in this operation.
The principal polymers made by this process are styrene polymers and co-
polymers, a-methylstyrene copolymers, polyacrylic acid, polymethacrylic acid,
polyacrylamide, and poly(vinyl pyrrolidone) and copolymers; the last four are
generally formed in aqueous media.
Two process descriptions are presented for this operation: 12) Polymeri-
zation and 13) Solvent Recovery. They are shown in Figure 7.
55
-------
CATALYST
POLYMERIZATION
WATER
POLYMER j
SOLUTION /
I AIR
LJL
SOLVENT RECOVERY
TO SALES
FIGURE 7. SOLUTION POLYMERIZATION
HQiMD
IMtBSIONS
Q 90UO EMISSIONS
^ LIQUID EMISSIONS
56
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SOLUTION POLYMERIZATION PROCESS NO. 12
Polymerization
1. Function - The monomer(s) and initiator are combined with a suitable
solvent. If the catalysts used are subject to poisoning problems, a feed
purification procedure such as distillation is necessary. Vertical vessels
with turbine agitators may be used for polymers with viscosities up to 5 Pa«s
(5000 cp). Anchor-type agitators are chosen for polymers with viscosities up
to 100 Pa-s (100,000 cp). A series of tubular agitated reactors constructed
of aluminum or stainless steel is reportedly used in polystyrene production by
the solution polymerization method.
Temperature control is often accomplished by circulating water in the
vessel jackets and by the addition of cold solvent. Some polymers may be
cooled by reflux cooling or by the use of an external flash loop. The dis-
solved polymerized material from the reactor is treated in the Solvent Re-
covery Process (No. 13).
2. Input Materials - Monomer materials include styrene, a-methylstyrene,
acrylic acid, methacrylic acid, acrylamide, N-vinyl-2-pyrrolidone, and
polymerizable vinyl comonomers.
Hydrocarbon solvents are used in some systems, water in others. Ethyl -
benzene is often used in making polystyrene.
3. Operating Parameters - The following data were found in the literature
for solution polymerization processes.
For copolymerization of N-vinyl-2-pyrrolidone
solvent: alcohol or benzene
temperature: 50 to 75°C
catalyst: benzoyl peroxide, lauroyl peroxide or azobis(isobutyronitrile)
For homopolymerization of N-vinyl-2-pyrrolidone
solvent: water
temperature: 50 to 80°C
catalyst: hydrogen peroxide and ammonia or azobis(isobutyronitrile)
For styrene-acrylonitrile copolymers
solvent: ethyl benzene or toluene
temperature: 150°C
reaction rate: 27%/hr
4. Utilities - Data were not available in the literature consulted for this
study.
5. Waste Streams - The reactor is essentially a closed system, but fugitive
emissions of hydrocarbon solvent and monomer materials may occur at pump and
compressor seals, pipe flanges, vents, and other points in the equipment. Re-
actor vents in polystyrene plants are reportedly the source of 0.00334 kg of
hydrocarbon emissions to the atmosphere per kg of polystyrene produced. An
additional 0.00065 kg of hydrocarbons per kg of polystyrene product is emitted
in the feed preparation step.
57
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6. EPA Source Classification Code - Polyprod. General 3-018-01-02
7. References:
(1) Billmeyer, Fred W., Jr.
N.Y., Wiley, 1971.
Textbook of Polymer Science, 2nd Ed.
(2) Environmental Protection Agency. Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the Synthetic Polymers
Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-75-036-b. Washington, D. C.,
January 1975.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Riegel's Handbook of Industrial Chemistry, 7th Ed. James A.
Kent, ed. N.Y., Van Nostrand Reinhold, 1974, p. 265.
(4)' Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houdry Div.,
March 1974.
(5) Schlegel, Walter F., Design and Scaleup of Polymerization
Reactors. Chemical Engineering, 7_9:88-95, 20 March 1972.
58
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SOLUTION POLYMERIZATION PROCESS NO. 13
Solvent Recovery
1. Function - Solvent is recovered from the contents of the reactor for re-
cycle in various ways. This may be accomplished by flashing or evaporation
followed by devolatilization. Equipment used for the first step of removing
up to 90 percent of the volatile materials from the polymer includes vacuum
drum driers, spray driers, multiple-vent extruders, and thin film evaporators.
Devolatilization removes the remaining volatiles down to about 0.1 to 0.5
percent and is usually accomplished in an extruder equipped with evacuation
zones. The solvent recovered from the driers, evaporators, and extruders is
recycled to the reactor.
Another method of separating solvent from polymer involves "crumbing."
Spraying of the polymer solution into vigorously agitated hot water causes the
solvent to evaporate, leaving small particles of polymer suspended in the
water. The polymer solution may be premixed with steam or hot water before
it is injected into the agitated vessel. The slurry of polymer in water must
then be subjected to liquid-solid separation methods. Filtration and centrif-
ugation employing belt filters, perforate basket centrifuges, solid-bowl
centrifuges, or pusher centrifuges are generally used.
The remaining water must be removed by drying. Although no information
as to the type of dryer used for these specific polymers was found in the
literature consulted, rotary driers are quite common in the polymer industry.
Extruded polymer is pelleted, blended and packaged. Pneumatic conveying
systems often accomplish transport of the pellets.
2. Input Materials - The polymerization reactor contents form the feed
material to this process. Hot water and steam may be inputs if crumbing opera-
tions are used. Air may be required for drying operations. Direct drying
with air requires 0.2 to 0.3 m3/min (8 to 10 ftVmin) of air to remove 0.5
kg (1 Ib) of water.
3. Operating Parameters - Operating conditions for rotary driers are dis-
cussed in Process No. 7.
Spray driers may operate under positive or negative pressures.
4- ytjj_i_tj_e_s - Table 16 in Process No. 7 summarizes utilities for various
types of centrifuges. Also discussed is the power requirement for rotary
driers.
5. Waste Streams - A liquid waste stream may result from the centrifugation or
filtration procedures if crumbing is used. Recycle methods may keep this volume
to a minimum.
Flashing, vacuum drying, and devolatilization may result in fugitive
emissions of hydrocarbon solvent at vents, valves, and seals. Polystyrene
manufacturing operations reportedly emit 0.00184 kg of hydrocarbon per kg of
polystyrene produced in this manner.
Volatile materials may be emitted from the driers along with dust particles,
Dust collection equipment usually consists of cyclones and bag filters; wet
scrubbers may be used. If only cyclones are used, an estimated 1 percent of the
59
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plant capacity will be lost as dust. Pneumatic conveying systems also contribute
to the participate emissions. An estimated 0.00010 kg of polystyrene particu-
lates per kg polystyrene produced are discharged in this manner in the manufacture
of polystyrene. Off-spec and waste resin form a solid waste stream amounting to
as much as 12 Mg/day (26,000 Ib/day) of polystyrene for a plant with a capacity
of 136 Gg/yr (150,000 tons/yr).
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y.,
McGraw-Hill, 1963.
(2) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point
Source Category. EPA 440/1-75/036-b. Washington, D. C., Jan.
1975.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Riegel's Handbook of Industrial Chemistry, 7th Ed. James A.
Kent, ed. N.Y., Van Nostrand Reinhold, 1974, p. 265.
(4) Oringer, Kenneth. Current Practice in Polymer-Recovery Opera-
tions. Chemical Engineering, 79^:29-106, 20 March 1972.
(5) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005
a-d, Contract No. 68-02-0255. Air Products & Chemicals,
Houdry Div., March 1974.
60
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PARTICLE FORM POLYMERIZATION PROCESSES
The Phillips Particle Form Process (also called the Phillips slurry
process to avoid confusion with the Phillips solution process) is presented
in this operation. This process accounts for production of more high-density
polyethylene than all of the other processes combined. Commercially avail-
able products have densities ranging from 0.939 to 0.964 and molecular
weights of 25,000 to 1,000,000. Ethylene-olefin copolymers are also produced
by this process. This operation is similar to the Ziegler operation in that
it employs a metal catalyst to produce high-density polyethylene at relatively
low pressures. An improvement over the Ziegler polymerization is found in
the elimination of catalyst recovery for most uses; the small amounts of
catalyst remain in the polymer.
The descriptions in the literature consulted for this study were often
vague with regard to this type of polymerization. Two process descriptions
were written as definitively as possible using the information at hand:
14) Polymerization, and 15) Polymer Recovery. Figure 8 is a flow sheet for
the Particle Form Polymerization Operation.
Some data on utilities and waste streams were available for the entire
operation of producing high-density polyethylene although the type of commer-
cial process is not specified. These data are included in Table 18.
Table 18. UTILITY REQUIREMENTS AND WASTE GENERATION FOR
PRODUCTION OF 454 kg OF HIGH DENSITY POLYETHYLENE3
UTILITIES
electricity 390 kWH
natural gas 0.067m (2.5 scf)
water 6.74m (1780 gal)
WASTES
solid 1 .1 kg (2.4 lb)
gaseous (hydrocarbon) 2.3 kg (5.0 lb)
1iquid
BOD 0.17 kg (0.37 lb)
COD 0.93 kg (2.04 lb)
suspended solids 0.28 kg (0.62 lb)
Commercial process not identified
Source: Sittig, Marshall. Pollution Control in the Plastics and
Rubber Industry. Park Ridge, N. J., Noyes Data Corp., 1975,
61
-------
REGENERATION
GASES
POLYMERIZATION
POLYETHYLENE
PRODUCT
O9AMOU8 EMISSIONS
Q SOUO IMIS3ION8
uoun EMISSIONS
FIGURE 8.
PARTICLE FORM POLYMERIZATION
62
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PARTICLE FORM POLYMERIZATION PROCESS NO. 14
Polymerization
1. Function - Polyethylene is produced in a continuous process in stirred
or loop-type reactors. Catalyst, hydrocarbon solvent, and monomer are intro-
duced into the reactor which is agitated mechanically or by convection.
Temperature control may be provided by water circulation through cooling
jackets. Both the ethylene feed and the catalyst must be treated before
they are used. The catalyst must be activated by passing hot air over it;
the ethylene feed is treated in a molecular sieve bed for removal of
catalyst poisons such as carbon dioxide, oxygen, and water. A polymer
stream is continuously withdrawn as input to polymer recovery, Process
No. 15.
2. Input Materials - 99+ percent ethylene is required as a feed to this
process. Two hydrocarbon solvents mentioned in the consulted literature
were pentane and cyclohexane. One description of the Phillips process
listed feed requirements of 0.95 Mg (2100 Ib) of ethylene and 54 kg (119 Ib)
of cyclohexane per 0.90 Mg (one ton) of product high-density polyethylene.
Ninety-five percent and higher conversion rates per pass are claimed. Hot
air is required for catalyst activation, and a stream of regeneration gas
is required for the molecular sieve beds.
Table 19 lists input requirements for ethylene-olefin copolymers of
various compositions.
TABLE 19. RATIOS OF FEED MATERIALS FOR VARIOUS COMONOMERS OF ETHYLENE
Product9
Ethylene-propylene Ethylene-1-butene
Feed9 copolymer copolymer
5 129
10 19 15
15 25 21
20 32 26
30 44 39
aweight ratio of ethylene to comonomer
Input materials for an ethylene-propylene copolymer with a density of 0.930
are cited as 80/20 volume % ethylene/propylene in a 1% solution of 99%
2,2,4-trimethylpentane.
63
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3. Operating Parameters - Conditions which may be varied to produce commer-
cial products are temperature, pressure, feed concentration, and catalyst
preparation method. Approximate operating conditions for high-density poly-
ethylene are as follows:
temperature: 140°C
pressure: 3 MPa (30 atmospheres)
catalyst: hexavalent chromium oxide on silica-alumina
The catalyst is activated by calcining in air at 400 to 850°C. A typical
operating temperature for an ethylene-propylene copolymer with a density of
0.93 is 115°C.
4. Utilities - See Table 18.
5. Waste Streams - Two potential sources of particulate emissions exist in
this process. Catalyst activation, accomplished by blowing net air, may re-
sult in emission of catalyst fines. Regeneration of molecular sieve beds by
purging with a gas stream may result in silica gel particulate emissions to
the atmosphere.
Start-up and emergency vents and flares may contribute intermittent
gaseous emissions of pollutants to the atmosphere. Purging of the molecular
sieve beds may be accompli shea with a hydrocarbon gas stream. The composi-
tion was not clearly stated in the sources consulted for this study.
Fugitive emissions may occur at valves, seals, and flanges. An esti-
mated 0.0200 kg of hydrocarbons are emitted per kg of polyethylene produced
in this manner.
6- EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Caldwell, E. D. High-Molecular-Weight Ethylene Polymers, In;
Encyclopedia of Polymer Science and Technology, Vol 6. H. F. Mark,
ed. N.Y., Wiley, 1957, p. 332-38.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Man-
ufacturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Friedlander, Herbert N. Ethylene-1-Olefin Copolymers. In: Encyclo-
pedia of Polymer Science and Technology, Vol 6. H. F. Mark, ed.
N.Y., Wiley, 1967, p. 338-86.
(4) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes,, Final Report. Contract 68-02-0226, Task 9, MRC-DA-
406. Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-ds Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
54
-------
(6) Polyethylene—Phillips Petroleum Co. Hydrocarbon Processing,
5_i:187, November 1975.
(7) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
65
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PARTICLE FORM POLYMERIZATION PROCESS NO. 15
Polymer Recovery
1. Function - This process isolates and finishes the polymer product. A
stream of polymer from the reactor enters a flash drum in which a reduction
in pressure produces an overhead stream containing solvent, ethylene, waxes,
and light gases. This overhead stream must be purified before the ethylene
and solvent may be recycled. It is assumed that this purification is accom-
plished by distillation with the light gases vented or flared and the waxes
sent to incineration or disposal. There also may be a water scrubber to remove
polymer fines from the overhead stream.
The polymer is taken continuously from the bottom of the flash drum to
be dried. One account of this type of processing specifies a rotary steam
tube drier which supplies indirect heat. The dry polyethylene may be blended
with colorizers and other additives in a Banbury mixer or in an extruder. The
extruded strands are usually water cooled before they are chopped into pellets,
dried and stored. Air conveying is the usual method of transferring polymer
to various processing and storage points in the plant, but at least one plant
uses a water system for some of its conveying.
Ultra-high molecular weight polymers require special extruding equipment
that has no screw. The details are proprietary.
2. Input Materials - The reaction product from Process No. 14, steam for the
drier, air for conveying, and possibly water for cooling and conveying are
input materials. Approximately 0.5 to 1.4 kg (1 to 3 Ib) of 0.96 MPa (125 psig
steam) is required per 0.5 kg (one pound) of dry product in the rotary steam
tube dryer.
3. (Operating Parameters - Vertical vessels are commonly used as flash tanks.
Pressures encountered in Banbury mixers are generally 0.10 to 0.14 MPa (15 to
20 psi). Extrusion temperatures for polyethylene are generally in the range
of 150 to 260°C (300 to 500°F).
4- Utilities - A No. 11 Banbury mixer operating at 20 rpm and processing
0.25 mj/10 min (9 ft3/10 min) consumes 190 kW (250 hp). The same mixer operat-
ing at 40 rpm processing 0.25 m3/5 min (9 ft3/5 min) requires 370 kW (500 hp).
5. Waste Streams - The light gases from the solvent and monomer recovery
purification step are vented or flared to form one of the main sources of
gaseous emissions in this operation. An estimated 0.0020 kg of hydrocarbon
per kg of polyethylene produced is emitted to the atmosphere in this manner.
Water scrubbers are sometimes used to scrub polymer fines from the
flashed gases. This results in a waste-water stream which contains hydro-
carbons and polymer fines.
Pneumatic conveyors and associated vents are a source of hydrocarbon
and particulate emissions. An estimated 0.003 kg of hydrocarbons and 0.0010
kg of particulates are emitted per kg of polyethylene produced.
66
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Cooling water for extruded strands must be treated for solids removal be-
fore disposal. One plant operator in answering an EPA questionnaire reported a
discharge rate of 0.38 to 0.57 m3/min (100 to 150 gal/min) of waste water from
cooling and pellet transferring operations.
Non-specification product is disposed of by landfilling or incineration.
Reported disposal rates are 90 to 900 Mg/yr (0.2 to 2 million Ib/yr). Waxes
removed from the recycle stream are disposed of in a similar manner. A pro-
ducer of 80 Gg/yr (90,000 tons/yr) capacity reported a production rate of 90
Mg/yr (0.2 million Ib/yr) of waxes. The production rate of waxes varies con-
siderably from plant to plant.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y..
McGraw-Hill, 1963,
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Oringer, Kenneth. Current Practice in Polymer-Recovery Operations.
Chemical Engineering, 79_:29-106, 20 March 1972.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houdry Div.,
March 1974.
(5) Polyethy!ene--Phillips Petroleum Co. Hydrocarbon Processing, 5<4:187,
November 1975.
67
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POLYOLEFINS POLYMERIZATION (ZIEGLER) PROCESSES
The Ziegler process is characterized by the use of a metal alkyl or
alky! halide catalyst which is recovered from the polymer and by the pre-
cipitation of the polymer as it is formed. The product of the reaction
is a slurry of high-density polyolefins. It is similar to the Phillips process
in that low or moderate pressures are required as opposed to the high pressures
required for manufacturing low-density polyethylene. Polymers produced by
this operation include high-density polyethylene with a density range of
0.940 to 0.965 g/cm3 and a molecular weight of over 1,000,000; polypropylene;
polybutene; and various copolymers.
Figure 9 illustrates the three processes described in this operation: 16)
Polymerization, 17) Catalyst and Solvent Removal, and 18) Product Preparation.
A general description of Ziegler-type commercial operations is intended in
this treatment; there are many variations in existing plants. Quantitative
data concerning utilities and waste streams were not always available in the
literature consulted for this study. Table 18 gives information concerning
production of high-density polyethylene by an unspecified method. Table 20
lists utility requirements for two commercial Ziegler-type polyethylene pro-
cesses along with one commercial process for production of polypropylene using
a Ziegler catalyst. Utility requirements may vary widely from plant to plant.
Table 20. UTILITY REQUIREMENTS FOR ZIEGLER-TYPE POLYOLEFINS PROCESSES0
Utilities
electricity
steam (kg)
Polyethylene
(kWh)
cooling water (m3 )
700
2,200
250
Polyethylene
490
2,400
180
Polypropylene
200
3,340
250
values are for 1000 kg of product.
Source: Polyethylene (HD) - Snamprogetti. Hydrocarbon Processing,
54_:188, November 1975.
Polyethylene (HD) - Veba-Chemie AG. Hydrocarbon Processing,
54_:191, November 1975.
Polypropylene - Hoechst AG. Hydrocarbon Processing, 54:196,
November 1975.
68
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( SOLVENT ] ( MONOMER ] [ CATALYST J
O
POLYMERIZATION
STEAM
/REACTOR \
I SLURRY I
CATALYST AND
SOLVENT REMOVAL
UI3INO
Q CU3IOU8 8MI39IONI
Q 30UO 8MISSION5
£ LIQUID IMISSIONS
PRODUCT
FIGURE 9. POLYOLEFIN PRODUCTION (ZIEGLER)
69
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POLYOLEFIN PRODUCTION (ZIEGLER) PROCESS NO. 16
Polymerization
1. Function - In this process ethylene and/or other olefins are polymerized
to form a high density product. Catalyst preparation is usually accomplished
by combining a transition metal halide with a metal alkyl or metal alkyl
chloride in an anhydrous hydrocarbon solvent. Poisoning of the catalyst is
usually inhibited by neutralization of sulfur- and oxygen-containing compounds
with alkylaluminum compounds.
Monomer, catalyst, and hydrocarbon solvent are added to the stirred
kettle reactor; the process may be a batch-type or continuous. The polymer
precipitates as it forms, producing a polymer slurry. Temperatures and pres-
sures encountered are generally lower than for the other two polyethylene
polymerization processes. The product slurry is then treated in process No. 17
for catalyst and solvent removal.
2. Input Materials - Catalyst components, hydrocarbon solvent, chain transfer
agents, and monomers are input materials to this process. Useful chain transfer
agents are hydrogen and alkyl-zinc compounds. Approximately 1040 kg of
ethylene are required to make 1000 kg of dry polyethylene power.
3. Operating Parameters - Temperatures for Ziegler-type polymerizations are
reported to be below 100°C, usually 20 to 80°C. Pressures are reported as
0.1 to 2.5 MPa (1 to 25 atm).
Temperature, agitation rate, and specific catalyst components control the
activity and selectivity of the catalyst. Titanium trichloride is reported
to be the most widely used catalyst; the most frequently named metal alkyl
compounds are ethyl- and isobutyl-aluminum hydride and chlorides and trialkyl
aluminum compounds. The ratios used are generally 1 to 4 moles of alkyl metal
compound per mole of transition metal compound.
4. Utilities - See Table 20.
5. Waste Streams - The compressor vent for the recycle stream in a poly-
ethylene plant is reported to emit 18 kg (40 Ib) ethylene, 0.9 kg (2 Ib)
ethane, and 20 kg (45 Ib) hexane per 0.9 Mg (one ton) of product.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs.
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D.C., 1974.
70
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(2) Friedlander, Herbert N. Ethylene-1-Olefin Copolymers. In:
Encyclopedia of Polymer Science and Technology, Vol 6. H. F.
Mark, ed. N.Y., Wiley, 1967, p. 338-386.
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MCR-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Riegel's Handbook of Industrial Chemistry, 7th Ed. James A. Kent,
ed. N.Y., Van Nostrand Reinhold, 1974, p. 284.
(5) Polyethylene--PhiHips Petroleum Co. Hydrocarbon Processing, 54:187,
November 1975.
(6) Raff, R. A. V. Ethylene Polymers. In: Encyclopedia of Polymer
Science and Technology, Vol 6. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 275-332.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
71
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POLYOLEFINS POLYMERIZATION (ZIEGLER) PROCESS NO. 17
Catalyst and Solvent Removal
1. Function - The catalyst and solvent are removed from the polymerization
product (Process No. 16) in this process to form a crude polymer. If the
polymerization takes place under pressure, the pressure is reduced in a flash
tank. Volatilized monomer and solvent are recovered for recycle.
The polymer is washed with an aqueous alcohol solution which dissolves
and removes the catalyst. The catalyst is precipitated in the form of metal
oxides which will settle to form a sludge. The effluent is sent to a distilla-
tion unit in which alcohol is recovered for recycle, while aqueous waste con-
taining catalyst fines and alcohol is discharged.
Solvent is removed from the polymer by steam stripping. The solvent is
distilled for recycle, producing a waste stream containing water and heavy
ends. The aqueous polymer slurry is subjected to centrifugation or filtration
to produce crude crumb which is further treated in Process No. 18.
2. Input Materials - The reactor product, steam, and make-up alcohol are
required for this process.
3. Operating Parameters - None were available in the information consulted
for this study.
4- Utilities - See Table 20,
5. waste Streams - The largest raw waste load from the plant is reported
to be the aqueous phase from the alcohol distillation unit. The waste water
contains alcohol and metal oxide fines. Consolidation of the metal oxide
sludge has posed a solid waste disposal problem in the industry. It is assumed
that the tower bottoms from solvent distillation form a waste stream, but no
indication was found of treatment or disposal method. Fugitive gaseous emissions
of alcohol and solvent result from distillation.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthe-
tic Resins Segment of the Plastics and Synthetic Materials Manufactur-
ing Point Source Category. EPA 440/1/74-010-a. Washington, D.C.,
1974.
72
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(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 284.
(4) Polyethylene—Phillips Petroleum Co. Hydrocarbon Processing, 54:187,
November 1975.
(5) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
73
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POLYQLEFIN PRODUCTION (ZIEGLER) PROCESS NO. 18
Production Preparation
1. Function - The crude polymer crumb is dried, extruded, and pelletized to
form the final product.
One source indicates the use of rotary steam tube driers for drying the
polymer crumb; it is assumed that this type of equipment would be used for
drying the pellets as well. It is probable that the extrusion and pelletiz-
ing methods are very similar to those of the Particle Form and Low Density
Operations. The dried polymer crumb is processed in an extruder. A single
helical screw is most often used for polyethylene. Ultra-high molecular
weight polyolefins require special equipment. The strands are water-cooled
and pelleted. Separation occurs by screening. Pellets are then dried for
storage. Water and/or air conveying is used for transporting pellets to
various processing points in the plant.
2. Input Materials - Polymer crumb, cooling water, steam, and air (and/or
water) for conveying are input materials to this process. An estimated 0.5
to 1.4 kg (1 to 3 Ib) of 0.96 MPa (125 psig) steam are required per 0.5 kg
(one pound) of dry product in the rotary steam tube dryer.
3. Operating Parameters - Extrusion temperatures for polyethylene are gen-
erally in the range of 150 to 260°C (300 to 500°F).
4. Utilities - See Table 20.
5. Waste Streams - No quantitative data were available in the sources con-
sulted for Ziegler-type operations, but they are assumed to be essentially the
same as those for the Particle Form Operation (Process No. 15). Pneumatic
conveyors and associated vents are a source of hydrocarbon and particulate
emissions.
Waste water from cooling and pellet transfer operations contains poly-
olefin particles which must be separated before disposal. Solid waste is com-
posed of non-specification and excess product which is disposed of by in-
cineration or landfilling. The dryers may be a source of liquid and gaseous
emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y.,
McGraw-Hill, 1963.
74
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(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N. Y.,
Van Nostrand Reinhold, 1974, p. 284.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(5) Raff, R. A. V. Ethylene Polymers. In: Encyclopedia of Polymer
Science and Technology, Vol 6. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 275-332.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
75
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PHENOLIC RESIN PRODUCTION PROCESSES
This operation treats the formation of resins by polymerization of phenol
and formaldehyde. There are two major types: resols (one-stage resins) and
novolaks (two-stage resins). The resols are formed in an alkaline medium with
an excess of formaldehyde and are marketed as thermosetting resins, bonding
resins, varnishes, and laminates. Novolaks are formed in an acid medium de-
ficient in formaldehyde. These thermoplastic resins require mixing with formal
dehyde or a formaldehyde donor such as hexamethylene tetramine to produce a
thermosetting product. Thermosetting resin powders, varnishes, and laminates
are novolak products.
Waste stream information is available for production of phenolic resins
in general. The type of resin produced is not specified, and the waste load
for the entire plant is included, as summarized in Table 21.
Table 21. WASTE STREAM INFORMATION FOR PRODUCTION OF PHENOLIC RESINS
Dry solids to disposal
Reported waste water flow
BOD
COD
Suspended Solids
Phenols (concentration in waste water)
Formaldehyde (concentration in waste water)
Methanol (concentration in waste water)
10-15 kg/Mg product
10-20 m3/Mg product
15-51 kg/Mg product
90-64 kg/Mg product
0.7-7 kg/Mg product
5-7 wt %
5-8 wt %
5-7 wt %
Source: Environmental Protection Agency, (Office of Air and Water
Programs, Effluent Guidelines Div.) Development Document
for Effluent Limitations Guidelines and New Source Perfor-
mance Standards for the Synthetic Resins Segment of the
Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-74-010-a. Washington, D.C., 1974.
Sittig, Marshall. Pollution Control in the Plastics and
Rubber Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
Four process descriptions are included in this operation to describe
the production of the two types of products: 19) Polymerization (Resols),
20) Product Preparation (Resols), 21) Polymerization (Novolaks), and 22)
Product Preparation (Novolaks). Figure 10 is a flow sheet illustrating the
interrelation of the four processes treated in this operation.
76
-------
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77
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PEHNOLIC RESIN PRODUCTION PROCESS NO. 19
Polymerization (Resols)
1. Function - Phenol and formaldehyde react in an alkaline medium in a batch
process. Phenol is charged to the agitated reactor through a weigh tank be-
fore the formaldehyde is similarly added, rinsing residual phenol out of the
lines. Sodium hydroxide is added, and steam is supplied to the kettle jacket
and to the internal coils to initiate the reaction. As the exothermic reaction
begins, cooling water is supplied to the kettle to maintain temperature control.
Additional cooling is accomplished by using a reflux condenser.
The degree of polymerization is monitored by withdrawing samples and test-
ing them. The extent of reaction determines the molecular weight of the polymer
and the physical properties of the product.
If the reaction is halted at the point at which the polymer is still
water-soluble, the product may be used for bonding resins. If the reaction
is allowed to progress to the point at which the polymer precipitates, the
water may be removed, and organic solvent may be added to form a varnish. The
polymerization reaction may be allowed to continue until the resin reaches a
brittle stage, at which point it may be used for a thermosetting molding powder.
Rapid cooling and neutralization with H2S04 stop the reaction. The mixture is
then distilled to purify the resin. If the resin application requires a low
concentration of water, the resin is dehydrated, often under vacuum.
2. Input Materials - Formaldehyde, phenol and base are inputs to this process.
Formaldehyde to phenol ratios are usually 1.5 to 1. Formaldehyde solutions may
be 37 to 50 percent by weight and often contain 5 percent methanol which acts
as a stabilizer. Solid paraformaldehyde is sometimes used.
The feed materials for a one-stage resin were reported by one source to be
1 to 2 parts calcium hydroxide to 100 parts phenol with a formaldehyde to
phenol ratio of 1.1 to 1.5.
3 Operating Parameters - The pH of the polymerization reaction mixture is
between 8 and 11.The kettle is heated to about 60°C to initiate the reaction.
The temperature may then be held at 60 to 80°C or at a higher temperature.
Reaction times for solid resins are from 1 to 5 hours depending on the tempera-
ture. The reaction is stopped by cooling to about 35°C. Pressure may range
from 7 to 70 kPa (1 to 10 psi).
Kettle sizes vary from 7.6 to 38 m3. Turbine agitators are adequate for
production of resin solutions (viscosity ^ 2 Pa-s [20 poise]), but close-fitting
anchor-type agitators equipped with powerful motors are required for solid
resin production (viscosity ^ 30 Pa-s[300 poise]). Materials of construction
were specified in one source of information as stainless steel or Monel.
4. Utilities - Steam and cooling water are required for temperature control.
Power is required for agitation and for pumps. No quantitative data were
found in the sources consulted for this study.
78
-------
5. Waste Streams - A liquid waste stream results from distillation of the
reaction mixture containing water, phenol, formaldehyde, and low molecular
weight polymer. This waste stream requires careful treatment and disposal.
Dehydration procedures may add to the waste-water stream. Carbon adsorption
and liquid extraction are control methods in use for phenol recovery.
Fugitive gaseous emissions occur at the condenser, vacuum line, sample
ports, and vents. Intermittent emissions occur at safety blow-off valves. These
gaseous emissions contain phenol and formaldehyde.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02; Bakelite -
General 3-01-018-05.
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Florentine, Frank P. Phenolic. In: Modern Plastics Encyclopedia,
Vol 51, No. 10A, Sidney Gross, ed. N.Y., McGraw-Hill, October 1974, p. 58,
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 267- 71.
(5) Keutgen, W. A. Phenolic Resins. In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 15. Anthony Standen, ed. N.Y., Wiley,
1968, p. 176-208.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N. Y., McGraw-Hill, 1958, p. 943-1035.
79
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PHENOLIC RESIN PRODUCTION
PROCESS NO. 20
Product Preparation (Resols)
1. Function - There are generally three types of resol products prepared
in this process. Water-soluble bonding resins, varnishes and laminating
resins, and dry thermosettina molding powder. The production of dry
product requires discharge of the resin from the reactor through a special
quick-discharge valve to prevent it from becoming an insoluble, infusible
solid. Cooling must be accomplished by spreading the material in thin layers
because of the low thermal conductivity. Cooling devices include water- or
air-cooled floors, trays in racks, and moving belts. After cooling, the
solid is ground, screened, and packaged. Some of the solid resols require
several water washing steps. This procedure necessitates drying the resin
before it is packaged. The solid resin may be blended with fillers and
additives before it is readied for marketing.
The water soluble bonding resins are discharged from the reactor to a
filter. After filtration, the substance is packaged in drums or tanks.
The varnish and laminate resin solutions (non-water-soluble) are dis-
solved in a solvent, filtered, and then stored in drums or tanks for sale.
2. Input Materials - The resol formed in Process No. 19, solvents, fillers,
and additives are feed materials to this process. Solvents in use include
cellosolve acetate, butanol, ethanol, methyl ethyl ketone, and cyclohexanone.
3. Operating Parameters - Data were not found in the literature consulted
for this study.
Power for grinding
in the sources con-
4- Utilities - Cooling water and/or air are required.
is also necessary. No quantitative data were available
suited for this study.
5. Waste Streams - Screening procedures in preparing the dry, solid resin
generate some solid waste. Grinding and packaging may emit particulates to
the atmosphere. Filtration of the liquid resin products is another source
of solid waste. Water washing of some resols produces a waste-water stream.
No quantitative data were available in the sources consulted for this study.
6. EPA Source Classification Code - Polyprod.
Bakelite - General 3-01-018-05
7. References -
General 3-01-018-02;
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthe-
tic Resins Segment of the Plastics and Synthetic Materials Manufac-
turing Point Source Category. EPA 440/1-74-OiO-a. Washington, D. C.,
1974.
8n
-------
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 267-71.
(4) Keutgen, W. A. Phenolic Resins. In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 15. Anthony Standen, ed. N.Y., Wiley,
1968, p. 176-208.
(5) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(6) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
81
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PHENOLIC RESIN PRODUCTION PROCESS NO. 21
Polymerization (Novolaks)
1. Function - In this batch process formaldehyde and phenol are polymerized
under acid conditions with a deficiency of formaldehyde to produce a thermo-
plastic product.
As in Process No. 19, phenol, acid, and formaldehyde are charged to a
jacketed batch-reactor. An acid, frequently sulfuric or hydrochloric acid,
is added and the temperature is raised to initiate the reaction. If strongly
acid conditions are used, a vacuum reflux system must be employed for cooling;
for some polymerizations atmospheric reflux is sufficient. Additional cooling
is provided by circulating cooling water in the jacket and in the internal
coils of the reactor.
When the reaction is completed, the resin is purified by distillation
and dehydrated under vacuum.
2. Input Materials - Formaldehyde, phenol, and acid are inputs to this
process. The ratio of formaldehyde to phenol is normally 0.75 to 0.90.
Formaldehyde solutions of 37 to 50% by weight are used. These solutions
often contain 5% methanol by weight. Solid paraformaldehyde is also used.
One source listed feed materials for a novolak resin as 100 parts phenol,
0.5 parts concentrated H2S04, and 69 parts of 37% formaldehyde. These
quantities amount to 0.8 mole formaldehyde per mole of phenol. Another
source of information reports that 0.835 Mg (1,840 Ib) of phenol and 0.663 Mg
(1,460 Ib) of 40% formaldehyde are required per 0.9 Mg (one ton) resin
produced.
3. Operating Parameters - The pH of the reaction mixture is usually 0.5 to
1.5. The kettle is heated to 60 to 85°C to initiate the reaction. A vacuum
reflux system is used to maintain the reaction temperature to 85 to 90°C.
Mildly acidic reactions are allowed to reflux at atmospheric conditions.
Distillation temperatures are allowed to reach 120 to 150°C. Vacuum dehydra-
tion conditions are 160°C and 84 to 91 kPa (63.5 to 68.5 cm of Hg). Reaction
times are 3 to 6 hours.
Kettle sizes range from 7.6 to 38 mj; kettles are constructed of
stainless steel or Monel. Turbine or anchor-type agitators are used.
4. Utilities - Steam and cooling water are required for temperature control.
Power is required for agitation and for pumps. No quantitative data were
found in the sources consulted for this study.
5. Waste Streams - Distillation and dehydration result in a liquid waste
stream containing phenol, formaldehyde, acid, and low molecular weight poly-
mer. This waste stream requires careful treatment and disposal. A caustic
solution is used to clean the reactors. This caustic solution contributes
to the wastewater stream for the plant. Fugitive gaseous emissions occur at
the condenser, vacuum line, sample ports, and vents. Intermittent emissions
occur at the safety blow-off valves. These gaseous emissions contain
formaldehyde and phenol.
82
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6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthe-
tic Resins Segment of the plastics and Synthetic Materials Manfactur-
ing Point Source Category. EPA 440/1-74-010-a. Washington, D. C.,
1974.
(2) Florentine, Frank P. Phenolic. In: Modern Plastics Encyclopedia,
Vo. 51, No. 10A. Sidney Gross, ed. N.Y., McGraw-Hill, October 1974,
p. 58.
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 267-71.
(5) Keutgen, W. A. Phenolic Resins. In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 15. Anthony Standen, ed. N.Y., Wiley,
1968, p. 176-208.
(6) Sittig, Marshall. Polluton Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
83
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PHENOLIC RESIN PRODUCTION
PROCESS NO. 22
Product Preparation (Novolaks)
1. Function - The novolak resin products are produced from the reactor
product of Process 21. The molten polymer may be neutralized before it is
further processed. In making a solid resin product the charge is dumped onto
cooling surfaces in thin layers. Water- or air-cooled floors, trays in racks,
and moving belts are used for rapid cooling. The solid resin is then ground
and screened. Fillers, coloring agents, and hexamethylenetetramine may be
blended with the resin before it is packaged. It may then be fused on hot
rollers, ground and packaged as a finished product thermosetting resin. If
a product is needed in solution (varnishes and laminating agents), solvent
is added in the kettle. The solution is then packaged in drums or tanks.
2. Input Materials - The reactor product, solvent, fillers, hexamethylene
tetramine, and other additives are input materials to this process. One
source of information states that 10 to 15 parts hexamethylenetetramine per
100 parts novolak resin are blended with additives in a 50:50 ratio, that
is 50 parts resin and hexamethylenetetramine to 50 parts additives. Solvents
in use include cellosolve acetate, butanol, ethanol, methyl ethyl ketone,
and cyclohexanone.
3. Operating Parameters - Data were unavailable in the literature con-
sulted for this study.
4. Utilities - Cooling water and/or air are required. Power for grinding
is also necessary. No quantitative data were available in the sources con-
sulted for this study.
5. Waste Streams - Blending, screening, grinding, and packaging procedures
may emit particulates to the atmosphere. No quantitative data were available
in the sources consulted for this study.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 267-71.
84
-------
(4) Keutgen, W. A. Phenolic Resins. In: Kirk-Othmer Encyclopedia
of Chemical Technology, Vol 15. Anthony Standen, ed. N.Y.,
Wiley, 1968, p. 176-208.
(5) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(6) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
85
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AMINO RESIN PRODUCTION PROCESSES
Amino resins are produced by the reaction of formaldehyde with nitrogen-
containing compounds, the most important of which are urea and melamine. The
chemistry is complex but basically involves two steps. Intermediate compounds
are formed which subsequently condense to form polymer materials.
In commercial production the reaction is controlled so that only a small
amount of polymerization takes place. The user completes the polymerization
by the addition of acid and/or heat to form a thermosetting plastic.
Quantitative data concerning wastes from the individual processes in this
operation were not available in the sources consulted for this study. Some waste
stream data were available concerning the whole operation and are presented in
Table 22.
Table 22. EMISSION DATA FOR AMINO RESIN PRODUCTION
Urea-Formaldehyde Resins Melamine-Formaldehyde Resins
Waste water
flow
Formaldehyde
Urea
Melamine
0.90 m3/Mg of product 0.64 m /Mg of product
(216 gallons/ton of product) (154 gallons/ton of product)
35 g/kg of product
(70 Ib/ton of product)
35 g/kg of product
(70 Ib/ton of product)
20 g/kg of product
(40 Ib/ton of product)
20 g/kg of product
(40 Ib/ton of product)
Source: Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
Figure 11 is a diagram relating the three processes described herein:
23) Polymerization, 24) Alkylation, and 25) Product Preparation.
The processing methods presented here are the ones described in the
literature consulted for this study. There appears to be variability in
processing methods involved in making amino resins.
86
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POLYMERIZATION
23
TO SALES -=
ALKYLATION
24
PRODUCT PREPARATION
25
SURFACE
COATING
RESINS
TO SALES
TO SALES
LEGEND
O GASEOUS EMISSIONS
Q SOUO EMISSIONS
£> LIQUID EMISSIONS
FIGURE 1 1 . AMINO RESIN PRODUCTION
87
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AMINQ RESIN PRODUCTION PROCESS NO. 23
Polymerization
1. Function - Urea or melamine and formaldehyde are allowed to condense
under controlled pH and temperature conditions to form polymers of molecular
weights suitable for specific applications. The batch-type reaction is gen-
erally stopped at a low molecular weight stage. Further condensation is
done by the user.
Urea or melamine and formalin solutions are charged to a jacketed,
stirred kettle equipped with a condenser, internal cooling coils, and a
vacuum system. The equipment is very similar to that used for phenolic
resin production and may, in fact, be used for both types of resin production.
The reaction mixture is adjusted to a neutral or slightly alkaline pH
and the temperature is controlled during the reaction. Formation of the
intermediate methylol compounds and further condensation of the inter-
mediates are monitored by periodic sampling of the reactor contents. When
viscosity measurements indicate the appropriate degree of polymerization,
the temperature is lowered and the pH is raised to curtail further condensa-
tion. The condenser outlet is then transferred to a receiver to facilitate
vacuum dehydration.
2. Input Materials - Urea, formaldehyde, melamine, and alkaline compounds
are all inputs to this process.
Formaldehyde is generally used as a 30 to 40% aqueous solution. Methanol
is present as a stabilizer in formalin solutions and must be removed for
production of urea resins but may be tolerated in production of melamine
resins. Formic acid must also be removed, as it catalyzes the polymerization
reaction.
For a urea resin one source specifies that 1.7 Mg (3760 Ib) of 40% formalin
and 0.68 Mg (1500 Ib) of urea are required per 0.9 Mg (one ton) of product.
Molar ratios of formaldehyde to nitrogen compound cited in another source
are 1.6 to 1.7:1 for urea and 2 to 3:1 for melamine.
3. Operating Parameters - In making a urea-formaldehyde resin the initial pH
is adjusted to 7.0 to 7.8. The pH may be allowed to drop to 4 or 5 as the re-
action continues. To stop the reaction, the pH is adjusted to slightly al-
kaline. Refluxing occurs at atmospheric pressure (100°C) and subsequently
at a cooler temperature under vacuum (40 to 70°C). Reaction times for the
urea-formaldehyde resin are given in one source as 2 hours under atmospheric
reflux plus 5 hours under vacuum reflux with a total cycle time for poly-
merization and drying of 10 hours.
For melamine resin production the initial pH is adjusted to 9, and the
reaction temperature is held at 80°C until the methylolation has taken place.
Kettle capacity may be 7.6 to 38 m3. Construction materials are stainless
steel or rnonel.
-------
4. Utilities - Quantitative information was not available in the sources
cited for this study. Power is required for agitation; steam and cooling
water are also required.
5. Waste Streams - The water removed under vacuum forms a liquid waste
stream containing formaldehyde and urea or melamine. Fugitive gaseous
emissions may occur at relief valves. These gaseous emissions contain
formaldehyde and urea or melamine along with intermediate compounds. The
kettles are cleaned between batches by washing with caustic solution.
This solution becomes part of the waste water associated with the plant.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Cordier, E. C. Amino. In: Modern Plastics Encvclooedia. Vol 51,
No. 10A. Sidney Gross, ed. N.Y., McGraw-Hill, October 1974, p. 25
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C. , 1974.
(3) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(5) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
(6) Vale, C. P. Aminoplastics. New York, Interscience Publishers,
Inc., 1950.
(7) Widmer, Gustave. Amino Resins. In: Encyclopedia of Polymer
Science and Tehcnology, Vol 2. H.F. Mark, ed. N.Y., Wiley,
1965, p. 1-95.
89
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AMINO RESIN PRODUCTION PROCESS NO. 24
Alkylation
1. Function - Amino resin condensation products are generally insoluble
in cormion organic solvents and incompatible with other surface coating
resins such as alkyds. Solubility in organics is increased by alkylating
the condensation products from Process No. 23. Alkylation is accomplished
by reaction with an alcohol. The alcohol and water are removed by distilla-
tion.
2. Input Materials - Condensation products from Process No. 23, formalde-
hyde, and an alcohol are feed materials to this process. Common alcohols
in use are methanol, butanol, and octanol.
3. Operating Parameters - One source of information indicates that a close-
fitting anchor-type agitator is required, as the viscosity of the reactor
contents reach 30 Pa«S (300 poise). Other operating parameters were not found
in the sources consulted for this study.
4. Utilities - Information was unavailable in the sources consulted for
this study.
5. Waste Streams - The alcohol and water removed by distillation probably
forms a liquid waste stream. There was no indication of its final disposition
in the literature consulted for this study. Fugitive gaseous emissions at
the condenser, valves, and fittings probably occur. If there is a relief
vent, intermittent emissions may occur there. These gaseous emissions will
contain formaldehyde and alcohol vapors.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Cordier, E. C. Amino. In: Modern Plastics Encyclopedia, Vol 51,
No. 10A, Sidney Gross, ed. N.Y., McGraw-Hill, October 1974, p. 25.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Rodriguez, Ferdinand. Principles of Polymer Systems. N.Y., McGraw-
Hill, 1970.
(5) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(6) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
90
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AMINO RESIN PRODUCTION PROCESS NO. 25
Product Preparation
1. Function - The condensation products from Processes No. 23 and 24 may be
marketed in three forms: a viscous resin syrup, a spray-dried resin, or a
molding powder.
The reactor contents may be used directly or stored for shipment as a
water or alcohol soluble syrup which is fully polymerized by the user with the
application of acid and/or heat.
If the resin must be stored before its use, it may be provided in dry form
to be dissolved in water or alcohol when it is needed. This is accomplished
by spray drying the syrup of condensation products. Spray-dried resin is also
blended into molding powders to achieve the proper flow characteristics. Mold-
ing powders are generally made by impregnating filler materials with amino
resin. The filler and resin are mixed, dried, pulverized, and densified to
produce a molding compound. A kneading-type mixer (Banbury or Werner-Pfleiderer)
is used to mix the resin with the filler and a small amount of mold release
agent (lubricant). This mechanical mixing breaks the filler into individual
fibers and impregnates them with resin. Drying is generally accomplished in a
continuous-drum or continuous-screen dryer. An impact pulverizing machine such
as a hammer mill is first used to pulverize the dried resin material. Further
pulverizing is accomplished in a ball mill which also serves to densify the
resin. Additives and pigments may be mixed with the material in the ball mill
to produce a finished molding powder.
An alternative method of preparing a molding powder involves mixing and
drying under vacuum with hot air circulation within the kneading-type mixer.
The mixture is screened before it is passed through an impact mill where a
dense molding compound is produced. The large screenings are recycled to the
mixer. This method produces molding powders of inferior quality compared with
those produced by the first method.
2. Input Materials - The product of the condensation reaction is the major
feedstream to this process. Fillers such as alpha cellulose, wood flour, and
asbestos; pigments; mold release agents (lubricants) and other additives are
also used. Ethanol may be used as a solvent. Air is needed for spray drying.
3. Operating Parameters - The mixer temperature range is 50 to 80°C. Drum
dryer air temperatures are 70 to 120°C. Air temperatures are 20 to 30°C
lower on the conveying screen dryer. Air temperatures for spray drying urea
resins are cited in one source as 230 to 260°C (450 to 500°F) at the inlet and
82 to 88°C and (180 to 190°F) at the outlet. Pressures encountered in Banbury
mixers are generally 0.10 to 0.14 MPa (15 to 20 psi).
91
-------
4. Utilities - Power requirements for Werner-Pfleiderer mixers range from
33 to 390 kW/m (0.67 to 2.0 hp/gal) capacity. A No. 11 Banbury mixer operat-
ing at 20 rpm and processing 0.25 m3/10 min (9 ft3/10 min) requires 190 kW
(250 hp), while one operating at 40 rpm processing 0.25 m3/5 min (9 ft3/5 min)
requires 370 kW (500 hp).
5. Waste Streams - Spray-drying operations may produce particulate emissions.
Cyclones and bag filters are often used as collection devices.
Belt driers, continuous-drum dryers and continuous screen dryers produce
water-laden air which is vented to the atmosphere. This gaseous waste stream
contains organic compounds and particulates.
Pulverizing and packaging operations are a potential source of particulate
emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Engineers' Handbook, 4th Ed. Robert H. Perry, ed. N.Y.,
McGraw-Hill, 1963.
(2) Cordier, E. C. Amino. In: Modern Plastics Encyclopedia, Vol 51,
No. 10A, Sidney Gross, ed. N.Y., McGraw-Hill, October 1974, p. 25.
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec, 1973.
(5) Rodriguez, Ferdinand. Principles of Polymer Systems. N.Y., McGraw-
Hill, 1970.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N,Y., McGraw-Hill, 1958, p. 943-1035.
(3) Vale, C. P. Ar.iinoplastics, New York, Intcrscionce Publishers, 1950.
92
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POLYCARBONATE PRODUCTION PROCESSES
Polycarbonates are linear thermoplastic polyesters of carbonic acid. The
only commercially important polycarbonate is formed by the reaction of bisphenol-A
with phosgene in the presence of pyridine. The commercial process described in
this operation is the one employed by the General Electric Company. It is the
only commercial process for which information was found in the literature con-
sulted for this study. Reference has been made to the fact that Mobay Chemical
Company has a process based on diphenyl carbonate instead of phosgene. No in-
formation concerning the process was found in the literature consulted for
this study, however.
Quantitative data on utilities requirements were available for the entire
operation and are presented in Table 23.
Table 23. UTILITY REQUIREMENTS FOR POLYCARBONATE MANUFACTURE3
cooling water 2 m3/min (500 gal/min)
steam, 1.4 MPa (200 psig) 8.6 Mg/hr (19,000 Ib/hr)
electricity 810 kW
refrigeration 19.8 GJ (65 tons)
a9 Mg/yr (20,000 Ib/yr) capacity
Source: Medley, W. H., et al. Potential Pollutants from Petro-
chemical Processes, Final Report. Contract 68-02-0226,
Task 9, MRC-DA-406. Dayton, Ohio, Monsanto Research
Corp. Dayton Lab., Dec. 1973.
Quantitative emissions data were generally scarce in the sources consulted for
this study. The use of phosgene and pyridine indicates the potential for toxic
emissions problems.
Figure 12 is a flow sheet which illustrates the five processes included in
this operation: 26) Polymerization, 27) Washing, 28) Precipitation, 29) Drying,
and 30) Product Preparation.
93
-------
BREAKING
AGENT STEAM
TO SEWER
LEGEND
Q GASEOUS EMISSIONS
Q SOUO EMISSIONS
& UOUIO EMISSIONS
PRECIPITATION
28
CRYSTALLINE
POLYMER
-4 PRECIPITANT!
AIR
i
L <^,
DRYING
29
\
f
-i-J
•«^ j
1
PRODUCT
PREPARATION
30
FIGURE 12. POLYCARBONATE PRODUCTION
94
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POLYCARBONATE PRODUCTION PROCESS NO. 26
Polymerization
1. Function - Bisphenol-A, pyridine, and a chlorinated hydrocarbon solvent
are charged to an agitated, jacketed reaction vessel. Phosgene in the gaseous
state is bubbled through the reactor contents.
Temperature is carefully controlled by circulating water through the reac-
tor jacket. The reactor contents containing polymerized product, unreacted
pyridine, and pyridine hydrochloride are treated by washing (Process No. 27)
when the reaction is complete.
2. Input Materials - Input materials are phosgene vapor, bisphenol-A,
pyridine, and a solvent such as methylene chloride or chlorobenzene. It is
reported that an excess of pyridine may be used to provide the basic medium
necessary for the reaction. The reactants must be free of monofunctional
alcohols or phenols which act as chain terminators. Pyridine and solvent are
recycled so that make-up requirements are thought to be low. Polycarbonates
require 0.08 Mg (1780 Ib) Bisphenol-A and 36 kg (810 Ib) of phosgene.
3. Operating Parameters - The important factors affecting the polymerization
reaction include residence time, temperature, purity of reactants, and propor-
tions of reactants. Reaction temperature for a typical process is below 40°C
(104°F). The residence time is 1 to 3 hours.
4- Utilities - See Table 23.
5. Waste Streams - Fugitive gaseous emissions are likely to occur at valves
and fittings in this process. These fugitive emissions may contain phosgene
and pyridine which have offensive odors and toxic properties.
6. EPA Source Classification Code - Polyprod. General 30-1-018-02
7. References -
(1) Bottenbruch, L. Polycarbonates. In: Encyclopedia of Polymer
Science & Technology, Vol 10. H. F. Mark, ed. Y.Y., Wiley, 1969,
p. 710-64.
(2) Chopey, N. P. Making Polycarbonates: A First Look. Chemical Engi-
neering, 1953 (14 Nov.), 174-77.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment of
the Plastics and Synthetic Materials Manufacutring Point Source
Category. EPA 440/1-75/-36-b. Washington, D.C., Jan. 1975.
95
-------
(4) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Polycarbonates—General Electric Company. Hydrocarbon Processing,
44:262, November 1965.
96
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POLYCARBONATE PRODUCTION PROCESS NO. 27
Washing
1. Function - The reactor contents from Process No. 26 are fed to wash tanks
for removal of residual pyridine. Washing is done with hydrochloric acid and
water. The excess pyridine is thus converted to pyridine hydrochloride. The
aqueous phase is removed by decantation. Polymer is recovered from the solvent
phase by precipitation (Process No. 28).
Pyridine is recovered from the aqueous phase. Sodium hydroxide is combined
with the pyridine hydrochloride solution to form sodium chloride, then solvent
is removed by steam stripping. An azeotropic distillation column separates
sodium chloride as bottoms and a pyridine-water azeotrope as an overhead stream.
The azeotrope is dehydrated by a proprietary method involving the addition of
a breaking agent and distillation. The overhead pyridine stream is recycled,
while the bottoms are treated for recovery of breaking agent. The disposition
of the water is not indicated in the sources consulted for this study.
2. Input Materials - Polymerization reactor contents from Process No. 16,
sodium hydroxide, and an undisclosed breaking agent are feed streams. Steam is
required for removal of solvent by steam stripping.
3. Operating Parameters - Information was not available in the sources con-
sulted for this study.
4. Utilities - See Table 23.
5. Waste Streams - The washing process is the major source of waste water for
this operation. The waste water will probably be alkaline, and its major con-
stituent is sodium chloride. Sodium chloride produced in this manner amounts
to 0.69 Mg (1520 Ib) per 0.90 Mg (one ton) of product. Fugitive emissions of
pyridine and solvent are expected from the stripping and distillation columns.
The method of disposition of the water removed from the pyridine is not men-
tioned. It may be sent to disposal, or some of the water may be recovered.
It is probable that some waste water contaminated with pyridine will result.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
?• References^ -
(1) Bottenbruch, L. Polycarbonates. In: Encyclopedia of Polymer
Science & Technology, Vol 10. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 710-64.
(2) Chopey, N. P. Making polycarbonates: A First Look. Chemical
Engineering, 1953 (14 Nov.), 174-77.
(3) Environmental Protection Agency. Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
97
-------
Source Performance Standards for the Synthetic Polymers Segment of
the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., Jan. 1975.
(4) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Reigel's Handbook of Industrial Chemistry, 7th Ed. James A. Kent,
ed. N.Y., Van Nostrand Reinhold, 1974, p. 292.
(6) Polycarbonates—General Electric Company. Hydrocarbon Processing,
44:262, November 1965.
98
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POLYCARBONATE PRODUCTION PROCESS NO. 28
Precipitation
1. Function - The polymer-solvent stream from Process No. 27 is treated with
an organic compound such as an aliphatic hydrocarbon to effect precipitation
of the polymer. The polycarbonate precipitates and is separated by filtra-
tion; a rotary filter is indicated as a possible equipment choice. The powder
is transferred to a drying process, while the solvent and precipitant are re-
covered in a distillation column.
2. Input Materials - The polymer solution and the precipitant are feed streams
to this process.
3. Operating Parameters - Data were not available in the sources consulted
for this study.
4. Utilities - See Table 23.
5. Waste Streams - Fugitive gaseous emissions of hydrocarbon compounds probably
occur as a result of the distillation employed for solvent and precipitant re-
covery.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bottenbruch, L. Polycarbonates. In: Encyclopedia of Polymer
Science & Technology, Vol 10. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 710-64.
(2) Chopey, N. P. Making Polycarbonates: A First Look. Chemical
Engineering, 1953 (14 Nov.), 174-77.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., Jan. 1975.
(4) Hedley, W. N., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Polycarbonates—General Electric Company. Hydrocarbon Processing,
44:262, November 1965.
99
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POLYCARBONATE PRODUCTION PROCESS NO. 29
Drying
1. Function - The polymer is dried by direct contact with hot air. The exact
type of dryer is not readily evident from the information consulted for this
study. Dust collectors are auxiliary pieces of equipment necessary to prevent
excessive product losses.
2. Input Materials - Hot air and polymer are input materials to this process.
The flow rate of air required to evaporate 0.5 kg (1 Ib) of water is 0.23 to
0.28 m3/min (8 to 10 ft3/min). The air flow in large polymer dryers may be
570 to 850 m3/min (20,000 to 30,000 ft3/min).
3. Operating Parameters - None were available in the sources consulted for
this study.
4- Utilities - See Table 23.
5. Waste Streams - Dusting is a problem in drying operations. If cyclones
alone are used for control, a significant loss of product may occur. Assum-
ing 99 percent collection efficiency, a plant with an annual capacity of 23 Gg
(50 million Ib) will produce particulate emissions of 230 Mg (500,000 Ib) per
year.
Although a solvent recovery step is indicated in the literature, it is
possible that air exhausted from the drying operation will contain traces of
solvent.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bottenbruch, L. Polycarbonates. In: Encyclopedia of Polymer
Science & Technology, Vol 10. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 710-64.
(2) Chopey, N. P. Making Polycarbonates: A First Look. Chemical Engi-
neering, 1953 (14 Nov.), 174-77.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., Jan. 1975.
(4) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
100
-------
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Oringer, Kenneth. Current Practice in Polymer-Recovery Operations.
Chemical Engineering, 79_: 29-106, 20 March 1972.
101
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POLYCARBONATE PRODUCTION PROCESS NO. 30
PRODUCT PREPARATION
1. Function - The dried polymer material is extruded and pelletized for use
as a molding powder. Single-stage screw extruders are commonly used pieces
of equipment. It is likely that typical pelletizing machines are used.
2. Input Materials - Dried polymer powder.
3. Operating Parameters - None were available in the sources consulted for
this study.
4- Utilities - See Table 23.
5. Waste Streams - Pelletizing operations are a potential source of parti -
culate emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bottenbruch, L. Polycarbonates. In: Encyclopedia of Polymer
Science & Technology, Vol 10. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 710-64.
(2) Chopey, N. P. Making Polycarbonates: A First Look. Chemical
Engineering, 1953 (14 Nov.), 174-77.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(4) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
102
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EPOXY RESIN PRODUCTION PROCESSES
Epoxy resins, characterized by the presence of epoxy groups within the
molecule, are intermediate, thermoplastic materials which must be cured by
the addition of reactive substances to form thermosetting materials. Curing
agents include such materials as amines; polyamides; acids; acid anhydrides;
and phenolic, urea, or melamine resins. The choice of curing agent is dicta-
ted by the specific end use of the resin, as the curing agents impart differ-
ent properties to the final product.
Although epoxy resins may be obtained by condensation of epichlorohydrin
with a number of polyphenols or polyacohols, more than 90 percent of the
commercial production is of the resin formed by the reaction of epichlorohydrin
with Bisphenol-A. This treatment is therefore limited to the discussion of
the production of those specific resins.
Utilities are available on a weight of product basis for an unspecified
method of production. Since they include requirements for the entire oper-
ation, these utility requirements are presented here in Table 24.
Table 24. UTILITY REQUIREMENTS FOR EPOXY RESIN PRODUCTION'
cooling water
steam (50 psig)
(150 psig)
power
process water
5.3m3/min(1400 gal/min)
900kg/hr(2000 Ib/hr)
9.5Mg/hr(21,000 Ib/hr)
125 kWh
0.545mVmin( 144 gal/min)
9Mg/hr (20,000 Ib/hr) capacity
Source: Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA
406. Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec.
1973.
A waste water loading of 2.5 to 5.1m3/Mg has been reported for epoxy resin
manufacture. The raw waste load from the entire operation is reported as
follows: BOD5, 57 to 82 kg/Mg; COD, 30 to 127 kg/Mg; suspended solids,
5 to 24 kg/Mg.
103
-------
The processing methods presented are meant to represent typical operations
There are, undoubtedly, other ways to make epoxy resin products. Figure 13
is a schematic representation of the processes presented in this treatment.
The processes included in this operation are: 31) Polymerization
(one step), 32) Polymerization (two steps), 33) Washing, and 34) Polymer
Recovery.
104
-------
EPICHLORO-
HYDRIN
BISPHENOL A
POLYMERIZATION
(TWO STAGE*
32
POLYMERIZATION
(ONE STAGE*
EPICHLORO-
HYDRIN
WASTE
WATER
THER / SALT
MIXTURE
ETHER/ SALT
MIXTURE
SODIUM
DIHYDROGEN
PHOSPHATE
ORGANIC
PHASE
1 .^ , ^
)
r
POLYMER
RECOVERY
34
r9"
LtOiNO
O OASCOUS EMISSIONS
Q SOLID EMISSIONS
A LIQUID EMISSIONS
FIGURE 13 . EPOXY RESIN PRODUCTION
105
-------
EPOXY RESIN PRODUCTION PROCESS NO. 31
Polymerization (One Step)
1. Function - A one-step batch process may be used to produce either solid
or liquid product resins. Epichlorohydrin, Bisphenol-A, and a caustic solu-
tion are introduced into the reactor. The reactor is generally of the kettle
type, fitted with an agitator, a heater, and a condenser which may be equipped
with a separator for decanting reflux water. The epoxidation reaction takes
place under atmospheric reflux conditions with the formation of salt. When
the reaction is complete, the aqueous phase containing salt and some caustic
is decanted. Epichlorohydrin is removed by distillation at both atmospheric
and vacuum conditions.
2. Input Materials - The molecular weight of the epoxy resins may be varied
by varying the epichlorohydrin to Bisphenol-A ratio. A low molecular weight
resin requires a 10:1 mole ratio as indicated in Table 25, describing feed re-
quirements for an epoxy resin production process patented by Shell
Table 25. INPUT MATERIALS FOR A SHELL EPOXY RESIN PRODUCTION PROCESS
Bisphenol-A 5130 parts (22.5 moles)
Epichlorohydrin 20,812 parts (225 moles)
Water 104 parts
Solid NaOH 1880 parts
The use of lower mole ratios result in higher molecular weight resin products.
An example of materials necessary for the production of this type of resin is
given in Table 26.
Table 26. INPUT MATERIALS FOR A ONE-STAGE EPOXY RESIN PRODUCTION PROCESS
Input Material Volume (g/Kg Product) Volume (Ib/ton Product)
Bisphenol-A 670.5 1341
Epichlorohydrin 556 1112
NaOH 240 480
106
-------
3. Operating Parameters - It appears that operating parameters may vary con-
siderably from process to process. Temperature encountered are generally less
than 200°C, however. The accounts of the Shell process specified reaction
temperatures of 90 to 100°C. One of the unidentified one-step processes uti-
lizes a reflux temperature of 77°C (171°F),
Distillation conditions cited in a description of the Shell process are
100°C at atmospheric conditions and 160°C at 133 Pa (1 mm/Hg).
4- Utilities - See Table 24.
5. Haste Streams - The aqueous phase decanted or separated from the re-
actor is a caustic liquid waste stream containing sodium salts. Refluxing
during the reaction and distillation of the epichlorohydrin are potential
sources of fugitive gaseous emissions. If steam ejectors are used for re-
moval of epichlorohydrin, a fouled condensate results.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bannerman, D. G., and E. E. Magat. Polyamides & Polyesters. In:
Polymer Processes, Vol X. Calvin E. Schildknect, ed. N.Y.,
Interscience Publishers, 1956, p. 235-94.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Man-
ufacturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(5) Potter, W. G. Epoxide Resins. London, Iliffe Books, 1970.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.H., Noyes Data Corp., 1975.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N.Y., McGraw-Hill, 1958, p. 943-1035.
107
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EPOXY RESIN PRODUCTION PROCESS NO. 32
Polymerization (Two Steps)
1. Function - The two step process, used in an effort to minimize the molec-
ular weight of the product, is suitable for producing liquid products and
may be batch or continuous. An excess of epichlorohydrin is introduced with
Bisphenol-A into the reactor with an unspecified catalyst. After a suitable
reaction time has elapsed, the epichlorohydrin is removed by distillation
for recycle. A solvent and caustic are then added to effect the epoxidation
with the resulting formation of sodium chloride.
2. Input Materials - input Materials for a two-step system are listed below
in Table 27.
Table 27. INPUT MATERIALS FOR A TWO-STEP EPOXY RESIN POLYMERIZATION
Input Material Volume (g/kg Product)
Bisphenol-A 690.4
Epichlorohydrin 512.7
50% NaOH Solution 443.4
Solvent quantities are not indicated; the solvent is usually a ketone
such as methyl isobutyl ketone (MIBK).
3. Operating Parameters - Data were not available in the sources consulted
for this study.
4- Utilities - See Table 24.
5- Waste Streams - The use of steam ejectors for vacuum removal of
epichlorohydrin is indicated. This results in losses of epichlorohydrin
in a fouled condensate. No accounts of methods of treatment or disposition
of this waste stream were available in the literature consulted.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the
Synthetic Resins Segment of the Plastics and Synthetic Materials
Manufacturing Point Source Category. EPA 440/1-74-010-a.
Washington, D. C., 1974.
108
-------
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical
, Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(4) Potter, W. G. Epoxide Resins. London, Iliffe Books, 1970.
(5) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
109
-------
EPOXY RESIN PRODUCTION PROCESS NO. 33
Washing
1. Function - The epoxy polmer is washed with several reagents. The
procedure most generally described in the literature consists of extraction
of the ether and salt mixture with a solvent. The solvent is already present
if the two-stage process described in Process No. 32 is used. The aqueous
phase is discarded. The organic phase containing the epoxy is washed (often
in the reactor vessel) with water followed by sodium hydroxide to remove the
chlorine residue. Washing with sodium dihydrogen phosphate neutralizes the
residual caustic.
2. Input Materials - 2218 g of wash water are required per kg of product
according to one source of information. Another reference describing the
process covered by a Shell patent prescribes a weight of MIBK equal to the
weight of the reactor contents and three times that weight in water require-
ments. The sodium hydroxide solution used is an equal weight of 5% solution.
The NaH2POi4 is a half-weight quantity of 2% solution.
3. Operating Parameters - The description of the process patented by Shell
indicates a temperature of 25°C and agitation for two hours for the MIBK
extraction. Washing with sodium hydroxide occurs at 80°C with an agitation
time of one hour. The NaH?P04 wash is performed at 25°C.
4- Utilities - See Table 24.
5. Waste Streams - The washing procedures generate a large volume of waste
water.No indication of methods of treatment or disposition was evident in
the literature consulted.
A solid waste stream is formed in the reactor bottoms. This solid waste
consists of 41 kg (90 Ib) MIBK, 312 kg (688 Ib) NaCl, 15.2 kg (33.4 Ib)
Na2HP04, and 13.4 kg (29.5 Ib) epichlorohydrin-methanol by-product per ton
of resin produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bannerman, D. G., and E. E. Magat. Polyamides & Polyesters. In:
Pol ymer Processes, Vol X. Calvin E. Schildknecht, ed. N.Y.,
Interscience Publishers, 1956, p. 235-94.
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
110
-------
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Riegel's Handbook of Industrial Chemistry, 7th Ed. James A.
Kent, ed. N.Y., Van Nostrand Reinhold, 1974, p. 292.
(5) Potter, W. G. Epoxide Resins. London, Iliffe Books, 1970.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.H., Noyes Data Corp., 1975.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N. Y., McGraw-Hill, 1958, p. 943-1035.
Ill
-------
EPOXY RESIN PRODUCTION PROCESS NO. 34
Polymer Recovery
1. Function - In this process the polymer is isolated, and the final product
is prepared. The organic solvent is removed from the resin by distillation
under atmospheric and vacuum conditions for recycle.
The isolated resin may be stored in the liquid form for shipment to sales
if its molecular weight is low enough. If it is a higher molecular weight
resin, it may be solidified by cooling and ground to form a solid resin pro-
duct. Alternatively, the liquid or solid resin may be dissolved in an organic
solvent.
Various types of additives may be introduced to the resin to modify its
properties for different end uses.
2. Input Materials - The organic phase from the washing operations and a
solvent are feeds to this process.
Additives include diluents (aromatic hydrocarbons, dibutyl phthalate,
pine oil, vinylcyclohex-3-ene dioxide, n-butyl glycidyl ether, phenyl glycidyl
ether, p-tolyl glycidyl ether, glycidyl esters of tertiary carboxylic acids,
tetramethylene diglycidyl ether); fillers (marble flour, chalk powder, silica
flour, mica flour, slate powder, zircon flour, sand, vermiculite, phenolic
microballoons, aluminum powder, asbestos fibre, chopped glass fibre, metal
oxides, graphite, calcium carbonate); resinous modifiers (coal tar pitch,
petroleum derived bitumens, furfural resins, unsaturated polyesters, PVC,
teflon, silicone resins); and flexibilizers (glycidyl fatty acid esters).
3- Operating Parameters - Methyl isobutyl ketone is distilled at 160°C at
atmospheric pressure and then at 133 Pa (1 mm Hg) at the same temperature.
The resins generally have melting temperatures between 70° and 150°C.
4. Utilities - See Table 24.
5. Waste Streams - Distillation generally results in fugitive gaseous
emissions of volatile solvent vapors. Grinding and packaging operations are
potential sources of particulate emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bannerman, D. G., and E. E. Magat. Polyamides & Polyesters. In:
Polymer Processes, Vol X. Calvin E. Schildknecht, ed. N.Y.,
Interscience Publishers, 1956, p. 235-94.
112
-------
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.). Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-73-010-a. Washington,
D. C., 1974.
(3) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, Ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(5) Potter, W. G. Epoxide Resins. London, Iliffe Books, 1970.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(7) Unit Processes in Organic Synthesis, 5th Ed., Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
113
-------
UNSATURATED POLYESTER RESIN PRODUCTION PROCESSES
This operation concerns the manufacture of what are considered polyester
resins in the plastics and resins industry. The definition is narrower than
the strict chemical definition. Polyester resins are mixtures of unsaturated
polyester resin and vinyl monomers which crosslink to form thermosetting
plastics in the presence of curing agents. Curing agents include peroxides
such as benzoyl peroxide, methyl ethyl ketone peroxide, di-t-butyl peroxide,
and dicumyl peroxide. Curing is done at the fabrication point and may
require heat as well as a curing agent.
Quantitative waste stream data were largely unavailable in the sources
consulted for this study. Waste water loading for polyester resin manufacture
was reported to be 0 to 167 m3/Mq with a BOD5 of 0 to 10 kg/Mg and a COD of
1 to 30 kg/Mg. Qualitative indications of the possible sources of emissions
are given in the process descriptions. Utility data were found for the entire
operation and are included in Table 28.
Table 28. UTILITY REQUIREMENTS FOR UNSATURATED POLYESTER RESIN PRODUCTION3
cooling water 1060 m3 (280,000 gal)
electricity 740 kWh
steam 3.3 Mg (7200 Ib)
natural gas 230 m3 (8600 scf)
aBasis 13.4 Mg (29,600 lb)/12 hour. Batch-type solvent polymerization.
Source: Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
Figure 14 is a process flow sheet illustrating the processing sequence
involved in this operation. Two process descriptions are included:
35) Polymerization and 36) Mixing.
114
-------
O (JASioua tMISSIONS
Q SOUO EMISSIONS
& uoun EMISSIONS
AROMATIC
DIBASIC ACID
OR I
ANHYDRIDE/
UNSATURATE
DIBASIC ACID
\ OR /
ANHYDRIDE'
N2 OR N^ "x
I RESIN I
FIGURE 14. UNSATURATED POLYESTER RESIN PRODUCTION
115
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UNSATURATED POLYESTER RESIN PRODUCTION PROCESS NO. 35
Polymerization
1. Function - An aromatic dibasic acid or anhydride, an unsaturated dibasic
acid or anhydride, and a dihydric alcohol are charged to a stainless steel or
glass-lined reactor equipped with an agitator, a condenser, inert gas facilities,
fume scrubbers, sampling devices, and a heat source. The temperature is raised,
and the reaction is allowed to continue in an inert atmosphere until acid number
or viscosity measurement specifications are met.
The water of reaction is removed by one of two alternate methods. The
fusion process removes water and maintains an inert atmosphere by sparging
with nitrogen or carbon dioxide. The other method, commonly called the
solvent or azeotropic method, involves the addition of a solvent and dis-
tillation of the water and solvent as an azeotrope during the reaction. The
solvent is then recovered for recycle.
The overhead vapors from the reactor are sometimes scrubbed for removal
of entrained liquids and solids.
2. Input Materials - The most commonly used unsaturated dibasic acids are
maleic and fumaric acids, generally provided in the form of anhydrides. The
most common aromatic dibasic acid in use is phthalic acid. However, iso-
phthalic, adipic, and azelaic acids are also used. The dihydric alcohol
may be ethylene glycol, diethylene glycol, propylene glycol, dipropylene
glycol, neopentyl glycol, or some similar compound. A typical polyester
resin has input materials listed in Table 29.
Table 29. POLYESTER RESIN FEED MATERIALS
Feed Material
Resin
Aa
Resin
Ba
Resin
Cb
Phthalic anhydride 28.86 40.5 3
Maleic anhydride 19.11 26.7 5
Propylene glycol 14.83 43.8
Ethylene glycol 12.10 - 4
Diethylene glycol 4
aln kg/100 kg resin
In moles
Source: Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-
406. Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
116
-------
3. Operating Parameters - In the preparation of Resin C in Table 29 the
temperature is raised to 375°C with nitrogen or carbon dioxide sparging until
an acid number of 60 to 65 is achieved. The temperature is then raised to
440°C and maintained until an acid number of 45 to 50 is reached. The total
reaction time is about 5 hours. At the end of this time the temperature is
reduced to 150°C in preparation for mixing with a cross-linking agent.
4. Utilities - See Table 28.
5. Waste Streams - Liquid waste streams result from this process. The water
of reaction must be disposed of whether removed by azeotropic or fusion methods.
Contaminants include glycols, acids, and solvents.
Scrubbing the reactor overhead streams results in an aqueous waste stream.
The concentrations of contaminants will depend on whether the mode of opera-
tion is once-through or recirculating. Recirculating scrubber waste may be
as high as 200,000 to 400,000 ppm in BOD and COD. These high concentrations
are often discharged to landfill or are treated in incineration operations.
Caustic solutions are used to clean reactors, tank cars, and tank trucks.
This solution is generally recycled but must be disposed of eventually.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Bannerman, D. G., and E. E. Magat. Polyamides & Polyesters. In:
Polymer Processes, Vol X. Calvin E. Schildknect, ed. N.Y., Inter-
science Publishers, 1956, P. 235-94.
(2) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y.,
Wiley, 1971.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(4) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics, In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
117
-------
UNSATURATED POLYESTER PRODUCTION
PROCESS NO. 36
Mixing
1. Function - When the polymerization reaction (Process No. 35) has reached
the desired stage, the reactor contents are transferred to a tank for mixing
with a reactive solvent or monomer, usually styrene. An inhibitor may be
added to prevent preliminary polymerization. The mixture is then cooled and
stored in drums or tanks. The final curing is done at the point of application.
2. Input Materials - The linear polymer from Process No. 35, reactive monomer,
and often an inhibitor are feed materials to this process. Styrene is most
often used as a reactive monomer or solvent; although, methyl methacrylate
and vinyl toluene are also used. Inhibitors in commercial use include hydro-
quinone, jD-t-butyl catechol, phenolic resins, aromatic amines, pyrogallol,
chloranil, picric acid, and quinones. Resin C of Table 29 is mixed with
6.5 moles of styrene containing 0.02 percent (based on the total solution)
£-t>butyl catechol. Resin A of Table 29 requires 30 kg styrene per 100 kg
resin and a trace of hydroquinone.
3. Operating Parameters - In mixing resin C of Table 29 the temperature
is maintained at 40°C. It is cooled to 20°C before it is pumped to storage
facilities.
4. Utilities - See Table 28.
5. Haste Streams - Caustic solutions are used to clean out the storage
vessels. Although this is recycled, it eventually ends up as a waste stream.
It may be landfilled or incinerated. Spills and leaks during transfer are
another source of emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Billmeyer, Fred W., Jr. Textbook of Polymer Science, 2nd Ed. N.Y.,
Wiley, 1971.
(2) Boenig, H. V. Polyesters, Unsaturated. In: Encyclopedia of
Polymer Science & Technology, Vol 2. H. F. Mark, ed. N.Y., Wiley,
1969, p. 129-68.
(3) Environmental Protection Agency. Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(4) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
118
-------
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
119
-------
ALKYD RESIN PRODUCTION PROCESSES
The term "alkyd" in the plastics and resins industry has a fairly narrow
connotation which has evolved through usage. Alkyd resins are specific poly-
ester resins formed from polyhydric alcohols, polybasic acids, and fatty acids.
These compounds are usually produced in hydrocarbon solvent solutions. A large
amount of the production of alkyds is ultimately blended with other resins.
Varying amounts of different reactants makes possible an almost limitless
number of products with different characteristics.
The alkyd resins are often manufactured in the same plants and even in
the same reactors as the unsaturated polyesters. They have similar chem-
istries, processing, and waste problems. Figure 15 is a flow sheet included
as an aid in understanding the processing sequence in making alkyd resins.
The similarity to Figure 14 of the unsaturated polyester operation is notable;
the differences occur in the reactants and solvents used.
Waste water loading for alkyd resin production is 0.3 to 12.0 m3/Mg.
Raw waste loads include BOD5, 9 to 25 kg/Mg; COD, 15 to 80 kg/Mg; and
suspended solids, 1 to 2 kg/Mg.
120
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OOASBOUS EMISSIONS
Q 3OUO EMISSIONS
£ LIQUID EMISSIONS
FIGURE 15. ALKYD RESIN PRODUCTION
121
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ALKYD RESIN PRODUCTION PROCESS NO. 37
Polymerization
1. Function - A polybaslc acid, a polyhydric alcohol, and a fatty acid or
oil are charged to a reactor and are processed by fusion or azeotropic methods
(See Process No. 35) in an inert atmosphere. The kettle may be heated
directly or indirectly. The condenser used in the azeotropic method is
usually a tube and shell, single pass type with cooling water in the shell.
2. Input Materials - The most often used polybasic acid is phthalic
anhydride; isophthalic acid, adipic acid, and sebacic acid are also used.
Maleic and fumaric acids may replace part of the aromatic acids in amounts
up to 10 percent on a molar basis.
The two most frequently used polyhydric alcohols are pentaerythritol
and glycerol. Others which have been used include dipentaerythritol,
trimethylolethane, sorbitol, ethylene glycol, and propylene glycol.
Fatty acids and oils in common use include soya oil, safflower oil,
castor oil, linseed oil, coconut coil, cottonseed fatty acids, and tall oil
fatty acids.
Metal salts are sometimes used as catalysts. Litharge and lithium
compounds are common. Concentrations used are 0.01 to 0.05 percent based on the
triglyceride oil.
Solvents used in the azeotropic method are usually xylene or toluene.
A typical alkyd resin is made from feed materials described below in
Table 30.
Table 30. FEED MATERIALS FOR A TYPICAL ALKYD RESIN
Feed Materials Parts by Weight
linseed oil 2000
glycerol 580
lime 2
phthalic anhydride 1400
122
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3. Operating Parameters - Reaction temperatures range from 210 to 280°C.
A pitched-blade, fan-type turbine is widely used for agitation. A useful
turbine diameter is 35 to 50 percent of that of the kettle. A peripheral
speed of 3 to 4 m/sec (600 to 800 ft/min) is used.
Inert gas flow rate is usually 0.04 to 0.3 m3/min/m3 (0.005 to 0.04 ft3/
min/gal) of reactants.
The shell and tube condenser must provide 2 m2 (20 ft2) condensing area
for a 4 m3 (1000 gal) kettle.
Xylene returns to the reactor from the condenser at 25 to 40°C.
4. Utilities - None were available in the sources consulted for this study.
5. Waste Streams - Scrubbing the reactor overhead stream produces waste
water which contains reactants and solvent. Water of reaction removed
from the kettle forms another liquid waste stream. Kettle cleaning with
caustic or solvents between batches also contributes to the liquid waste
stream from the plant. The cleaning solutions are generally recycled but
eventually end up as waste to be disposed of. This source of waste is
reported to be the major source of waste water from alkyd resin production.
The waste water production from alkyd resin manufacture is about 15 m3
(4000 gal) per 0.90 Mg (one ton) of product. About 5.5 kg (12 Ib) of
cleaning solution are disposed of per 0.90 Mg (one ton) of product.
Gaseous emissions of solvent and reactants may occur at the scrubber
vent. The high processing temperatures approach the boiling points of many
of the reactants.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency. Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D. C., Jan. 1975.
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Mraz, Richard G. and Raymond P. Silver. Alkyd Resins. In: Ency-
clopedia of Polymer Science and Technology, Vol 1. H. F:. Mark,
ed. N.Y., Wiley, 1964, p. 663-734.
(4) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J. , Noyes Data Corp., 1975.
(5) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
123
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ALKYD RESIN PRODUCTION PROCESS NO. 38
Mixing
1. Function - When the polymerization reaction (Process No. 37) reaches
the desired stage, the batch is dropped into a jacketed, agitated tank
equipped with a condenser. The reaction products are cooled and diluted to
the desired resin content. The cooled, diluted resin is then filtered
and transferred to drums or tanks for storage prior to sale.
2. Input Materials - The alkyd resin from the reactor and a solvent such
as toluene or xylene are feed materials to this process.
3. Operating Parameters - The volume of the thinning tank must be twice
the volume of the reactor. Agitation is probably accomplished with a
turbine agitator. A condenser should be provided to recover volatilized
vapors.
4. Utilities - None were detailed in the sources consulted for this study.
5. Waste Streams - Fugitive gaseous emissions may result from the condenser.
The gaseous emissions may contain solvent and reactant vapors.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency. Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., Jan. 1975.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Mraz, Richard G. and Raymond P. Silver. Alkyd Resins. In: Ency-
clopedia of Polymer Science and Technology, Vol 1. H. F. Mark,
ed. N.Y., Wiley, 1964. p. 663-734.
(4) Sittig, Marshall. Pollution Control in the Plastics and Rubber
Industry. Park Ridge, N.J., Noyes Data Corp., 1975.
(5) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
124
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POLYETHYLENE TEREPHTHALATE) PRODUCTION PROCESSES
This operation treats the producion of poly(ethylene terephthalate)
which is used almost exclusively in the synthetic fiber industry. Poly
(butylene terephthalate) is another thermoplastic polyester of the same
type which is becoming increasingly important. Almost no information was
available in the references consulted, however, concerning its production
and resultant environmental problems. Because of the lack of information,
this treatment is necessarily restricted to poly (ethylene terephthalate)
production. The products of this operation take the form of chips and fibers
spun directly from the molten polymer. Although batch and continuous pro-
cesses are both in use, the trend for new operations is toward continuous
processes integrated with spinning equipment for production of fibers (see
Synthetic Fibers Industry, Chapter 11).
The use of terephthalic acid (TPA) has become an alternative to the
use of dimethyl terephthalate (DMT) as a raw material. Economic advantages
indicate the use of TPA in new plants. In spite of the economic advantages
in the use of continuous processes and TPA as a raw material, a large amount
of poly (ethylene terephthalate) is still produced in existing plants using
DMT in a batch process representing the older technology.
Estimates of utility requirements for production of poly (ethylene
terephthalate) from DMT and TPA are presented in table 31.
Table 31. UTILITY REQUIREMENTS FOR POLYETHYLENE TEREPHTHALATE)3
TPA, continuous process
DMT, batch process
cool ing water
makeup water
electricity
fuel
247 m3(65,300 gal)/hr
11 m3(2800 gal)/hr
64-850 kW
358 m3/hr(13,400 scfh)
251 m3(66,400 gal)/hr
12 m3(3200 gal)/hr
850.8 kW
6.88 Mg (15,160 lb)/hr
206 m3/hr (7,300 cfh)
aBased on 38 Mg (83,000 lb)/yr capacity
Includes cooling water and steam requirements
Source: Hedley, W.H., et al. Potential Pollutants from Petrochem-
ical Processes, Final Report. Contract 68-02-0226, Task 9,
MRC-DA-406. Dayton, Ohio, Monsanto Research Corp. Dayton
Lab., Dec. 1973.
Figure 16 is a flow sheet illustrating the processes involved in this
operation. The production of poly(ethylene terephthalate) is accomplished
in three processes: 39) Ester exchange or esterfication, 40) Polymerization,
and 41) Product Formation. In integrated plants the spinning process consumes
most of the production.
125
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©I DMT \
I OR TPA I
O OAMOU9 IMIS3IOM3
Q SOUO IMI8SION3
& LIQUID IMISSIONS
CATALYSTS
i
ESTER EXCHANGE
OR ESTERIFICATION
39
TJ02
AND OTHER
ADDITIVES
/ MOLTEN \
1 POLYMER I
PRODUCT FORMATION
n
TO SPINNING
OPERATIONS
FIGURE 16. POLY (ETHYLENE TEREPHTHALATE ) PRODUCTION
126
-------
K)I.Y(I fllYLt'NI H
1
WUCT ION
Ester Exchange or Esterification
LVj NO. 39
Function - In the batch process which is widely used, dimethyl terephthalate
(DMT) or terephthalic acid (TPA), catalysts and ethylene glycol are charged to
a heated, agitated, glass-lined or stainless steel kettle equipped with a con-
denser, a vacuum system, and an inert gas system. The temperature is raised
to initiate the reaction. The DMT reaction produces a by-product of methanol
which is removed as it forms along with refluxed ethylene glycol.
Continuous processes have been developed and newer plants employ these
processes. Molten DMT or TPA, catalysts, and ethylene glycol are charged
to a horizontal sectioned reactor operated with a temperature gradient or to
a column equipped with a condenser and reboiler. The column condenser is
equipped with capabilities to separate water and qlycol; pressure rectifica-
tion is one indicated method. The glycol is recycled to the column after
purification and the water becomes a waste stream.
2. Input Materials - Molar ratios of ethylene glycol to DMT are reported
by one source as 2.1 to 2.2. Another source cites requirements of 0.909 Mg
(2,002 Ib) DMT and 0.63? Mg (1,391 lb) of ethylene glycol per ton of product
resin. The glycol to TPA mole ratio is generally lower: 1.3 to 1.5. Re-
quirements of 0,781 Mg (1,721 lb) of TPA and 0.50 Mg (1,111 lb) of ethylene
glycol per 0.9 Mg (one ton) of product are reported.
3. Operating Parameters - The batch reactor of 0.4 to 23 Mg (0.5 to 25
ton) capacity is heated to 150 to 210°C for DMT processes. Temperatures of
200-250°C are reported for TPA systems at a pressure of 0.2 to 1.0 MPa
(2 to 10 atm). The continuous process has a temperature gradient from
170° to 245°C (338°F to 473°F) and requires 4 hours for reaction. The
process is conducted at atmospheric pressure. Catalysts for this process
and for Process No. 40, Polymerization, are both added here and include
oxides, carbonates, and acetates of zinc, calcium, manganese, magnesium,
cobalt and antimony. The quantities used are generally 0.05 to 0.1% based
on the weight of DMT.
4- Utilities - See Table 31.
5. Waste Streams - Water from the condenser forms a waste stream contaminated
with the reactor contents. The treatment and/or disposition of this stream
is unspecified in the literature consulted for this study.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Brownstein, Arthur M. The Xylenes. In: U.S. Petrochemicals.
Arthur M. Brownstein, ed. Tulsa, OK, The Petroleum Publishing Co.,
1972, p. 192-210.
(2) Dux, James P. Polyester Fibers. In: Chemical and Process Tech-
nology Encyclopedia. Douglas M. Considine, ed. N.Y., McGraw-Hill
1974, p. 896-97.
127
-------
(3) Environmental Protection Agency, (Office of Air and Hater Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Goodman, I. Polyesters. In: Encyclopedia of Polymer Science and
Technology, Vol 11. H. F. Mark, ed. N. Y., Wiley, 1969, p. 110-17.
(5) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(6) Rodriguez, Ferdinand, Principles of Polymer Systems. N.Y., McGraw-
Hill, 1970.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
128
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POLYETHYLENE TEREPHTHALATE) PRODUCTION
PROCESS NO. 40
polymerization
1. Function - Before polymerization or polycondensation takes place, addi-
tions of toners, optical brighteners, delusterants, and other substances are
made. Titanium oxide is commonly added as a delusterant, as most of the
production is used for polyester fibers.
The temperature and pressure are then adjusted to initiate the poly-
condensation reaction. The continuous process utilizes horizontal compart-
mented reactors with individual agitators. Two series of reactors may be
used to effect extensive polymerization. The excess glycol is recovered
for recycle.
2. Input Materials - The ester or prepolymer from Process No. 39 and
various additives are feeds to this process.
Titanium oxide concentrations range from 0.02 to 2 percent by weight.
Triaryl phosphites or phosphates and phenolic compounds may also be added.
3. Operating Parameters - In the batch process the temperature is adjusted
to 270 to 280°C, and the pressure is adjusted to 66 to 133 Pa (0.5 to 1 mmHg)
Two horizontal reactors in series may be operated at 270°C, 2 to 3kPa (15 to
25 mmHg) and 280 to 285°C, 66 to 133 Pa (0.5 to 1 mmHg), respectively, for
continuous modes of operation.
4- Utilities - See Table 31,
5. Waste Streams - Ethylene glycol purification operations are reported to
contribute emissions of 2.2 kg (4.8 Ib) ethylene, 21 kg (46 Ib) of poly-
ethylene glycols, 86 g (0.19 Ib) sodium hydroxide and sodium bisulfite, and
86 g (0.19 Ib) of other wastes per 0.9 Mg (one ton) of product. The method
of purification from which these wastes arise is not specified. The waste
stream is described as a solid.
The use of steam ejectors for glycol recovery is indicated. This type
of processing produces a fouled condensate or waste-water stream.
6- EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References^ -
(1) Brownstein, Arthur M. The Xylenes. In: U. S. Petrochemicals.
Arthur M. Brownstein, ed. Tulsa, OK, The Petroleum Publishing
Co., 1972, p. 192-210.
(2) Dux, James P. Polyester Fibers. In: Chemical and Process Techno-
logy Encyclopedia. Douglas M. Considine, ed. N.Y., McGraw-Hill,
1974, p. 896-97.
129
-------
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Goodman, I. Polyesters. In: Encyclopedia of Polymer Science and
Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley, 1969, p. 110-17.
(5) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(6) Rodriguez, Ferdinand. Principles of Polymer Systems. N.Y., McGraw-
Hill, 1970.
(7) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins,
ed. N.Y., McGraw-Hill, 1958, p. 943-1035.
130
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POLYETHYLENE TEREPHTHALATE) PRODUCTION PROCESS NO. 41
Product Formation
^- Function - When the desired molecular weight is reached, the polymer may
be transferred to the spinning machinery while still molten (Chapter 11). If
a resin product is desired the polymer is extruded and chilled before it is
cut or broken into chips.
2. Input Materials - Molten polymer and cooling water are required for this
process.
3. Operating Parameters - None were available in the sources consulted for
this study.
4. Utilities - See Table 31.
5. Waste Streams - Palletizing, chipping, and packaging operations are
potential sources of particulate emissions. Chilling the polymer may be done
by direct or indirect contact with cooling water. If direct contact with
water is the method used, a waste-water stream containing polymer fines may
result. Details concerning this process were scarce in the sources consulted
for this study.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Brownstein, Arthur M. The Xylenes. In; U. S. Petrochemicals,
Arthur M. Brownstein, ed. Tulsa, OK, The Petroleum Publishing Co.,
1972, p. 192-210.
(2) Dux, James P. Polyester Fibers. In; Chemical and Process Techno-
logy Encyclopedia. Douglas M. Considine, ed. N.Y., McGraw-Hill,
1974, p. 896-97.
(3) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(4) Goodman, I. Polyesters. In: Encyclopedia of Polymer Science and
Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley, 1969, p. 110-117,
(5) Rodriguez, Ferdinand. Principles of Polymer Systems. N.Y., McGraw-
Hill, 1970.
(6) Unit Processes in Organic Synthesis, 5th Ed. Philip H. Groggins, ed.
N. Y., McGraw-Hill, 1958, p. 943-1035.
131
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NYLON 6 RESIN PRODUCTION PROCESSES
Nylon 6 is one of the polyamides made by polymerization of an amino acid
or a lactam. Other commercially significant nylons of this type are nylon 11
and nylon 12. Nylon 6, the most important product of this type in terms of
volume produced, is made from caprolactam. Nylon 11 is derived from 11-
aminoundecanoic acid; nylon 12 is made from lauryllactam. The production of
the latter two nylons is not discussed in this chapter.
The two different pathways to the production of nylon 6 shown in Figure
17 indicate two different commercial methods of polymer recovery after the
polymerization reaction. Both methods, aqueous extraction and vacuum distilla-
tion, are continuous methods. However, the vacuum distillation method is
suitable for integration with spinning equipment; moreover, the trend in the
industry is toward integrated facilities.
Three process descriptions define the operation of making nylon 6:
42) Polymerization, 43) Polymer Isolation (aqueous extraction), and 44) Poly-
mer Isolation (vacuum distillation). These process descriptions are shown
in Figure 17, which also indicates waste streams discussed in the process
descriptions.
When quantitative waste stream data for each process were unavailable,
a qualitative description was included. Waste-water loading for nylon 6
production is reported to be 54.2 m3/Mg product. Raw waste load data include
BOD, 1 to 135 kg/Mg, COD, 1 to 300 kg/Mg; and suspended solids, 0 to 8 kg/Mg.
Utility requirements for making nylon 6 resin chips are summarized in Table
32. Although not specifically stated, the process used for monomer recovery
appears to be aqueous extraction.
TABLE 32. UTILITY REQUIREMENTS FOR MAKING NYLON 6 RESIN CHIPS3
cooling water 2.71 m3/min (715 gal/min)
steam (100 psig) 4 Mg/hr (9000 Ib/hr)
(300°C) 0.54 Mg/hr (1200 Ib/hr)
electric power 830 kW
fuel 733 W (2.5 x 103 Btu/hr)
a!3.6 Mg(30,000 lb)/yr capacity
Source: Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-
406. Dayton, Ohio, Monsanto Research Corp. Dayton Lab.,
Dec. 1973.
132
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NYLON 6 RESIN PRODUCTION PROCESS NO. 42
Polymerization
1. Function - Molten caprolactam, water, catalyst, Ti02, and acetic acid are
charged to a vertical tube reactor. Temperature is controlled by heat ex-
change with dowtherm. As the reaction mass proceeds slowly down the reactor,
polymerization takes place. The effluent, consisting of polymer, unreacted
monomer, oligomer, and water, is further processed in Polymer Isolation,
Process No. 43.
2. Input Materials - Caprolactam, catalysts, water, stabilizer (acetic acid)
and delusterant (Ti02) are feed materials to the reactor. An operation pro-
ducing 13.6 Mg (30,000 Ib) nylon resin per year is reported to require 0.867
Mg (1,909 Ib) caprolactam and 2 kg (4 Ib) acetic acid per 0.90 Mg (one ton)
of product. Another source of information presents a material balance which
specifies a requirement of 1.2 Mg (2600 Ib) makeup and recycle caprolactam
per 0.90 Mg (one ton) of product. The reasons for the wide variation were
not clear.
3. Operating Parameters - The reaction temperature is 250 to 260°C, and the
time required is 20 to 24 hrs. Pressure is atmospheric. The vertical reactor
is usually 8 to 10 m (26 to 33 ft) tall,
4- Utilities - See Table 32.
5. Waste Streams - Caprolactam emissions to the atmosphere may occur at
mixing tank vents and at reactor vents. Average emission factors
compiled by EPA from questionnaire responses indicate 0.00012 kg
caprolactam emitted at the mixing tank vent and 0.00034 kg capro-
lactam emitted at the reactor vent per kg nylon 6 produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Koh&n, Melvin I., ed. Nylon Plastics. New York, Wiley-Interscience,
1973.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emission from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974
134
-------
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley, 1968,
p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics Hand-
book. Menlo Park, Ca., Stanford Research Institute, March 1974, p.
580.1031A-580.1032F., 580.1032E - 580.1032F.
135
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NYLON 6 RESIN PRODUCTION PROCESS NO. 43
Polymer Isolation (Aqueous Extraction)
1. Function - The reactor contents from Process No. 42 are extruded from
the bottom of the vertical tube reactor. The extruded ribbon is cooled by
direct contact with water and is then cut into chips with a rotary cutter.
Caprolactam and oligomer are extracted with hot water by countercurrent
contact. The polymer chips are dried in a hot nitrogen atmosphere or under
vacuum before being stored for use in spinning or molding.
Recovery of caprolactam from the water used for extraction is accomplished
in several steps. Concentration by evaporation is effected in multiple stages.
The concentrated solution of caprolactam is then treated with potassium per-
manganate to oxidize impurities which are discarded as solid waste. A distilla-
tion process separates the caprolactam for recycle from the water and higher
boiling compounds which form waste streams.
2. Input Materials - The polymerization reactor contents, consisting of 10 to
15 percent monomer and oligomer; nitrogen; water for cooling the polymer rib-
bon and for the extraction process; and permanganate are all needed in this
process. Steam may also be required for evaporation and distillation procedures.
3. Operating Parameters - Water temperature for extraction is 90 to 100°C. The
aqueous extraction results in a solution which is 5 percent caprolactam. This
concentration is increased to 70 percent by evaporation procedures. Drying
temperature for the polymer chips is 100 to 120°C.
4, Utilities - See Table 32.
5. Haste Streams - Emissions of caprolactam vapor may occur at several points
in this process. When the molten polymer is quenched, caprolactam vapors es-
cape to the atmosphere. One plant responding to an EPA questionnaire reported
emissions of 0.00337 kg caprolactam per kg nylon 6 produced. Small amounts of
caprolactam vapor are also lost from the dryer vent. The distillation and
evaporation procedure for monomer recovery are subject to fugitive losses at
seals, valves, and fittings. In addition, the pellet cutting step may emit
small amounts of particulate matter to the atmosphere. Atmospheric emissions
of caprolactam and nylon particulates from cutting are 0.00272 kg/kg nylon 6
produced.
Solid wastes may be generated as still bottoms in the monomer recovery
section. This waste stream is generated at the rate of about 19 g/kg of
product and contains oligomer, high-boiling liquids, and about 2 percent
caprolactam. The permanganate treatment of the aqueous caprolactam solution
results in sludge for disposal. Waste polymer and off-spec product also
form solid waste streams. Indications in the literature are that all of the
solid waste streams are landfilled.
The water used to extract monomer from the nylon 6 polymer contributes
liquid waste which originates at several points. About 98 percent of the
water used for extraction is removed in the evaporator. Other sources of
136
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waste water are at the dryers and in the distillation for final monomer
purification. A range of waste-water parameters from these sources is
presented in Table 33.
TABLE 33. CHARACTERISTICS OF AQUEOUS EFFLUENT FROM
NYLON 6 RESIN WASHING AND DISTILLATION
BOD5 0.1-135 g/kg product 0.2-270 Ib/ton product
COD 0.2-300 g/kg product 0.4-600 Ib/ton product
Suspended Solids 0-8 g/kg product 0-16 Ib/ton product
Another source of waste water is found in quenching of the extruded poly-
mer.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Inter-
science, 1973.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houdry Div.,
March 1974.
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia
of Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley
1968, p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics Hand-
book. Menlo Park, Ca., Stanford Research Institute, March 1974,
p. 580.1031A-580.1032F., 580.1032E-580.1032F.
137
-------
NYLON 6 RESIN PRODUCTION PROCESS NO. 44
Polymer Isolation (Vacuum Distillation)
1. Function - Water, unreacted monomer, and oligomer are removed from the
molten polymer produced in Process No. 42 by vacuum distillation. This
separation may be accomplished in a distillation column or in a thin-film
evaporator. The molten polymer may then go directly to spinning operations
or may be extruded and chilled in water before pelletizing.
It is assumed that the overheads containing water, monomer, and oligomer
are then separated for recycle of caprolactam. In some processes oligomer
is depolymerized to provide additional recycle monomer.
2. Input Materials - The reaction products from Process No. 42 consisting of
monomer, polymer, and water are the main feed stream to this process. Water
for quenching is required in making resin pellets or chips.
3. Operating Parameters - A typical vertical, agitated, thin-film evaporator
with non-scraping blades rotates at a speed of 9 to 12 m/sec (30-40 feet/sec).
Normal evaporators can handle viscosities up to 300 Pa-s (300,000 cp); evapora-
tion rates for high-viscosity materials may be as low as 100 to 150 kg/hr m2
(20-30 Ib/hr ft2). Clearances between the blade tip and the shell are usually
0.08 to 0.2 cm (0.03 to 0.10 in). Pressures of 0.7 to 1.3 kPa (5 to 10 mmHg)
are used for removal of monomer and water from the nylon 6 polymer.
4. Utilities - Data were not available in the sources consulted for this
study. Power is needed for the vacuum system, and steam is required for
monomer recovery procedures.
5. Waste Streams - Although it was not specified in the literature consulted
for this study, monomer is probably recovered for recycle by distillation and
by depolymerization. Excess oligomer and water probably form waste streams
from this process. The vacuum recovery system may be a source of fugitive
gaseous emissions at valves and fittings. Particulates are a potential
emission threat in pelleting or cutting operations.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
138
-------
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Inter-
science, 1973.
(4) Mutzenburg, A. B. Agitated Thin Film Evaporators, Pt. 1, Thin Film
Technology. Chemical Engineering 72^175, (13 Sept. 1965).
(5) Parker, N. Agitated Thin Film Evaporators, Pt. 2, Equipment and
Economics. Chemical Engineering 72^179, (13 Sept. 1965).
(6) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions
from the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d,
Contract No. 68-02-0255. Air Products & Chemicals, Houdry Div.,
March 1974.
(7) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia
of Chemical Technology, Vol 16. Anthony Standen, ed. N.Y.,
Wiley, 1968, p. 1-46.
139
-------
NYLON 66 RESIN PRODUCTION PROCESSES
This operation is restricted to the discussion of nylon 66 production
as it is by far the most significant product of this type. Other nylons of
this type having some commercial significance are nylons 610, 612, and 69.
All of these nylons are made from hexamethylene diamine and a dibasic acid.
Adipic acid is used in nylon 66 production, sebacic for nylon 610, dodecan-
oic for nylon 612, and pelargonic for nylon 69.
Both batch and continuous operations are represented in Figure 18.
Economic conditions favor continuous operation integrated with spinning
equipment, but batch production is still in use. New plants are expected
to adopt continuous processing methods.
Utility requirements for a continuous nylon 66 operation are listed
below in Table 34. The estimates are based on a plant with a 13.6 Mg
(30,000 lb)/yr capacity.
Table 34. UTILITY REQUIREMENTS FOR A CONTINUOUS NYLON 66 OPERATION
cooling water
demineralized water
steam
power
nitrogen
dowtherm heat
1.46 m3/min
0.0012 m3/min
3.5 Mg/hr
190 kW
690 m3/hr
1758 W
(386 gal/min)
(0.31 gal/min)
7600 Ib/hr
(26,000 scfh)
(6000 Btu/hr)
Source: Hedley, W. H., et al. Potential Pollutants from Petro-
chemical Processes, Final Report. Contract 68-02-0226,
Task 9, MRC-DA-406. Dayton, Ohio, Monsanto Research
Corp. Dayton Lab., Dec. 1973.
Figure 18 is a process flow chart included as an aid to understanding the
sequence and interrelation of the six processes described in this operation.
The processes included are: 45) Feed Preparation, 46) Evaporation, 47) Poly-
merization (Batch), 48) Resin Product Preparation, 49) Polymerization (Con-
tinous), 50) Product Preparation.
An environmental problem may exist in plant localities due to the forma-
tion of a "blue haze." This is caused by particulate and aerosol emissions
from various vents throughout the operation. Waste-water loading from nylon
66 production is 0 to 152.3 m3/Mg. Raw waste load includes BOD5, 1 to 135 kg/
Mg; COD, 1 to 300 kg/Mg; and suspended solids, 0 to 8 kg/Mg.
140
-------
OIATOMACEOUS EARTH
ACTIVATED CARBON
WATER
MeOH
FEED PREPARATION
49
EVAPORATION
Ti O2
HOAC I
II
BATCH METHOD
POLYMERIZATION
(BATCH)
50-«0%
NYLON SALT
SLURRY
• CONTINUOUS METHOD
T, 0,
a
HOAC
n
POLYMERIZATION
(CONTINUOUS)
RESIN
PRODUCT
PREPARATION
-a
TO SPINNING
uagNO
Oa*»iOU« IHIMIONS
Q SOLID IMISdONl
& LlOUIC fMU«IOM«
FIGURE 18. NYLON 66 RESIN PRODUCTION
141
-------
NYLON 66 RESIN PRODUCTION PROCESS NO. 45
Feed Preparation
1. Function - The first step in the batch process for preparing nylon 66 is
neutralizing adipic acid with hexamethylene diamine (HMDA) in methanol or
water. The resulting nylon salt may be crystallized from methanol solution
and dried by centrifugation. Some nylon 66 producers buy a nylon salt solution
instead of making the salt from the acid and diamine. In either case the
salt solution must then be decolorized with activated carbon before use to re-
move impurities which would discolor the product polymer.
2. Input Materials - Hexamethylene diamine and adipic acid or hexamethylene
diamineacfipate ""[nylon salt) are inputs to this process. Water and activated
carbon are also required. If a crystalline material is desired, methanol is
used for crystallization. Feed materials required for 0.9 Mg (one ton) of
product are estimated to be 0.47 Mg (1043 Ib) of HMDA, 0.590 Mg (1299 Ib) of
adipic acid, and 10.7 kg (26.3 Ib) of methanol.
3. (Derating Parameters - Data were not available in the sources consulted
for this study.
4- Utilities - See Table 34.
5. Waste Streams - Decolorizing results in liquid and solid waste streams.
Effluents contain spent carbon, diatomaceous earth, and some nylon salt.
Quantitative estimates of 14 kg (30 Ib) of carbon and 2.9 kg (6.3 Ib) of
nylon salt per 0.90 Mg (one ton) of nylon 66 produced are reported by one
reference for a plant producing 14 Mg (30,000 Ib) per year.
6- EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References. -
(1) Environmental Protection Aaency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Inter-
science, 1973.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
142
-------
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley,
1968, p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics
Handbook. Menlo Park, Ca., Stanford Research Institute, March
1974, p. 580.1031A-580.1032E.
(7) Work, Robert W. Man-Made Textile Fibers. In: Riegel's Hand-
book of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 323-24.
143
-------
NYLON 66 RESIN PRODUCTION
PROCESS NO. 46
Evaporation
1. Function - The aqueous suspension of nylon salt from Process No. 45 is
fed to a steam-heated evaporator operated in a continuous or batch mode for
concentration. One source specifies the use of an agitated, thin-film evapora-
tor.
2. Input Materials - An aqueous nylon salt slurry is the feed to this process;
the concentration is usually about 10 percent.
3. Operating Parameters - The concentrated slurry is generally 50 to 60 per-
cent nylon salt in the batch process, but it may range as high as 75% solids.
The bulk of the water is removed in the continuous method. A temperature of
110°C (230°F) is reported in the use of a thin-film evaporator.
4. Utilities - See Table 34. Steam is required for the evaporator.
5. Haste Streams - The water vapor removed by the evaporator is condensed
and sent to the sewer. The liquid waste stream contains up to one percent HMDA
and is one of the major sources of BOD in the aqueous waste from the plant.
Additional contaminants in the waste water are reported by one source; 2.4 kg
(5.2 Ib) methanol; 4 kg (8 Ib) nylon salt; and 1.4 kg (3.1 Ib) of other im-
purities including glutaric acid, succinic acid, acetic acid, 1,2-cyclo-
hexanediamine per 0.90 Mg (one ton) of nylon 66 produced. An EPA summary of
emissions based on replies to questionnaires indicates an emission of 0.000333
kg of particulates and aerosols per kg of nylon produced. These particulates
and aerosols contain HMDA, adipic acid, nylon salt, nylon polymer, cyclo-
pentanone, halide, and sulfonamide and are responsible for the "blue haze"
formation in the plant.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Inter-
sdence, 1973.
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
144
-------
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 16. Anthony Standen, ed. N.Y. Wiley,
1968, p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics Hand-
book. Menlo Park, Ca., Stanford Research Institute, March 1974,
p. 580.1031A-580.1032E.
(7) Work, Robert W. Man-Made Textile Fibers. In: Riegel's Handbook
of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y., Van
Nostrand Reinhold, 1974, p. 323-24.
145
-------
NYLON 66 RESIN PRODUCTION PROCESS NO. 47
Polymerization (Batch)
1. Function - Batch polymerization generally takes place in an indirectly
heated, stirred autoclave reactor. The concentrated slurry from Process No. 46
and additives such as acetic acid and titanium dioxide are charged to the
reactor after it is purged with inert gas. The temperature is raised, and the
pressure is maintained by a steam bleed vent. When the reaction is complete
the pressure is lowered to remove the remaining water. The vapor from the
reactor may be scrubbed with water. The scrubber water and the condensate form
a waste stream for treatment and disposal.
2. Input^ Materials - The 50 to 75 percent nylon salt slurry is a feed stream
to this process. Also added are chain terminator (acetic acid) and delustrant
(Ti02), plasticizers, pigments, and other additives.
3. Operating Parameters - Reaction temperature is 260 to 280°C. Reactor
pressure is held at 1.83 MPa (250 psig). Reaction time is two to three hours.
4. Utilities - No data were available for the batch process in the sources
consulted for this study.
5. Waste Streams - The steam from the reactor and the scrubber water, if
scrubbing is practiced, are combined to form a liquid waste stream containing
HMDA and small amounts of monomer and polymer. If the steam is vented to the
atmosphere, the contaminants may cause a "blue haze" as well as an odor problem.
An EPA summary of emissions based on replies to questionnaires indicates emis-
sions of particulates and aerosols (including HMDA, adipic acid, nylon salt,
polymer, cyclopentanone, halide and sulfonamide) amounting to 0.002100 kg/kg
nylon 66 produced. This number is assumed to be for uncontrolled emissions.
Another liquid waste stream is formed during reactor cleaning by washing with
acetic acid.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Interscience,
1973.
146
-------
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia
of Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley
1968, p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics Hand-
book. Menlo Park, Ca., Stanford Research Institute, March 1974, p.
580.1031A-580.1032E
(7) Work, Robert W. Man-Made Textile Fibers. In: Riegel's Handbook
of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y., Van
Nostrand Reinhold, 1974, p. 323-24.
147
-------
NYLON 66 RESIN PRODUCTION PROCESS NO. 48
Resin Product Preparation
1. Function - When the desired molecular weight is reached, the polymer
from Process No. 47 is removed from the bottom of the reactor under a nitrogen
atmosphere. Chilling is accomplished quickly by direct contact with water.
The polymer is band cast and the ribbon is cut or chipped before it is sent to
blending and/or storage.
2. Input Materials - The molten polymer from the polymerization reactor and
cooling water are required for this process.
3. Operating Parameters - Data were not available for the batch method in
the sources consulted for this study.
4- Utilities - Data were not available for the batch method in the sources
consulted for this study.
5- Waste Streams - Pelleting and flaking procedures, pneumatic conveying
methods, and dry blending procedures are potential sources of particulate emis-
sions.
The once-through cooling water for the casting section forms a liquid waste
stream containing polymer fines. One plant indicated, in answering an EPA question-
naire, that this waste stream is generated at the rate of 0.14 m3 (36 gal)/min.
No indication of the plant capacity was given. Another source indicated that
a portion of this waste water may be used as cooling tower makeup water.
Casting scrap forms a solid waste stream which is reportedly incinerated.
One plant reports incinerating 0.003 kg nylon scrap per kg produced. Complete
incineration would result in 0.00123 kg NOX per kg nylon 66 produced, but no
data were reported on the composition of the incineration gases.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Medley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Kohan, Melvin I., ed. Nylon Plastics. New York, Wiley-Interscience,
1973.
148
-------
(4) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(5) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia
of Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley
1968, p. 1-46.
(6) Wallace, Peter T. Polyamide Resins. In: Chemical Economics
Handbook. Menlo Park, Ca., Stanford Research Institute, March 1974,
p. 580.1031A-580.1032E.
(7) Work, Robert W. Man-Made Textile Fibers. In: Riegel's Handbook
of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y., Van
Nostrand Reinhold, 1974, p. 323-24.
149
-------
NYLON 66 RESIN PRODUCTION PROCESS NO. 49
Polymerization (Continuous)
1. Function - Additives such as acetic acid and titanium dioxide along with
dewatered monomer from Process No. 46 are fed to tank reactors, tubular columns,
or thin-film reactors. The reaction mixture is subjected to elevated tempera-
ture and pressure to effect polymerization. Water produced by the reaction is
removed as steam. Additional water of reaction is removed by reducing the
pressure to atmospheric in a flashing step. The vapor streams consisting of
contaminated steam may be scrubbed with water to reduce atmospheric emissions.
2- Input Materials - A concentrated nylon salt slurry from Process No. 46,
chain terminator (acetic acid), and delustrant (Ti02) are feed streams to this
process.
3- Operating Parameters - Reaction temperature is 232°C (450°F) and reactor
pressure is about "1.5 MPa (200 psig). The flashing step is accomplished at
160°C (320°F) and atmospheric pressure.
4- Utilities - See Table 34.
5. Waste Streams - The water removed as steam forms a liquid waste stream of
fouled condensate. If scrubbers treat the vapor stream, the scrubber water also
becomes a liquid waste stream.
A summary of emissions prepared from EPA questionnaires lists atmospheric
emissions of particulates and aerosols (including hexamethylene diamine, adipic
acid, nylon salt, nylon 66 polymer, cyclopentanone, halide, and sulfonamide)
as 0.00210 kg from the reactor and 0.001100 kg from the flasher per kg of
nylon 66 produced. It is these materials that cause the "blue haze" formation.
Another source indicates emissions of 1.2 kg (2.6 Ib) of HMDA per 0.90 Mg
(one ton) of nylon 66 produced.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Pervier, J. W., et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
150
-------
(4) Work, Robert W. Man Made Textile Fibers. In: Riegel's Handbook
of Industrial Chemistry, 7th Ed. James A. Kent, ed. N. Y., Van
Nostrand Reinhold, 1974, p. 323-24.
151
-------
NYLON 66 RESIN PRODUCTION PROCESS NO. 50
Product Preparation
1. Function - In some continuous operations the polymer goes through a
finisher at elevated temperature to assume complete polymerization. Molten
polymer from a continuous process may go directly to spinning operations as
described in Chapter 11, Synthetic Fiber Industry. The polymer may also be
cast and pelleted as in the batch method (Process No. 48) to form a resin
product.
2. Input Materials - Molten polymer from the flashing step in Process No. 49
is the feed material to this process.
3- Operating Parameters - Finishing takes place at a temperature of 280°C
(540°F).
4. Utilities. - See Table 34.
5. Waste Streams - The vent from the finisher contributes emissions of
particulates and aerosols: 0.044g per kg Nylon 66 produced. This stream
is normally not scrubbed.
Process No. 48 describes casting and pelleting waste streams.
6- EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.) Development Document for Effluent Limit-
ations Guidelines and New Source Performance Standards for the Syn-
thetic Resins Segment of the Plastics and Synthetic Materials Manu-
facturing Point Source Category. EPA 440/1-74-010-a. Washington,
D. C., 1974.
(2) Hedley, W. H., et al. Potential Pollutants from Petrochemical Pro-
cesses, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(3) Pervier, J. W. , et al. Survey Reports on Atmospheric Emissions from
the Petrochemical Industry, 4 Vols. EPA 450/3-73-005 a-d, Contract
No. 68-02-0255. Air Products & Chemicals, Houdry Div., March 1974.
(4) Sweeny, W. Polyamides (General). In: Kirk-Othmer Encyclopedia of
Chemical Technology, Vol 16. Anthony Standen, ed. N.Y., Wiley,
1968, p. 1-46.
(5) Work, Robert W. Man-Made Textile Fibers. In: Riegel's Handbook of
Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y., Van Nostrand
Reinhold, 1974, p. 323-24.
152
-------
POLYURETHAN FOAM PRODUCTION PROCESSES
Polyurethans are produced in the form of elastomers, coatings, and foams.
This discussion is restricted to the production of foams as they contribute
the largest volume of production to the market. There are two types of foam
products: one-shot foams and prepolymer systems. For prepolymer products
the crosslinking and foaming steps are done at the point of fabrication. In
this respect, polyurethans differ from typical resin products such as molding
powders, latices, or polymer solutions.
Polyurethans are produced by the condensation polymerization of polyhydric
alcohols and diisocyanates. The actual composition of starting materials
employed by polyurethan producers is not clear from the literature consulted
for this study. It appears that some polyurethan producers synthesize
isocyanates from toluene and aniline, while others purchase amines and
phosgenate them to form isocyanates. Others may purchase isocyanates
directly.
As shown in Figure 19, there are three process descriptions included in
this operation: 51) Phosgenation, 52) Polymerization (one shot), and
53) Polymerization (prepolymer systems). The Phosgenation process, of
necessity, relies heavily on data for toluene diisocyanate, as the informa-
tion was available and it is used in the largest volume.
153
-------
CATALYST
BLOWING AGENT
STABILIZERS
OLYHYDROX
COMPOUNDS
POLYMERIZATION
(ONE SHOT)
TO SALES
(PREPOLYMER SYSTEM)
53
TO SALES
TO SALES
LEQEND
O QASEOU3 EMISSIONS
D SOUO EMISSIONS
& UOUID EMISSIONS
FIGURE 19 . POLYURETHAN FOAM PRODUCTION
154
-------
POLYURETHAN FOAM PRODUCTION PROCESS NO. 51
Phosgenation
1. Function - Phosgenation of primary amines is the commercial method for
production of isocyanates. The usual method requires two stages. An amine
slurry is treated in a stirred, jacketed kettle with phosgene at a fairly
low temperature. The temperature is then raised and more phosgene is added.
Distillation provides a means of product purification. The isocyanates formed
are then used as a feed to polymerization processes. HC1 is obtained as a
marketable by-product.
2- Input Materials - Amines such as tolylene diamine and diphenylmethane
diamine are the most commonly used. Phosgene is the other reactant required.
Requirements for toluene diisocyanate (TDI) are 1.15 Mg (2,530 Ib) phosgene
and 0.6556 Mg (1,444 Ib) toluenediamine per ton of toluenediisocyanate pro-
duced.
3. Operating Parameters - The first stage of the phosgenation of toluene-
diamine takes place at 50° to 70°C. The second stage is at a higher tempera-
ture: 120° to 150°C. The reaction time for the second stage is 180 min.
4. Utilities - Utility requirements for producing TDI are listed below in
Table 35.
Table 35. UTILITY REQUIREMENTS FOR PRODUCING TOLUENE DIISOCYANATE3
cooling water 278 m3/hr (73,500 gal/hr)
process water 7.9 mVhr (2,100 gal/hr)
steam 0.73 Mg/hr (1,600 Ib/hr)
power 548 kW
fuel 51.8 kW (177,000 Btu/hr)
aBased on Mobay and Bayer patents and assuming 131 Mg (288,000 lb)/yr
capacity.
5. Haste Streams - A water scrubber is used on the waste gas stream. Scrub-
bing HC1 results in an acid waste stream amounting to 25 g HCl/kg TDI. Polymers
and tars from the purification procedures amount to 19.2 g per kg of TDI
produced. Although the literature did not include a discussion of the presence
of phosgene and aromatic amines in waste streams or in fugitive emissions, the
use of these toxic substances presents a potential hazard.
6- EPA Source Classification Code - Polyprod. General 3-01-018-02
155
-------
7. References -
(1) Frey, H. E. Diisocyanates and Polyisocyanates. In: Chemical
Economics Handbook. Menlo Park, Ca., Stanford Research Insti-
tute, Jan. 1976, p. 666.5021A-666.5022U.
(2) Frey, H. E. Polyurethane Foams. In: Chemical Economics Handbook.
Menlo Park, Ca., Stanford Research Inst., Jan. 1976, p. 580.1561A-
580.1562T.
(3) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(4) Piggot, K. A. Polyurethanes. In: Encyclopedia of Polymer Science
and Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 506-63.
(E) Wright, P. and A.P.C. Gumming. Solid Polyurethane Elastomers.
New York, Gordon and Breach Science Publishers, 1969.
156
-------
POLYURETHAN FOAM PRODUCTION PROCESSES PROCESS NO. 52
Po 1ymer izat1 on (One Shot)
1. Function - In the one-shot method all of the input materials are
combined and polymerization and foaming are completed. An isocyanate, a
polyhydroxy compound (polyester or polyether), stabilizers, blowing agents,
and catalyst are metered into a continuous mixer. Metering pumps with
±0.5% accuracy are required. They may be gear, piston, or high-pressure fuel
injection type. Variable speed drive is also necessary.
Foaming then takes place in forming devices where the foam is formed
and set. Slabs are formed on continuous conveyors; more complex shapes are
formed in molds. Foam slabs are cut into standard lengths, treated with
steam or heat, and transported to curing ovens.
2. Input Materials - Isocyanates commonly used in preparing polyurethan
foams are listed in Table 36.
Table 36. ISOCYANATES USED IN POLYURETHAN FOAM PRODUCTION
Chemical Name Common Name
80/20 2,4-/2,6-Tolylene diisocyanate 80/20 TDI
65/35 2,4/2,6-Tolylene diisocyanate 65/35 TDI
2,4-Tolylene diisocyanate 2,4 TDI
Modified tolylene diisocyanates crude TDI
4,4'-Diphenylmethane diisocyanate MDI
Polyisocyanates from aniline-formaldehyde Undistilled, crude, or
condensates polymeric MDI
1,6-Hexamethylene diisocyanate HDI
4,4'-Dicyclohexylmethane diisocyanate, —
mixed isomers
Polyhydroxy compounds may be polyester polyols, polyether polyols, or
naturally occuring compounds. Some of these are polypropylene glycols, pro-
pylene oxide adducts of glycerin, and 1,2,6-hexanetriol. There are hundreds
of combinations of reactants possible to make a wide variety of polyurethan
products.
157
-------
Catalysts include organic tin compounds used in conjunction with tertiary
amines such as tetramethylguanidine; N, N, N', N'-tetramethyl butane diamine;
triethylenediamine and dimethyl aminoethanol. Surfactants may be used to
stabilize the foam. Nonreactive blowing agents and flame retardants may also
be used. Flame retardants are usually liquid organic compounds containing
chlorine, bromine, and/or phosphorus.
Typical compositions for flexible and rigid foams are listed in Table
37.
Table 37. TYPICAL FORMULATIONS FOR FLEXIBLE AND RIGID FOAMS
Parts by Weight
Flexible
polyether polyol, functionality 2-3,
hydroxyl number 56 100
water 3.5
silicone copolymer stabilizer 0.1
stannous octoate 0.2
triethylene diamine 0.1
tolylene diisocyanate 45
Rigid
polyether polyol, functionality 4-8,
hydroxyl number 450 100
flame retardant 20
CFC1-j (blowing agent) 35
tertiary amine 2
silicone copolymer stabilizer 1
polymeric MDI-type polyisocyanate 115
158
-------
3. Operating Parameters - Foam machines have throughputs of 0.9 to 450 kg
(2 to 1000 lb)/min.Standard slab sizes are 2 m by 0.6 to 0.9 m and the
production rate is usually 45 to 90 kg (100 to 200 lb)/min. Conveyors are
from 15 to 30 m (50 to 100 ft) long and travel at rates up to 6 m (20 ft)/min.
4. Utilities - No data were available in the sources consulted for the
one-shot process.
5. Waste Streams - The only potential problem posed by this process is
in fugitive leaks and spills of isocyanate compounds. These compounds are
toxic and irritants and must be removed from work areas.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Backus, John K. Urethanes. In: Chemical and Process Technology
Encyclopedia. Douglas M. Considine, ed. N.Y., McGraw-Hill, 1974,
p. 1121.
(2) Chemical Technology: An Encyclopedic Treatment, Vol VI, N.Y.,
Harper & Row, 1973, p. 582.
(3) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the Synthetic Polymers
Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-75/036-b. Washington, D.C.,
Jan. 1975.
(4) Frey, H. E. Polyurethane Foams. In: Chemical Economics Handbook.
Menlo Park, Ca., Stanford Research Inst., Jan. 1976, p. 580. 1561A-
580.1562T
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In: Riegel's
Handbook of Industrial Chemistry, 7th Ed. James A. Kent, ed. N.Y.,
Van Nostrand Reinhold, 1974, p. 292.
(6) Piggot, K. A. Polyurethanes. In: Encyclopedia of Polymer Science
and Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 506-63.
(7) Wright, P. and A.P.C. Gumming. Solid Polyurethane Elastomers. New
York, Gordon and Breach Science Publishers, 1959.
159
-------
POLYURETHAN FOAM PRODUCTION PROCESSES PROCESS NO. 53
Polymerization (Prepolymer Systems)
1. Function - For some applications it is convenient to make a prepolymer
which is crosslinked and foamed later, often at the point of fabrication.
This is accomplished by reacting an excess of isocyanate with polyol to form
a low molecular weight polymer. Processing is generally by the batch method
but may be continuous. In the batch process the reactants are pumped to
a stainless steel, jacketed, agitated reactor which has been purged with
nitrogen. The reaction proceeds in a nitrogen atmosphere with temperature
control provided by steam and cooling water. The continuous process may
utilize scraped film heat exchangers instead of kettle reactors. The
prepolymer is stored under inert gas for marketing as a two-component system
for use by the consumer. The second component may contain more polyol and
water as a blowing agent.
2. Input Materials - In prepolymer systems an excess of isocyanate is
generally used. A two-step polyurethan prepolymer process is reported to
require 0.722 Mg (1590 Ib) toluene diisocyanate and 0.19 Mg (410 Ib) of
polyether per ton of product.
3. Operating Parameters - Reaction temperatures are 46 to 85°C (115 to
185°F) for batch processes and 100 to 120°C (220 to 240°F) for continuous
processes.
^' Utilities - Table 38 contains utility requirements for prepolymer
manufacture by both batch and continuous processes.
Table 38. UTILITY REQUIREMENTS FOR POLYURETHAN PREPOLYMER PRODUCTION9
steam (kg/hr)
cool ing water (m3/hr)
power (kW)
nitrogen (m3/hr)
dry air (mVhr)
Datchb
30
5.2
7.5
0.61
0.35
Continuous
34
4.
28
0.
0.
5
13
40
a4.5 Mg (10,000 lb)/yr capacity
b ,
average values
160
-------
5. Waste Streams - The pollution potential is reported in several references
to be very low, even insignificant. The only potential problem lies in the
use of toxic isocyanates which may be spilled or lost as fugitive emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Backus, John K. Urethanes. In: Chemical and Process Technology
Encyclopedia. Douglas M. Considine, ed. N.Y., McGraw-Hill, 1974,
p. 1121-25.
(2) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., Jan. 1975.
(3) Frey, H. E. Polyurethane Foams. In: Chemical Economics Handbook.
Menlo Park, Ca., Stanford Research Inst., Jan. 1976, p. 580.1561A-
580.1562T.
(4) Hedley, W. H., et al. Potential Pollutants from Petrochemical
Processes, Final Report. Contract 68-02-0226, Task 9, MRC-DA-406.
Dayton, Ohio, Monsanto Research Corp. Dayton Lab., Dec. 1973.
(5) Jones, Robert W. and K. T. Chandy. Synthetic Plastics. In:
Riegel's Handbook of Industrial Chemistry, 7th Ed. James A. Kent,
ed. N.Y., Van Nostrand Reinhold, 1974, p. 292.
(6) Piggot, K. A. Polyurethanes. In: Encyclopedia of Polymer Science
and Technology, Vol 11. H. F. Mark, ed. N.Y., Wiley, 1969,
p. 506-63.
(7) Wright, P. and A.P.C. Gumming. Solid Polyurethane Elastomers. New
York, Gordon Breach Science Publishers, 1969.
161
-------
POLYAMIDE RESIN PRODUCTION PROCESSES
This operation treats both the reactive and nonreactive polyamides which
are chemically based on fatty acids. Although there is a lack of quantitative
and definitive information, a general and qualitative description is given.
The resins produced in this operation are generally blended with other resin
products. These formulating or blending processes are not included here.
Figure 20 is a process flow sheet indicating the processing sequence
involved in producing these polyamide resins. Two processes are defined
and described in this operation: 54) Dimerization and 55) Condensation.
162
-------
Q dAMOua iMISSION*
Q SOUO IMISSIONS
& UQUIO fMISSIONS
DIMER12ATION
54
TO FORMULATION
OR SALES
FIGURE 20. POLYAMIDE RESIN PRODUCTION
163
-------
POLYAMIDE RESIN PRODUCTION PROCESS NO. 54
Dimerization
1. Function - Very little information is available concerning this process.
Mono-basic acids undergo cycloaddition to form a blend of monomers and poly-
mers containing predominantly dimer. The unreacted monomer must be removed
before the polyamides can be produced.
2. Input Materials - Fatty acids such as linoleic and ricinoleic acids
are input materials to this process.
3. Operating Parameters - Data were not available in the literature con-
sulted for this study.
4. Utilities - Data were not available in the literature consulted for
this study.
5. Waste Streams - Lack of information on this process precludes discussion
of potential emissions.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Technology: An Encyclopedic Treatment, Vol VI. N.Y.,
Harper & Row, 1973, p. 576.
(2) Floyd, Don E. Polyamide Resins. 2nd Ed. N.Y., Reinhold, 1966.
(3) Peerman, D. E. Polyamides from Fatty Acids. In: Encyclopedia of
Polymer Science and Technology, Vol 10. H. F. Mark, ed. N.Y.,
Wiley, 1969, p. 597-615.
(4) Wallace, Peter T. Polyamide Resins. In: Chemical Economics
Handbook. Menlo Park, Ca., Stanford Research Institute, March 1974,
p. 580.1031 A-580.1032E.
164
-------
POLYAMIDE RESIN PRODUCTION PROCESS NO. 55
Condensation
1. Function - The dimer acid product and an amine are charged to an agitated
autoclave reactor. As the temperature is increased the reaction begins, and
water of reaction is formed and distilled off continuously. A vacuum may be
applied to force the reaction to completion. The vacuum is released with
inert gas, and the resin is discharged.
2. Input Materials - The dimer acid charged to the reactor is a blend of
compounds containing 60 to 75 percent dimer, 5 to 20 percent trimer arid
higher homologs, and the remainder unextracted monomer.
The amine feed for nonreactive polyamides is a difunctional amine;
ethylene diamine is generally used. Reactive polyamide resins require poly-
functional amine feeds. Diethylenetriamine is most commonly used; triethylene-
tetramine and tetraethylenepentamine are also used.
3. Operating Parameters - Reaction temperature is 150 to 250°C.
4. Utilities - Data were not available in the sources consulted for this
study.
5. Waste Streams - The water of reaction forms a liquid waste stream. No
accounts of the disposition of this waste were evident in the literature
consulted for this study.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02
7. References -
(1) Chemical Technology? An Encyclopedic Treatment, Vol VI. N.Y.,
Harper & Row, 1973, p. 576.
(2) Floyd, Don E. Polyamide Resins. 2nd Ed, N.Y., Reinhold, 1966.
(3) Peerman, D. E. Polyamides from Fatty Acids. In: Encyclopedia of
Polymer Science and Technology, Vol 10. H. F. Mark, ed. N.Y.,
Wiley, 1969, p. 597-615.
(4) Wallace, Peter T. Polyamide Resins. In; Chemical Economics
Handbook. Menlo Park, Ca., Stanford Research Institute, March
1974, p. 580.1031A-580.1032E.
165
-------
POLY(PHENYLENE SULFIDE) PRODUCTION PROCESSES
Poly(phenylene sulfide) is characterized by a rigid backbone chain of
recurring para-substituted benzene rings and sulfur atoms. Processing
information was available in only one of the sources consulted for this study.
That information, although somewhat sketchy is presented here in two processes:
1). Polymerization and 2). Product Preparation. Figure 21 is a flowsheet indi-
cating the flow of materials in this operation, including waste streams.
166
-------
HYDRATED
SODIUM
SULFIDE
/ N-METHYL\
POLYMERIZATION
TO
DISPOSAL
OR
RECYCLE
/ CRUDE
1 POLYMER
V
PRODUCT PREPARATION
57
D
WASTE \ Iv
WATER I—-i/
TO
DISPOSAL
OR
RECYCLE
TO
STORAGE
OR SALES
LEQ6NO
O QAS6OUS EMISSIONS
Q SOLID EMISSIONS
& LIQUID EMISSIONS
FIGURE 21. POLY(PHENYLENE SULFIDE) PRODUCTION
167
-------
POLY(PHENYLENE SULFIDE) PRODUCTION PROCESS NO. 56
Polymerization
1. Function - Hydrated sodium sulfide and N-methyl-pyrrolidone are charged to
a reactor. The temperature is elevated, and the reactor is flushed with nitrogen
to remove the water of hydration. After the water has been removed, p-dichloro-
benzene is added, and the temperature is increased to the reaction temperature.
When the reaction is complete, the contents of the reactor are dropped into a
tank for washing in Process No. 57.
2. Input Materials - The mole ratio of p-dichlorobenzene to sodium sulfide
should be 0.9-1.3:1. Nitrogen and N-methyl pyrrolidone are also required.
3. Operating Parameters - Dehydration temperature is about 190°C; reaction
temperature is about 250°C.
4. Utilities - No data were available in the source consulted for this study.
5- Waste Streams - The water of hydration forms a liquid waste stream. This
aqueous stream is likely contaminated with sodium sulfide, and N-methyl pyrroli-
done may also be encountered.
6. EPA Source Classification Code - Polyprod General 3-01-018-02.
7. References -
(1) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-b. Washington, D.C., January, 1975.
168
-------
POLY(PHENYLENE SULFIDE) PRODUCTION P_ROCESS NO. 57
Product Preparation
1. Function - The reactor contents are washed with water to remove sodium
chloride and then with acetone to remove unreacted input materials. The polymer
is then dried and packaged.
2. Input Materials - 10,000 kg of wash water are required per 1000 kg of product
resin. Acetone is required in unknown quantities. It is expected that recovery
and recycle methods are used when possible, making requirements lower.
3. Operating Parameters - No data were given in the source consulted for this
study.
4. Utilities - No data were given in the source consulted for this study.
5. WasteStreams - Wash water and acetone containing sodium chloride, sodium
sulfide, and N-methyl pyrrolidone form a liquid waste stream from this process.
Some raw materials may be recovered for recycle. No mention was found regarding
the disposition of this waste.
It is assumed that particulate and gaseous emissions result from drying,
but no information on the dryinq technique was found.
6. EPA Source Classification Code - Polyprod General 3-01-018-02.
7. References -
(1) Environmental Protection Agency, Effluent Guidelines Division.
Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Synthetic Polymers Segment
of the Plastics and Synthetic Materials Manufacturing Point Source
Category. EPA 440/1-75/036-6. Washington, D.C., January, 1975.
169
-------
POLYACETAL PRODUCTION PROCESSES
Acetal resins are produced by addition of aldehyde molecules through the
C=0 group. This definition specifically excludes those polymers produced by
the aldol condensation. Because of their commercial significance, only poly-
mers derived from formaldehyde will be dealt with in this discussion.
Homopolymers and copolymers are produced, differing in the occurence of a
C-C bond in the copolymer. Stabilization of the hemiacetal end groups is a
common practice.
The description of the acetal resins manufacture which follows may appear
superficial. Sources available gave evidence of probable waste streams but
were seriously deficient in definitive data concerning processing. What follows
is an interpretation and analysis of a rather vague description of the produc-
tion of acetal resins.
170
-------
AQUEOUS
FORMAL-
DEHYDE
^SOLUTION/
ORGANIC
SOLVENTS
DESICCANTS
POLYOLS
ALCOHOLS
FEED PREPARATION
58
a
/ANHYDROUS\ / \
' ' ( TRIOXANE )
kin^*~ . *^
CHAIN
TERMINATORS
LIOINQ
O CJASiOUS EMISSIONS
Q SOUO EMISSIONS
A LIQUID SMISSION3
FORMAL-
DEHYDE
DISPERSING
AGENT
SOLVENT
POLYMERIZATION
ADDITIVES
FINAL PRODUCT PREPARATION
60
FIGURE 22. POLYACETAL PRODUCTION
171
-------
POLYACETAL PRODUCTION PROCESSES PROCESS NO. 58
Feed Preparation
1. Function - The formaldehyde feed is provided for the polymerization process
in the form of anhydrous formaldehyde or trioxane.
Anhydrous formaldehyde is furnished by thermal decomposition of a purified
prepolymer or hemi-formal which is thermally decomposed to release formaldehyde.
Paraformaldehyde is formed by evaporation and dessication of an aqueous form-
aldehyde solution, a-polyoxymethylene may be formed by heating paraformaldehyde
or by treatment of an aqueous formaldehyde solution with catalysts and dehydrating
agents. Hemi-formals are synthesized by adding alcohols (commonly cyclohexanol)
to an aqueous formaldehyde solution.
Impurities such as methanol, formic acid, and water may be removed by washing
with non-volatile polyols or by freeze-trapping slightly above the boiling point
of formaldehyde.
Trioxane is prepared by acidification and distillation from an aqueous
formaldehyde solution. The trimer may then be separated from the aqueous dis-
tillate by extraction or crystallization before it is further purified by
fractional distillation.
2. Input Materials - An aqueous formaldehyde solution is the major feedstock
to this process. Preparation of prepolymers and hemiformals for provision of
anhydrous formaldehyde may require dehydrating agents, alcohols, and non-
volatile polyals for washing. Trioxane preparation may utilize solvents such
as methylene chloride, trichloronaphthalene, and trichlorobenzene for extraction.
3. Operating Parameters - Thermal decomposition of the formaldehyde polymers
and the hemi-formals is usually accomplished at 130-165°C. The boiling point
of formaldehyde is -15°C. Trioxane is distilled from a 60-65% aqueous formalde-
hyde solution; trioxane boils at 114.3°C at atmospheric pressure.
4. Utilities - None available in the sources consulted for this study.
5. Waste Streams - Although waste streams were not defined in the sources
consulted for this study, an aqueous waste stream is assumed from distillation
and dehydration of the aqueous formaldehyde solution. Fugitive gaseous emissions
of formaldehyde are also assumed.
6. EPA Source Classification Code - Polyprod. General 3-01-018-02.
7. References -
(1) Barker, S. J., and M. B. Price. Polyacetals. American Elsevier
Publishing Company, Inc. New York, 1971.
172
-------
(2) Environmental Protection Agency, (Office of Air and Water Programs,
Effluent Guidelines Div.). Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthetic
Resins Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Bevington, J. C., and H. May. Aldehyde Polymers. Encyclopedia of
Polymer Science and Technology. Volume 1, H. F. Mark, ed., N.Y.,
Wiley, 1964, p. 609-628.
173
-------
POLYACETAL PRODUCTION PROCESSES PROCESS NO. 59
Polymerization
1. Function - In forming a polymer product from anhydrous formaldehyde the
monomer is added to an agitated inert diluent containing intiators and dis-
persants maintained at a low temperature. Molecular weight control is
accomplished through the addition of chain-termination and transfer agents.
The reaction is stopped by shutting off the flow of monomer. The solid
polymer is separated from the diluent by filtration or centrifugation.
End-stabilization, accomplished by acetylation is done by mixing with
acetic anhydride and refluxing. The product is then washed and dried.
Trioxane may be polymerized by bulk, suspension, or solution methods
(see processes 1-8). Stabilization is accomplished by copolymerization with
cyclic ethers.
2. Input Materials - Anhydrous formaldehyde or trioxane are the monomer ma-
terials used in this process. Solvents for polymerization of anhydrous for-
maldehyde include propane, cyclohexane, and aromatics. Indicated dispersing
agents are etherified polyethylene glycols. Chain termination and transfer
agents include water, methanol, formic acid, acetic anhydride, and ethylacetate.
Acetic anhydride is used in the ratio of 10 volumes per volume of dry polymer.
Indicated solvents for solution polymerization are cyclohexane, benzene,
nitrobenzene, methylene dichloride, and ethylene dichloride. Comonomers used
are oxacyclic compounds such as 1,3-dioxolane, 1,4-dioxolane, ethylene oxide,
and tetrahydrofuran.
3. Operating Parameters - Catalysts for formaldehyde polymerization include
amines, phosphines, arsines, stibines, metal carbonyls, onium compounds, and
metallorganic compounds. Sodium acetate is used as a catalyst for acetylation
with acetic anhydride. Reflux time is 30 minutes.
Catalysts for trioxane polymerization are boron trifuloride etherates,
aryldiazonium fluoroborates, antimony trifluoride, iodine, Friedel-Crafts
catalysts, perchloric acid, and acetyl perchlorate.
4. Utilites - None specified in the sources consulted for this study.
5. Waste Streams - Wastes from mass addition, suspension, and solution
polymerization are discussed in processes 1-8. Fugitive gaseous emissions of
formaldehyde and organic solvents are probable.
6. EPA Source Classification Code - Polyprod General 3-01-018-02.
7. References -
(1) Barker, S. J., and M. B. Price. Polyacetals. American Elsevier
Publishing Company, Inc. New York, 1971.
174
-------
(2) Environmental Protection Agency, (Office of Air and Water Programs.
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthetic
Resins Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Bevington, J. C., and H. May. Aldehyde Polymers. Encyclopedia of
Polymer Science and Technology. Volume 1. H. F. Mark, ed., New York,
Wiley, 1964, p-609-628.
175
-------
POLYACETAL PRODUCTION PROCESSES PROCESS NO. 60
Final Product Preparation
1. Function - Blending of additives with the polymer may be accomplished in
an extruder. Extruded molten strands are then quenched directly in a water
bath before pelletizing and storing.
2. Input Materials - Solid polymer from Process No.59 is blended with antioxidants,
stabilizers, and acid acceptors.
3- Operating Parameters - None available in the sources consulted for this study.
4- Utilities - None available in the sources consulted for this study.
5. Haste Streams - Particulates may be emitted from pelletizing and bagging
procedures. This source also has the potential for creating a solid waste stream
from spills in materials handling. Pneumatic conveyor systems may cause addi-
tional particulate emissions. A purge stream of quench water containing polymer
fines is commonly discarded as waste from water quenching operations.
6. EPA Source Classification Code - Polyprod. General 3-018-01-02.
7. References -
(1) Barker, S. J. , and M. B. Price. Polyacetals. American Elsevier
Publishing Company, Inc. New York, 1971.
(2) Environmental Protection Agency, (Office of Air and Water Programs.
Effluent Guidelines Div.) Development Document for Effluent Limita-
tions Guidelines and New Source Performance Standards for the Synthetic
Resins Segment of the Plastics and Synthetic Materials Manufacturing
Point Source Category. EPA 440/1-74-010-a. Washington, D. C., 1974.
(3) Bevington, J. C., and H. May. Aldehyde Polymers. Encyclopedia of
Polymer Science and Technology. Volume 1. H. F. Mark, ed., New York,
Wiley, 1964, p.609-628.
176
-------
APPENDIX A
RAW MATERIALS
177
-------
Table A-l. RAW MATERIALS LIST
Monomers and Initial Inputs
Styrene
Acrylonitrile
Butadiene
Vinyl chloride
Alkyl acrylates (e.g. methyl acrylate)
Allyl esters of aromatic acids
Vinylidene chloride
Tetrafluoroethylene
Trifluorochloroethylene (Chlorotrifluoro ethylene)
Vinyl acetate
Alkyl methacrylates (e.g., methyl methacrylate)
Chloroprene
Isoprene
a-Methylstyrene
Isobutylene
Methacrylic acid esters
Acrylic acid esters
Divinyl benzene
Ethylene
Acrylic acid
Methacrylic acid
Acryl amide
N-vinyl-2-pyrrolidone
Polymerizable vinyl comonomers
2, 2, 4-Trimethvlpentane
Phenol
Formaldehyde (or solid poraformaldehyde)
Hexamethylene diamine adipate
Alcohols (e.g., methanol, ethanol, butanol, octanol)
Hexamethylenedi ami ne
Hexamethylenetetrami ne
Bases (e.g., calcium hydroxide, sodium hydroxide, lime)
178
-------
Table A-l (Continued). RAW MATERIALS LIST
Monomers and Initial Inputs
Acids (H2S(K, HU1, HAc)
Nitrogen-containing compounds (e.g., urea, melamine, ami no acids)
Bisphenol-A
Phosgene
Pyridine
Epichlorohydrin
Polyphenols
Polyalcohols
Unsaturated dibasic acids (e.g., phthalic acid, maleic acid, fumaric acid-
(usually in form of anhydrides) (e.g., dodecanoic acid, pelargonic acid)
Aromatic dibasic acids (isophthalic acid, adipic acid, azelaic acid)
Dihydric alcohols (e.g. ethylene glycol, diethylene glycol, propylene glycol,
polypropylene glycol, dipropylene glycol, neopentyl glycol)
Vinyl toluene
Polyhydric alcohols (e.g., pentaerythritol, glycerol, dipentaerythritol,
tri methylolethane, sorbi tol)
Polybasic acids (adipic acid, sebacic acid)
Fatty acids (soya oil, safflower oil, castor oil, linseed oil, coconut oil,
cottonseed fatty acids, tall oil fatty acids, linoleic acid, ricinoleic
acid)
Terephthalic acid
Dimethyl terephthalate
Lactams (e.g., caprolactam, 11-aminoundecanoic acid, lauryllactam)
Toluene
Tolylene diamine
Diphenylmethane diamine
Polyester polyols
Polyether polyols
Polyfunctional amines (e.g., diethylene triamine, tetraethylene tetramine,
tetraethylene pentamine)
Propylene oxide adducts of glycerin and 1, 2, 6-hexanetriol
Tolylenedi i socyanate
179
-------
Table A-l (Continued). RAW MATERIALS LIST
Stabilizers and buffering agents
Casein
Glue
Tragacanth gum
Albumin
Starch
Methyl cellulose
Polyvinyl alcohol
Phosphates
Carbonates
Salts of styrene-maleic anhydride copolymers
Vinylacetate-maleic anhydride copolymers and salts
Gelatin
Methanol
Surfactants
Silicone copolymer
180
-------
Table A-l (Continued). RAW MATERIALS LIST
Initiators
Water-soluble peroxidic compounds
hydrogen peroxide
urea peroxide
potassium persulfate
sodium perborate
ammonium peroxysulfate
cumene hydroperoxide
Monomer-soluble catalysts
benzoyl peroxide
diacyl peroxides
lauroyl peroxide
diisopropyl peroxy dicarbonate
t-butyl peroxy pivalate
Air, oxygen
Sodium hydroxide
Calcium hydroxide
181
-------
Table A-l (Continued). RAW MATERIALS LIST
Catalysts
Water-soluble inorganic reducing agents (commonly chelated iron)
Benzoyl peroxide
Lauroyl peroxide
Azobis isobutyronitrile
Hydrogen peroxide
Ammonia
Hexavalent chromium oxide on silica-alumina
Metal alkyl compounds (ethyl and isobutyl aluminum hydride and
chlorides, trialkyl aluminum compounds)
Alkylhalides
Titanium trichloride
Metal salts (litharge, lithium compounds)
Oxides, carbonates, and acetates of zinc, calcium, manganese, magnesium, cobalt,
antimony
Organic tin compounds (stannous octoate)
Tertiary amines
tetramethylguani di ne
N, N, N1, N'-tetramethyl butane diamine
Triethylene diamine
Dimethyl aminoethanol
182
-------
Table A-l (Continued). RAW MATERIALS LIST
Modifiers, or chain-transfer agents
Mercaptans
Halogenated aliphatic hydrocarbons
Hydrocarbons with active hydrogens (cumene)
Ketones
Aldehydes
Alkanes
Olefins
Alcohols
Chlorinated compounds
Hydrogen
Alkyl-zinc compounds
183
-------
Table A-l (Continued). RAW MATERIALS LIST
Solvents
Water
Hydrocarbon solvents
Ethyl benzene
Alcohol (ethanol, butanol)
Benzene
Toluene
Pentane
Cyclohexane
Cellosolve acetate
Methyl ethyl ketone
Cyclohexanone
Ethylene chloride
Chlorobenzene
Ketones
Xylene
184
-------
Table A-l (Continued). RAW MATERIALS LIST
Emulsifiers
Soaps of long-chain alcohols
Potassium dihydroabietate
Potassium caprylate
Potassium caprate
Potassium laurate
Potassium myristate
Potassium palmitate
Potassium stearate
Potassium oleate
Sodium oleate
Sodium rosenate
Salts of aliphatic and aromatic sulfonic acids
Sodium decylsulfonate
Sodium tetradecyl sulfonate
Sodium decyl sulfate
Sodium dodecyl sulfate
Aliphatic amines and their salts (salts of amines, quaternary ammonium salts of
long-chain cylic amines)
Ammonium or ami no soaps
Non-ionic emulsifiers
Polyalcohols
Polyesters
Alky! sulfates
Alkyl sulfonates
185
-------
Table A-l (Continued). RAW MATERIALS LIST
Suspension Agents
(tri) calcium phosphate (hydroxy apatite)
Barium sulfate
Aluminum hydroxide
Bentonite clay
Calcium oxalate
Gelatin
Poly(vinyl pyrrolidone)
Poly(viny1 alcohol)
Carboxymethyl cellulose
Hydroxyethyl cellulose
Polyacrylic acid
Polymethacrylic acid
Acrylic-rnethacrylic acid
Ester copolymers
186
-------
Table A-l (Continued). RAW MATERIALS LIST
Other Additives
Colorants, pigments, toners
Plasticizers (See Synthetic Plasticizers)
Flocculating agents
Carbon (adsorbent)
Release agents, lubricants
Breaking agents
Precipitants (aliphatic hydrocarbons)
Optical Brighteners
Blowing agents (e.g., CFC13)
Oxidizers (e.g., potassium permanganate)
Flame retardants (e.g., liquid organic compounds containing chlorine, bromine,
and/or phosphorus)
Delustrants (e.g., titanium dioxide, uranyl phosphites or phosphates, phenol
compound)
Oxygen scavengers (e.g., sodium dithionate)
Inhibitors, short-stops, chain terminators (e.g. hydroquinone, p-tert-butyl
catechol, phenolic resins, aromatic amines, pyrogallol, chloranil, picric
acid, HAc)
Fillers (e.g., alpha cellulose, wood flour, asbestos)
Curing agents (e.g., amines; polyamides; acids; acid anhydrides; phenolic, urea,
and melamine resins; benzolyl peroxide; methylethyl ketone peroxide; di-t
butyl peroxide, dicumyl peroxide)
187
-------
Table A-2. ANTIOXIDANTS CHART
Recommended for use in:
Trad* BUM or designation
MtyitedptMtraliniiii
knphtnolt
BiditKiMlA
BvtyUtod hydroxy toliMEM
CAO-1.CAO.3
CAO-«4«
CAO4A14
CACK10
CAO-42
DBPC
BHA
BHT
Ch>mann«H
Cb*iuaox21
Clwuaox22
EtfeyltttlolfcUm702
£uyl Anboudant 764
Good-rite 3114
Good-rite 312S
boot
loool-CP
Ioaol-CP40
b|u»l8M
Intuo>-io7e
'IUXK IOH
UoehtB IW-4UI
MHIJK* ai
Ul
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
*
*
a.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
"
*
v>
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
o
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
t
_0
JC
X
X
X
X
X
X
X
X
x
u
u
0
a.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
x
Cellulosics
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Oilier
-
Acala!, ure thane.
rubber, oils, fata,
wax**, greaaen, fuel*
AB3, acetal \ir«th»n«,
rubber, oil*
ABS, aaetaJ, urethan*.
adh**ive«, rubber,
otb
Rubber, oiU
Lubncunto, oils, fuels, rubber
Rubber, mineral oil*,
tnimal ood vege-
tcble fats, wnjiea
Anunal and vegetable
fata, wuea
Rubber, nxin«ra] oil*,
uumal end vege-
table fate, waxe*
Petrol«om, iivn
rubber.oilii. faU,
wax**, «n""^l feeds
Syn rubber, ABS,
auHw«iv««
3yn rubber, ABa,
adh«8iv«ii
Coumarona indcoti,
w»«, rubber, pntro-
l*tun product*
Ajdheotvea, wax,
apiff"*! and
vegetable f ati
EPDM.ABS.poly-
ur»than«, adhesive
Nttnle, epichlorohydnn
EPDM, polyurwthane
Rubber, mineral aila,
aaiouUand vege-
table f«ta, wAxe-i
Rubber, ounerat oil*,
•nif^al and v^ge-
table fata, waxea
Rubber, mineral otla,
-------
Table A-2 (Continued). ANTIOXIDANTS CHART
Recommended lor use in:
Tud* ntmt or designation
AlkyKtrt phenols md
fc»pnnol» (Coofdi
Nvifutlui
N.uitrdBHTUch
N«uj«H BHT food fradi
N.ajudSP
NnuUinAkB
N
For UH« with all
thermoplastic r*«in*
-
General
characteristics
NondiMoloniig, Doutaining
Noodiaoolonog, nonataining
Nondiacolonog, aonstaining
NoDdi*colonn|,
oonstaiiuzig
NooatAining. light unber
Nonataiiung, light amber
Nontoxic
Nontouc
Nondiscolonng , oonstaiDiog
White flake*.
nonduoolonng
Nondiaoolonng, Donataimog
NofwUuzung, no&-
duoolonng, low volatility
NonstainiQg, oondi*-
colonng, amber liquid
NoastainiQg, nondu-
colonng, amber liquid
Noodiacolonag, nonstaining
cryataJline powder
Nondwoolonog, aonsttinmg,
colorleaa, odorlesa
Nonstajiujag
amber liquid
Cr*am colored to whit*
free-flowlag powder
Nonntairung pal* y«lluw liquid
Ofl-*hit* Iree-flowing
powder
NondiiKoionng, notutAining,
oolorjea*)
Nonirtajomg, clear,
light- it* ble, synergistii:
Nontouc
Non*tai0ing ajober liquid
Manufac-
turers/
suppliers'
me
1119
1110
1119
7&B
768
206.636
208. 5M
206.636
34«
206
427
469
469
378
362A
196
1119
62
f}2
M
62
738
206.636
872A
of Mfwftcturtrs/iuppllers of «ntto*
-------
Table A-2 (Continued). ANTIOX10ANTS CHART
Tod* name Of designation
Ttiio ln« di ttiw Hit, Im, and
aalf ilkylitt 4 phtnoli
A.Uo^.,40,
Ethyl antioiiout73«
I/gaao.1038
Sairioaox. Santoftoi R
Phtnal condensation products
TopaooICA
Winf-Mayl.
Amints
CareubSOl
Cantab 1193
IrganoxLO-6*
NaufardJ
Nau»»rf44S
Hound
*—*"*>«
Wlo«-««r MX). 200, 2M, 300
WxtuADP
bun
AackuidaBt HoecJutTM SE 1
Cantab DtTOP, DMTDP. DSTDP
Duvtyl thMxBproploodU
DU&yriaty! thlodipropiooau
DUauryl Uuodipropioaato
diatMryl thiodipropwiutf
DitrkUcyl thludipropionau
Naufand DSTDP
NaygMdDLTDP
PUftanox LTDP, STOP, A
1212
PUMaunTll
Orjjnlc pKoiphiUi and
•MlptlltM
CHIXJI
A4v.«ul> rii on
CAO31.34.3i
IU
a.
X
X
X
X
X
_
X
X
n
a.
X
X
X
X
X
X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
*
X
X
X
X
X
X
X
X
X
X
X
X
X
_
a.
T
X
X
X
X
~ —
X
X
X
X
-
»
—
a.
X
X
-
, —
X
eca
3.
mm
~
'a
a.
x
T
.1
X
x
—
T
X
~Jr-
u
XI X
I
T
T
X
-*
X
-
X
_
T
i- — ,
X
1-
X
X
Tf
X
X
X
X
X
X
X
-
end
~
o
o
u
x
X
-
_.
X
X
X
..
— . — 1
-
X
—
X
an icr am in:
liUier
Rubber /of piftAtics
FDA sanctioned
\and typ«
-
J -
rubber and adhenivea
I
" Miuiiooiera" " "
ABS adji*«3iv«(j
ABS
AJBS, atVtal
Syathetic rubber .
PolyacetaJ. nylon
Poljttcetal, uylon
hPetroleiuti resina
ABS. nynthetic lubncants,
polyacrylat.-.
AB3
L .
Kubbvr
(- - - H
Rubber Inr pla»-
Bl-tow"
ABS. EVA. EHDM
X| AJ3S.EVA,i.PUM
X! ABS-
x
X
1 X
1
•--
-
X
X
\
ABS
ABS
ABS
ABa, EVA
ABS. EVA
ABS. EVA
ABS
AMH
I H V v
-
With limitatioru for
PE. 121 2526
For iw*e with all
thermoplastic remm
-
-
-
-
Rubber article*
Hot-melt adJieuvea
-
-
-
-
[n food packaging
IE food packaging
In food packaging
In food packaging
In food packaging
outeruU*, m edjble
fata and oiU
-
Approved
Approved
In food packaging
nxet«n«U,io*.r.iu,....uh.hiir
Manufac-
turers/
suppliers'
1119
36/A
1%
T\H
206 'ilfi
469
238
238
196
1119
1119
20*.™
«»6
4*1
H72A
378
238
366
90,366
10,90.
206.366
10,90,238.366
1119
1119
52
52
; - ;
of m*nuf«cturtrs/luppl ten of «nt1ox!d«nts w'll IM found fn Tsbl« A-7.
Syothttlc Iutr1c*ntl for jet tn
-------
Table A-2 (Continued). ANTIOXIDANTS CHART
Recommended lor use In:
Trad* MM or detlgnation
U4 iMIpkalit (Cont'd)
Dlbtrlyl phoephiu
DuUcyl phoeprula
Dilauryl pKoephiU
Ihoeytl phoephlU
Dltlfjt phoaptuu
Dtghenyldecyl phoephiu
DiteUadecyl phoephit*
Mark 329
MvkC
Mark 1775
Hark 1178
NiufanlP.PHR
Phvnyldidacrl phoaphiu
PhtnyltMOpntyl phoephita
Phoacler. P,2
PhoaeUreP.3
Phoaclere P.!», P210.PJ10
Ph«cbr.PJ«
Phoad.rePlM
PhtaclanPm
PhoadaraP.lM
Pnoadare P.8W
Phoaclara P 316
PhoadtnP.347
PolyJanM
Polygan) HR
StabiluarTPP
Thermolite 187
Tnbutyl phoaphito
Trldecyl phoaphito
Tnlauryl tntrilophoephiu
Trtortyl phoaphiu
Tnphenyl pKoaphlU
Trtananylphenyt prfiephtu
TneJZ-ehlwwthyl pha»phlUii
Uvl-M.ill'W
WaM«
Wrv» X-MO
r
X
X
X
X
X
X
X
X
X
X
X
X
k.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
£
X
X
X
X
XXX
X
X
X
X
X
u
h.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
e
a
X
X
X
X
X
X
X
X
X
Polyester
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cellulosici
X
X
X
X
X
X
X
X
X
X
-
Other
-
-
-
-
-
ABS
ABS
ABS
EVA, polycarbonate
-
-
ABS, SBR, rubber
Epoiy, polyacrylatM
PolyurethaiM
EVA, polycarbonate.
ABS. SBR. SAN, rubber
ABS
Epoiy, ABS, SBR,
rubber
-
ABS.SAfJ
Epoxy
Synthetic rubber polymer*
-
-
-
-
Epoiy
-
A OH, rubber
ABy. r'PDM, rubber
ABb
.Synthetic rubber end t«teie«
FDA sanctioned
and type
-
-
-
-
-
-
-
121 25W
-
-
1212566
In food packaging
materials
-
-
-
-
-
-
-
Food packaging
mauna.i
Food packaging
mattnaU
-
Food packaging
-
For food
packaging
material*
_
-
-
-
-
-
-
In rood packapng
for food packaging
Fotyolefinj, (or ftxtd
conUctuM 121 2501
(C),l 1.2 1
121 2662
.21 2M2
General
characteristics
Clear, normtairung
Clear, non»Ummg
Clear, nonsuimng
Clear, norm La i rung
Clear, norutlaimng
Clear, noiutaming
Nonstaimng, clear
Non&taimng. dear
Nonxlaining, heat, color
& processing stabilizer
NonaUimng, heal, color &
processing stabilizer
Nona taming, nondmcolonng
clear liquid
-
-
Clear ooiaettairung
Good clarity
'
Light stability
Antucorch
Good clinty, noiintai rung
Clear norouinuig
Clear nonstaimng
Clear aonBtaiDing
-
Nondiacolonng,
oonataiDing,
clear liquid
Nonjj tain ing
Clear, low plate-out
Clear nonxtaining
-
-
Clear norwUimng
Light nubility
*„„„(.,-.,-,,. el,.r. .,„„„....
(Jle«nor.,ta,r,,n,
Noruuming nori'liHr/itoriny
(kef *yr.i-rgiHtif twiLh
iiyiiergletlc
NonMtaming. clrar, itynf rgiatic
Noiutatning, clear, eynergietic
Manufac-
turers/
suppliers'
722.1031
1031
722
1031,1177
722
619,571,1177
1031
91
91
91
91
1119
519,671
519
671
671
671
571
571
671
671
671
671
571
1119
577
674
722
519.571.1177
519.1177
722
10A.21H, '.I**
571,7W. 11!:
571 H7VA
1177
TU
1177
872A
H72A _
of manufacturtrs/SuppHers of jntloxidants will be found in Table A-7
191
-------
Table A-2 (Continued). ANTIOXIDANTS CHART
Recommended for use in:
Trtdt rum« or detignation
Orpnicpliotiinilii
ind ptaiplutii (Cont'd)
WaaMoTNPP
Wnton 399
WyU>i312
WytM345
Miicellintoui
Advuuti T360. TM 1 80
Advuub T3«0. TM 180, TM 181
A£tuxi
a.
X
X
X
X
X
X
X
X
X
c
o
3?
X
«>
"o
a.
X
X
X
X
X
X
X
—
X
Cellulosics
X
—
Other
ABS, rubber
A BS. rubber
-
ABS
ABS
ABS
Rubber for plastua
Polyben2imidazol«,
polyimjde
-
-
-
Monomer HtabiJization
Monomer utabilization
Monomer stabilization, rubber
Monomer stabilization, rubber
-
-
-
EVA
EVA
ABS, IPS, SBR
-
-
ABS
ABS
Monumet atahillur
Ureth.n.. BVA
Ureth*ne
OI«An oopolymm Alltrgrnden
ABS
-
CarhaiyUUxJ SltK/nitnUu
FDA sanctioned
and type
In food packaging
mat*nala
[n Tood packaging
matcnals
In food packaging
maunila
121 2562
-
Rigid* only
-
121 2566 Rubber
Articles, adhe^ivea
-
-
-
-
-
-
-
-
-
-
1212666
-
-
121 2001, 121 2566
1212566
-
ABS
In coouct with
fatty food.. 0 11.
Boafatty, 0 25^,
•zonpt m PS. ABS
In contact with
fatty fooda.O It.
oonfatty. 0 261
aioapt in 1*8. AB3
-
-
-
-
-
In food p«i'katpng
m«tmaln, m
edibia f*tn and oil*
-
General
characteristic*
Nonataimng, clear.
HynergiHtic
NonMLamm«. clear,
Hynergmuc
Noruttaining. clear, tynergistic
Nonataimng, clear, synergi'Uic
-
-
Noadiacolonng, norwtaioang
MettJ de activator
ie g copper)
Yellow powder, imprgv^M
high- temperature propvrti*1^
High temperature and
UVat*bili7«r,
nooatAirung, oondJacolonnK
Heat, litfht, and wtathtr
aUbduer for PVC
\Vhite crystaJliM no lid
White or light gray o-yutaJa
White cryataJa, nonitajaisj.;
Ught tan crystals
Buff powder
Pink to white cryttal*
Nonstaining. excellent heat,
color, and processing stabilizers
Nonataimng metal deacuvator
Nonataimng, dear
White ponder, •ynergiatic
White powder. ayn#rguitjc
Yellow cryHtallinoaulid
Hydro! yaia agent for milUiile
iu«th«n«, h#«t rctiiHt
•Ublhun far curable C V A
Hydro! ym» agent for
poiyeater-bajted cant urethune
NondiAColonng, wh,te powder
-
Nonatammn, clear
Uae in dark utockj
Manufac-
turer*/
suppliers1
1177
1177
H72A
B72A
238
23»
1119
378
tut
103
7«1
J4b
215,346,690
.141), 690
346
346, 690
346
91
91
91
91
91
91
91
1119
206, 536
206. 5.16
ttft
7t'J
719
52
674
366
H72A
of iMnufiCturers/suppi lers of antloxidants will be round in Table A-7
192
-------
Table A-3. ANTISTATIC AGENTS CHART
Trade iwmt and/or nunriMf
AMIMS
Ado«eol60E2
Adogtn 170E2
AlKaUtC-2
AnU-etauc aflent 108-6
Anu-etaUe afaot 273C
Aati-tuuc afant 273E
AnU-etaUc aftnt Hftechat
VPFA14
AnaottatllO
Armoatet410
Aatoa 123 (Thermoaetunf polyamma)
Aatoo 123M (Tharmoeetunf polyamiAa)
C«t«naf 477
D«hydat50
IioNoSut
LuknatatCAZ
LubrolLE
LubrolRO-0
Lubrol P£ * PEX
M«rkjtatAL-10
MirkjUtAS-16
UvkjUtAS-ia
NntnvfiUtDCooc
Nautf«4}Ut (or nifa
Npn-Ruat Native-Slat lAaroaol)
OnyuUCNU
9oUi3CW
ValatatE
VdiutEl-293
VaJaUtn,284
WeraUaaA
Quatonuiy ammonium compounds
Adof.n432
A4oo«4<2
An-ExiAmiol
AHMMMlOOV
Coating
or
internal
additive
Co-t
InL
Int
Int
lot
Int
lit
Int
Coat
Colt
Int
Int
Int
Int
Int
Int
Int
Int.
Int
Int
COM
C
CO
<
X
X
X
X
X
X
X
X
X
X
X
X
Polycarbonates
X
X
X
X
Polyacetates
X
X
X
X
X
X
X
X
X
X
Other
PVDC
Polyeiitcn,
modurylic
Polycitcn,
modicryhc
E V A polybuUne
EVA. polybutcne
EVA. polybuten*
Rugi and all
Uitila fiben
Polye*t«n,
modacrylic
M«l&nunc
Urrth.n.
Use
concen-
tration
per cent
0014 10
001-010
01
01-10
0 06-02
0 1-03
01-20
00&-06
005-05
10-20
10-20
01-15
01-20
10-30
0 01-0.5
0.&-2
05-20
01
01-04
02-10
laoUd)
03-10
(•olid)
10-50
10-20
A* received
10-20
01-10
01-O.B
0 1-06
005-02
01-10
001-010
001-0 10
Spray aa
rcmvod
006-10
FDA
approval
For Elm
For film
ror film
Y«.
Y*«
Yea
-
Yea
-
Yea
-
Yea
Yea
Yea
Yea
Yea
-
-
-
-
-
For film
-
-
-
-
-
Manufac-
turers/
supplier]'
103
103
34
393
39.1
393
378
SX
in
916
916
62
601
677
639
206
636
206.536
91
91
91
1006
1005
1005
918
743
1142
1142
1142
1MH
103
103
64
M
Names of manufacturers/suppliers of antistatic agents will be found in Table A-7.
Reprinted from the October 1974 issue of Modern Plastics Encyclopedia Copyright
1971 by McGraw-Hill., 1221 Avenue of the Americas, New York, N.Y. 10020 All
rights reserved.
193
-------
Table A-3 (Continued). ANTISTATIC AGENTS CHART
Trad* lumt and/or number
Quaternary ammonium compounds
(Coifd)
Anunut 100C
Araoetat900
Armoatat9lO
AnuxUlKO
AmauflTA.100
AflCO U313
AM-1001
Alton MS
BarquatCME
CataaatSM
f^l^paf.m
CMttttSN
CtUoacSP
Citol
LnknatMQAT
UvkatatAL-12
lbrkjUtAL-22
rfaotro-StarAIContt
Nntro-StM {Aeroaol ) Sid.
«at-E»
fcn-Slat BTC
fcaJStatffl
ValvaminaATS
Valvaiiuna 61
Warn A-2M gone •
Anloniea
Animal Ano-Sut DAS
Oafiut AD-810, AE-610. AS410.A
AS-710
LuknMmifUtur*rt/tuM>H«ri of «nt.Ut«t1c
b« found In Tiblt A-7
194
-------
Table A-3 (Continued). ANTISTATIC AGENTS CHART
Trade turn* and/or number
•tOfueUry iCont'd)
Mate MS 10
AldoKMS
An*UcU*2M
AntlatatA
AMlaUttl
AatiatatSl
Aouaut**
AnUaUtfta,
AntietatX-1198
AnUetaue Agent 575
Aotieutie agent Hoachat
TMHSl
Ami italic agent Hoachat
VPFE20
Antiatatic Plaaueuer AT
AnUataue Plaauazcr KA
Antiatadc Spray
ArmujUtH2
ArmoaUtaOO
ArmoeuttlO
Ataeoel&O
Annul 84
Dehydat 10
Dehydat 12
Dehydat 20
Dehydat Z2
DlepalM
Drewj>laat0174050
DnwpUatOZD
Drewplaat 032
Dwwpl*et092*096
Dnwplaatlie
Dnwpieat 123
KUeUoael 321
tlaatnaolD
Ebetraeeillir
Coa'ing
o:
intc-n.-l
additive
Both
Both
Coat
Int
Both
Both
Both
Both
Both
Coat
Int
Coat
Int.
Int
Coat.
Coat
Both
Both
iBt
Int
Int
Int
Int
Coat
Int
Int.
Coat
Int
Int
Both
lot
Coat
Int
Coat
Recommended lor:
" I
cj
CJ
X
X
)c
X
X
X
£ '
CJ
U
X
X
X
X
X
X
u
X
X
X
X
X
X
X
X
X
X
X
-^
X
X
X
X
X
X
X
X
X
X
X
1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
u
c:
"o
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-------
Table A-3 (Continued). ANTISTATIC AGENTS CHART
Trade name and/or number
Prepietaiy (Contd)
ItactfoaolM
tUctraolS-1-X
Iaowut-314
Eaceout-351
CK9VUI-317
Ethoqxne LA-4
Formula AR-AI, Aft-8. & AJl-9
AB-S with Anti-Fof
GjycMptTM 1^20
HallcnCPH-S3-N
H»llcoAjaUaUtC-1014
HaflcoAntutasC-1015
HmUcoAnti.tatC-1023
Halloo Aatutat C-102S, C- 1029
Haliec AnOatat 0-10*7
HuuiKoa
lucplut PU
Irgiaiatol
laoMoldLub. 112
LankTOftat NP8
Unirt»UtO-600
LukraK«tLME
LuknxUtPEOS
UnkroutLOB
UnkrwUtUa
UnlunUtLON
Ui^OiUtUOO
Ua&rMUt&400
LukroM»t ASB90
Unuailu-lSS
UouiM-ies
Lubnunt Horchit VT FE 2
UbmlPXACF
UcrluutAL-1
Mu-luul AS-7
MvluutAL->
j Recommended (or: J
1
Coating
or
internal
additive
LnL
1st
i
Cellulos2 acedia
_ , , 1
Both i
Both
Int.
tot !
Both
Both
X
X
Both
Both
Both
Int.
Both
Both
Both
Int.
Int.
Int
Coat.
lEt
Int.
Int.
Int
Both
Int.
Both
Int
Int.
Int.
Int
Int
Int
Int
X
x
X
X
Cellulose mttiie
i
\
>J
">•
u
<
o
t
CJ
o
>,
0
a.
X
!
c
C3
<
Polycarbonates
X
Polyacetatcs
1
Other
i
i
Use
concen-
tration
per cent
Dependi on
application
Depend* on
application 1
FDA
approval
1
1
Manufac-
turers/
suppliers'
3
35
- 36
j 05-20 ! - 345
i ; 20
i
X
X
X
i
X
X
X
X
Nat & ayn fibers
p! coat paper,
golf bajls, carp«u,
food And drug
containers.
X-ray, mov^
and phou> film
1-3
01-10
Add water
4 1
or supplier
dilute*
30-40
i
X X
X X
X X
X
X
X
10-50
06-50
05-50
X 05-50
X
05-50
X 05-50
X
1
X | X
X
X
X
X
0.1-10
! Urethane 2-5
PVC-awtatt
oopolytoer
X i Aa received
Urethane
Urwhane
j
DepencUon
application
Depends on
application
01-05
05-20
01-20
01-20
Depends on
application
Depend* on
application
05-20
10-20
10-20
05-20
-
20-30
EVA, polybuu>D«
03-10
(aohd)
20-30
-
-
Indirect
Y<*9,
outride
and inside
Indirect
Yen
-
Y«
-
Ye.
Yes
-
-
-
-
Yes
Yes
-
-
-
-
Y«a
Y««
Ye.
-
-
-
OnGRAS
lilt
Y««
345
345
4U
94H
94M
-U>4
4M6
485
4«6
486
485
485
474
165
196
577
639
639
639
639
639
S39
KM
039
\
6J9
639
659
659
378
206. 636
Yes 1 9 1
Yes
-
91
91
of »tnuftcturtr
-------
Table A-3 (Continued). ANTISTATIC AGENTS CHART
Trade name and/or number
Proprietary (Com'd)
M«rkiUtAU13
UwluutAL.14
M«rk.tatAl,!5
M«rk«utAS-20
M«nx Anti-SUUc »79 Gone
M«ru Anti Static #79 OL Cone
M«nilOOG«I WuhConc 1 100
Moru Mold Ku. Cone PCH
M«n»Wlp«Conc
Menx Rina Cone
Michel XO-21
Michel XO-24
Michel XO-108
Michel XO-85
UoldWa.Int.33PA
MoldWuOY
MoMWizDCZ
Myr)45
N«fom«IAl,5
NopoxrUtHS
Nopeo>ut092
Nopcoaut2162P
On Uw Bill
P«|o«p«rM 100-L
Pef«t»r*« 1600-MB
Pefoapenn 400-Mfl
Q-lx»d A-30
7 MM
Sllogrun Anti-eut epray
Spa.
Suuian K 1
T«bnullK12
Tebe«.tlK15
TebeiutOSN
V«l«tatr-L-163
VelvAnumi ATS (amphotanc)
VleUwe<12
Coiling
or
internal
additive
let
COM
Int
Int
lot
Out
Int
Cut
Int
Cut
Coal
Int
Cut
Both
int
Inc
Int
Int
Int
Coat
Int
Int
Int
Both
Roth
Both
Colt
Int
lot
!nt
Cut
COM
Co.1
Coet
Int
Int
Int
Int
Both
Co.i
Cut
Recommended lor:
Cellulose acetate
X
X
X
X
X
X
•J
n
c
•f
o
3
"Z
U
X
X
X
X
X
X
X
X
o
u
<
X
X
X
X
X
X
X
X
c
o
">*
z
X
X
X
X
X
X
Polyethylene
X
X
X
X
X
X
Polypropylene
X
X
X
X
X
X
X
X
Polystyrene
X
X
X
X
X
X
X
PVC
Flexible
X
X
X
X
X
X
X
X
X
X
X3
cit
£
X
X
X
X
X
X
X
X
X
-------
Table A-4. FLAME RETARDANTS CHART
1
as- 2 *'
53 » s s 5 s
ss E i 1 _„. 5s.
v v v = S S ZC. " -i.~
wi/iA3u,ti:r"*'^-'- >>.»..
oonc^Oo^T;-'"^!?;
•='" ^ (3 5 — e u ^ '* ^ -• •* •
vi £•'= = = 3 »• £ ^ -^_^ .r- j? .£•
•BUUKW £OOOOOO
4h.ueiun xxxxxxx xx
AJkyldUrylphoepriala X X X X XXXXX
Crwyldjph.nylpha.ph*!. XXXXXXX XXX
DieUiy|.3-«o«yl-4-hydrory. X XXXXX
benzyl phaaphanate
HMibromobenieM X XXXXX
XX XX X
X XX
tfaubnaiocycIoiJodecajie X X
Ocubnaodlphanyl X X
X X X X
Daabnniuliphin;! tuoia X X X X X
1Vi«(bro>uu XXXX XXXX
TlUyUtirl phonpluu X XXX XXXXX
X XX XXX X XX
tl\.uarnm\thi»i\' X XXX XXXXX
ptafh.1.
Phnyl-unpropyl- X XX XXX X XX
phraylthnphlU
» |
lli'f i
;' 6 2 S « 1 ? Tiad< (urnti
2-21 i c E 1 1 |
!i?i;51sg °" 0"
S aiici1"1*-*';; J? £ i <« *• "^
1 iUtl-iiiii
33Sz-S-Jz2o.o.a^)^*
XXX X F.»mn»-. CUP
X X Antuiol
Pli.brac
Krorut*»
X XXXX XX X S«nUcu«r U«
XXX XX X £»cofl«iCDP
S«nucu«r 140
Ouflmnoll DPK
Phoeflfx 112
PlmbracCUP
KroruwxCDP
XXX XX Busorb.14
Great Lakes BZ-87
Firenuuter HBB
XX
Great Lakes CD-73
Great L«ke«BP 79
FR-300-BA
Great Laluo DE-X3
X XX Great Uk«. TI'-43
XXXX XX X HantlcuerU!
Diaaamoll OPO
TB£
XX XX Flai»out6«aO-Bl
X X Eaoofle«TCP
Lindol. Phoafle. 179A, C 4 EG
X XXX TCP powder
Kroruus TCP
]
Pharfel 4
Kromtex TBP
X E»cofle«TBEP
Phoa8ex T-BEP
KP-140
XX XX FlamithaneM.KiT
Chlwez
Chlorpar«rfinea Hoechst
XXX XXXX CiuiBC-26
DuKamoll TOF
KrorutnTOP
XX X EaeofleiTPP
Ula«airwll TT
Pho-flfi TPP
X X KroniL,. TXP
X K/i>ni<*< 1(X1
X X Pll«hr.<-81a. 821*824
Manu-
facturers/
suppliers'
14S
160
11
171
71»
346
73«
146
1031
31
171
138
477
706
393
477
393
477
1180
330
11X0
.-193
477
477
738
14«
1160
90
348
31
1031
1162
371
31,345.738
1031
371
345
1031
738
371
909
329
378
240
146
31.345
371
.146
73ft
140
10.11
171
11
in
•11
1 Names of manufacturers/suppliers of flame retardants will be found in Table A-7.
*Reprinted from the October 1974 issue of Modern Plastics Encyclopedia. Copyright
1974 by McGraw-Hill., 1221 Avenue of the Americas, New York, N.Y. 10020. All
rights reserved.
193
-------
Table A-4 (Continued). FLAME RETARDANTS CHART
JUrtKii. «!••*• (ConTd)
Hcloflvfutmi or«.uue
polyptMMphonAU
HaJofenatid org *aic
lUlofftiuMd org.uue
Trufouehlorethyh
TnchJoropropyl phosphate
Tni (dicMoropropyl)
phosphite
Moooehjoro propyl
pho*ph*t4
Tnaryl phosphate (.rynUwbc)
PhotphooM* *.rt*rfl
PhoAphonataH chlor «poiy
Phaifphomt70g.ni polymtr
Chlont^polyplv.phat*
Chionn*t*d mixed pho*ph«u
Nitrogvnou* polymer
Nitrogvo-phocphoroui
polymer
Ethylene bu trii
(8-cyutoethyl)
phatphomuni bromide
PhonphoniuiD bromide
Trl* (2,3-dibromapropyh
ptxwphau
BorophoNphkU, urguur
Methyl p*nt«£hlorq>*U*s«U
Ptnul>r>imu(ti!i>r<>
PenUbiomovthylhenzene
PanUbrooxKaul...
Chloniuted patraJBa
5
x
X
X
X
X
S
X
X
X
X
X
X
X
X
X
XXX ]
V
u
X
X
X
X
X
X
X
X
X
X
X
Cellulose acetate bur/rate
X
X
X
X
X
[ XXX
X
X
X
X
X
X
X
X
X
o
D
a
X
X
X
X
X
X
X
X
X
X
X
X
X
S
o
X
X
X
X
X
X
X
X
'^
CJ
X
X
X
X
X
X
X
X
X
X
\
X
Po!)carbonates
X
X
X
•a
a.
X
X
\
X
X
X
X
X
X
X
X
X
X
S.
o
a.
X
X
X
X
X
x
X
X
X
X
X
X
X
X
r"
41
a
a.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
u
1
o
a.
X
X
X
X
X
x
X
x x x j
i.
o
a.
X
X
X
X
X
X
X
X
X
X
X
X
X
Uretnane foam, flenble
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XXX j
•a
Of
n
X
X
X
X
X
X
X
X
X
X
X
X
X
[ XXX
Intulnescent paints
X
X
X
X
X
X
X
X
X
X
Non intumescent paints
X
X
X
X
X
X
X
X
X
lain film
X
[ XXX
I
1
X
X
X
c
(U
a.
o
X.
X
X
X
X
^
X
X
X
x
x
c
D
a.
X
X
X
X
X
X
[ XXX
Potting compounds
X
x
X
_
X
X
X
X
X
X
X
X
X
0
I
X
x
X
X
Textile coatings
X
X
x
x
X
X
X
X
X
X
X
X
a
X
X
X
X
Ti*d« names
Plioagard C-22 ft
Photgard 2XC-20
DtchWane 604 It 604G
Chlon«
Doua.499
TCEP
Fyrol CEF
Great Uke»TP-37C
DuflunollTCA
TCPP
Fire master T33P
Fyrol FR-2
Great Lakes TP-49C
DaltogardF
[Jnflunoll 200 4 400
Kroiutti 100
K:
Caiull 202 EH & 203FK
Suogird 134B
Fyrol 99
Phwflei 200. 300. 400 & 500
EacoCei 2, 3, 4 & 6F
Sungard 131
Sungard 959
CyagardRF-l
Cyagard RF-473
Firemaater TOP & LV-T23P
DBPTP
GnatLaleaTP-69
Fyrol 32B * HB-32
FR 2406
KR 240&HP
FR 2406- HPX
WM/oonyl D
MPS-600
KR-681 A
Great L*keaEB-ttO
Great Lain TL-«2
Chlurowax IiqUJda
Chlorowax «olidji
CPK1-33
^LX1.12
Chlor*z*oli(ii& Paroil liquid*
Manu-
facturers/
suppliers'
738
1141
7S8
619
329
1146
178
1031
477
146
178
706
1031
477
10.31
536
146
171
Jl
346
577
722
217
677
1048
1031
1031
346
1048
1048
52
52
706
1180
477
31
1031
330
330
310
104H
61»
310
477
477
320
320
827
B27
328
of ««iiuf»ctLPtrj/iuppl1«rj of fUmt reurdants will Ix found in Table A-. .
199
-------
Table A-4 (Continued). FLAME RETARDANTS CHART
:
•tmm.**.«*r«
Chlorinated paraffliniOiato'l X
CnMilaiona and
X
Chlonnaud
ModtAadearbamidt
J
)
Brominatad organic ialt
EmuUnabl. bromln^ organ*
Enulatoo at brominatad organic
Chlonnatad organic '.
3
Chlorinatad inhydni, )
Chlorinatad phcaphaU )
Dibutylehlomdata
Dlmtthy) chlorandata
ftromofonn adduct ot tnJS.8,7.7 h««aehloro.N, N
Ml (IhiacarDamoyl )-9-
Borborvn^2*) dicarbu**uud«
IthyUo. vinyl chlorvd*
latai
Arwnitk bramd.
Dtcabncaoblph«fiyl
tbcrahromaalicyUnllidt
AMMm, IMIMW
Aluminum and* m hydrtud
Ammonium bromuk
Ammonium fluobarata
Ammonium •ulfamau
i
£•
u
X
X
X
X
X
X
x
X
X
C X
X
X
c
c
C X
X
X
X
X X
X
Cellulose iccljrr-
Celii.loit aceute butyiat*
X X
X
X X
X X
X X
X X
X X
X
X >
X )
X
Cellulose mtiate
x
C X
C X
1
ll
Q.
x
x
X
X
X
X
X
X
X
X
X
X
n
1
I
M
X
X
x
*;
o
' 0
5
I
x
X
X
X
X
c
X
c
X X
X
i c
X X
x
X X
X X
X *
X J
J
)
J
X
>
}
X
X
x
1
5
X
X
X
X
X X X >
X
L X
[
i X
[
c
X
I
X X
X
X X
J
x
x
X
X
X
X
X
X
X
X
X
X
X
•S
r
1
x
X
X
X
X
X
X
X
X
X
X
X
X
§
=
3
D
5
X
X
X
X
X
X
X
n
Of
5
X
X
X
X
X
X
X
X
X
X
I
x
X
X
X
X
X
X
X
X
X
VI
c
•5
VI
s
o
X
X
X
X
X
X
X
X
X
X
X
It
3
x
X
X
X
X
X
X
X
X
X
X
"I
x
l!
X
X
X
X
X
X
X
X
X
X
X
X
11
-
3
£
X
X
x
X
X
X
X
X
X
z
x
X
X
X
X
1
-
\
«j i
1
t
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
a: v
X X
X X
X X
X X
X
X X
X
X
X
X
X
X
X
x
Temle coalings
1
X
X
X
X
X
X
|X
X
X
X
X
X
X
X
X
X
X
X
< X
X
X
3
X
X
X
X
X
X
X
X
T'Ma rums
Or»elor4.i..S4'> Sr,2*70
f «con«i CLP i»ni>i
D-lvrtf>5t5JSp.-ci«l
Kloro 7065
BC-94 16
_
Diahlo 700X
ParoilUOT 1TO-»4170HV
FLX0009
On.cMor 65L
PrymrRN
CiK-iBN 21
Cltei BN-461
Ot»« BCL-462
Firrnuuur RBr 1 & I1BF-3
FR-100
P26
ECP4515
P-71P9
Kloro 4S15-66
Dochlorane Pliu 515 t 25
Dechlnrane 603
Cloran
Phoogird 2XC-20
DBC
DMC
Pyrotard BAP laqu«ou«l &
Pyrotard 104B (nolveot)
PyrotArd N
46J0.4HOO&, 4M14
Finnuuur 8PX
-
C JO. C JOBF. C .1 1 . C J3 1 . C-J 10
C-333, Hydral 7064 710
CHA 131,211 J31 4J1,
132. 232.J3244J2
-
Manu-
(actureri/
uppliers'
206. 516
141
6O3
320
329
603
1147
345
74
997
320
329
827
758
1048
240
240
240
70H
827
706
1180
603
1180
706
603
619
619
519
1139
738
1146
1146
1147
1147
738
706
393
19J
4.1
478
10. .1.10. 690
4'KI
10.31
of MKuflCturvrt/tupplUrs of flM* r*t
-------
Table A-4 (Continued). FLAME RETARDANTS CHART
w
.HitHfni. [iinniiiliiTrnrm
Antimony oxuU 3
)
J
Antimony oxide
duperaona
J
Barium meteborita 3
Bnro-pho«phata,
Inhibited
Pho^honi^tr^np*^
Zincboritt ' J
Zinc berate dupenioaj
Ammonium tuifamet*
Coopl*t inorganic pbotphat*
Bone add type
Pboaphonitnlu: chloride
Tlncbanucal
Organic-inorganic additive
Ammonium orthopboaphate
Ammonium polyphotphate
Re«ct)v« typei
Bromine containing prepolymer
Bromine and phoaphorua
containing high
molecular weight polyol
Chlorine containing polyol
0,0-dtathyll N,N bu
ami rnwiwtliy t ph wphwau
Dl fpnlyoryeihyUiuii
hydroowthyl pho*phon«u
Difcro.^u.^1
DlbromobuUnadiol
Dlbromopbetiol
THbr-^no,
icetate
Kt'j-.t butytat*
Mi'.t
c s » s
IsS i
c
L
X X
X X
C X X X
C X
(
X X X X
X X X X
X
s «
S « a
SSgl
M — C U
X
X X
X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X
X X
X
O 0 i
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X
X
X
X
X
5
II
X
X
X
X
X
X
X
X
X
X
1
X
X
*j
5
7)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1
I
e
^
X
X
X
X
X
X
X
X
X
X
X
X
X
X
•3
"B
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
\
ntunesce
X
X
X
X
X
X
X
X
X
X
X
Escent pat/ns
X X
X
X
X
X
X )
X
X J
X
IS
X
X
X
c x
C X
< X
< X
U ^
X !
X )
>
X >
X )
X ]
X
X
X
X
S 1
3
1
X
X
c
C X
C X
c
X
C X
K
X
K X
X
X
X
It
F
a
=-
g
X
X
£ '
X
X
X
X
)
X
X
X
X
1
X
V*
c
Textile C04
X
X
X
X
X
X
c
X
X
X
X
X
X
X
X
X
IX
X
X
X
M
•1
a
t
Tf jd« njmei
HtL
KR i Wtut- St*r gr«d<»
Sou- gr«d«. Oocor 23A,
76RA475RA2
ThermogUini FR. S. S-71 1 , S- 790,
S-hO! 1 842
R« O-Spen» A4
Dwchlorane A-O
AuUOI Whit* SUl-
Autiox BliuSUr
Harwich SO- 200 «no>
Ampacrt 11128
Buunll-Ml
ADIOIO! M
G«Jlei RC & HCW
Py^^dB
ZB-112, 326*237
f irebr.i. ZB
-
Amgarti AS
G4IW2BHH1CY-2
SuasudatlA
-
Th.nB08MrdFR.2120
AJIOOU 123« 4 1230
Pho«-Chek A. 31 259 DAP 1
MAP
Fm R«Uniuit A A C
Ph<»-Ch«k P/30
Bromu».9113*91!7
Brominez 160P
Brocunei 161P
Bronunei 163P
Brominei711P
Tharntolm RF-230
ThermolinRf 420 U
Thermolm X-4600
Fyrate
»™1HMP
-
-
Great L»k>» PH-63
DBPH
Great Lake. PH.73
FR-100-BA
Manu-
lacturersy
226
345, 493
490
748
5S3
674
329
619
553
553
242
493
527
868
1 162
997
74
11C2
360
427
1147
629
866,1162
10.31
427
1048
776
674
529
738
738
738
477
477
477
477
477
794
794
794
1031
1031
427
427
477
1180
477
330
of MnuflCturtrt/suppUtri of 'll« reurtants will be found 1n T«M« A-7.
201
-------
Table A-4 (Continued). FLAME RETARDANTS CHART
Mdhtn*. ((».,•<»
i*—*"—*"*
Dttownooeopeotyl glyool
IMnBoOMptaiyl.looh.1
TMnbromo-
b»pK.Dol A
TtdnibromophthiJti: anhydnd*
AJktttid* adductj of TBPA
Ithylen* oild» tdduct or
T»BPA
T**«hiorobuphtfwl A
AJtaudc Bdduct o( TCBA
ftaRylracoud* tdductof TCBA
JHainTniNliiiii iniilniiii
Vtoyi brooud*
CWorendic aad ind anhydndt
PhMphorotu-cootuaucg
TtlmliliiiiiiiliilitJiL anhydride
Ibfraku (hydroiyttwthyl *
phMphooium chJondi
Mflwnyl phctphiu
Hnachloroeyclo ptoudua*
n
X
*
c
X
Cellulose jctlJIe
X
5
a
0
u
X
n
•j
o
3
"v
o
X
Cpoiies
Ethyl cellulose
X
X
X
X
X
X
X
X
X
X
c
0 0
1 a.
X
X
X
vt
u
1,
r
X
X
X
X
X
X
X
X
-
o
o
1.
X
Polystyrene
n
|.
X
X
Polyvmyl cMonae
X
X
Uretr-aie tojm. flexible
X
X
X
X
X
X
X
X
13
r"
f|
X
X
X
X
X
X
X
X
X
X
intumescent paints
X
X
X
X
a
V
t
X
X
X
X
6
Lstei foam
X
ll
41 ^
C
O
u
1
Petting compounds
Of.
X
Shellac
Textile coatings
X
1
X
X
i
Trad* names
irt
3
TBPH
FR-ma
FH 11604 rR 2249
O-.l Lake., BA VI
f-irema«t«r BP4A
TBPA
t iromaatr Pin 4
F,r.»aat«rl
-------
Table A-5. FREE RADICAL INITIATOR CHART
Hall hie at selected temperatures'
CcMMfcW tan
UkrlaetextM.
tart-aajrl, tart-butyl
dl -ten any!
, .> • Ma It-butylparoxy)
dliaoprovyfbeixaaaa
dj'tert.-butyl peroxide, bquid
dl-tert -unyl peroxide, liquid
tart -butyl-2-hydroxy ethel
peroxide, hquid
Dlcumyl peroxide
3JWUBe«)>yl.2,6-bJaltert-
butytperovy) hesajia
2,6-4ln»*thyl-2,o-bia (bert -
butylptroxy) haxyca 3
Hat
2-t-butylazo-2-eyanopTO)aju
2-t-butylazo-a-cyaaobutane
2-t-butylaao-l-cyanacyclo-
hexaa*
OUcyl paroildM
Aoetyl peroxide in dimethyl
phthaJate
BeiuoyJ peroxide - granujju-.
•olid, or paeu fonaa
"C.
-
-
100
126
96
140
ISO
160
190
100
116
130
!20
130
140
120
130
140
100
126
160
176
116
130
146
116
130
146
160
70
86
100
86
90
106
100
no
120
60
70
86
70
86
100
Mr.
-
-
1260
52
100
1
06
017
002
2160
340
64
77
34
- 16
110
42
20
600
23
016
0016
170
28
04
400
8.2
17
03
326
4.6
07
76
4.7
12
67
23
08
1680
80
1 1
149
2 1
04
10-hr.
hall Hie.
•C.
-
-
120
118
126
117
122
113
119
128
79
82
*
98
69
72
Trade names and designations
ApoeetMO
ApaeetSSO
Vul-CupR(96(* nun active dlperoxlde)
Vul Cup 40hK <4(rfr active dlprroiide on clay)
Percudof 14 40I4(X* active dlperoxlde on clay)
Percadol 14 (96* nun active diparoxide)
HfUloK K40*
Peroximoo F40*
(40% active peroxide on calauca carbonate)
Apoaet 997(99%)
Aztec di-t-butyl peroxide (99%)
Cadet di-t-butyl peroxide (99%)
Luadol dl-t-butyl peroxide [99%)
Noroi di-t-butyl peroxide (99*)
Dl-t-butyl peroxide (99%)46-7!9
Di-tert-buty! peroxide (99%)
Di-t-butyl peroxide (99%)
DE-106(99%)
Artec di-t-amyl peroxide
Aztec t-butyl-2-hydroxy ethyl peroxide
Di-CupK (96% tma active peroxide), Di-CupT(90 to 93% active
peroxide), Dl-Cup 40 C(40^ active peroxide on cajcium carbonate)
Di-Cup 40 KE 140% active peroxide oo day)
Luperoi500R(96'*)Qin act) ve peroxide)
Luperox 600 T <90-93<* active peroude)
Luperoo 600-40 C (40% active peroxide on calcium carbonate)
Luperco 500-40 K£ r-tVi erti ve peroxide oa day)
Luperco 101-XJ. (45% on inert 6Uer)
Lupenol 101 (liquid)
Luparco 130- XL (46% on mart nller)
Lupereol 130 (liquid)
Luazo-79
Luazo-82
Luazo-96
Aztec aoetyl peroxide
Luodol acetyl peroxide
Apoeel 636, 650. 666. 570, and 698
Aztec benzoyl peroxide, Aztec wet beruoyl peroxide — 70, Aztec wet
benzoyl pero«icUj-77
Cavlet BPO (fTfcnu)e/, Cadet BPO wet 70 ami 7H, Cadet henw.yl
peroxide 7H wet jxjwder, {'iidoi IV. f I iftn powdt r). Cudoi B^ t 70;
Oadoi MY filnujtlt- t[rm>n\ftt> (. M,lrji p^tm IISl' V). MS)' 66, HIT,
W.S, Cad'n 40f, 'liquid frfiulHinni
Lucidol henroyl |>fr7Qt>, etc
Wet beiuoyl peroxide BZW 70, b«iuuyl per"iia> paetee B7Q 66, PI/.Q V>.
OZQ-4G
BP98. BP 100, BP 78, BP-70
Wanul
turer/
supplier*
«74A
674A
604
6S3.782
782
739
674A
127
693. 71)2
833
771
917
996
1134
669
127
127
604
833
833
H33
»33
833
833
833
833
833
833
833
674A
833
S74A
127
693. 782
H33
771
917
1134
663
AH half life determlnntlonr, were made In bpnzenc at conrentraMon1; of 0 I to 0 2H, unlps-i othrrwlr)e noted
Nawi of wmuficturtrs/supiiHers of orcjanfc p«ro«l(Je! will b* found (n I»bl* A-7
}Av>IUble outside U.S. ind Canada.
Reprinted from the October 1974 issue of Modern Plastics Encyclopedia.
Copyright 1974 by McGraw-Hill., 1221 Avenue of the Americas, New York, N.Y.
10020. All rights reserved.
-------
Table A-5 (Continued). FREE RADICAL INITIATOR CHART
IM UM M Mftcted tompeJJlures'
Comufcial hm
OMcyl peroiidM (Coma)
1,4-dKhtarob.njoyl perozjde
wuhdibulylphthalal*
2.4-djchlocnb.runyl peroxide
«nthMlia>M0.ujd
8«fuoyl peroxide paata with
tnoweyl phoaphaw
Battioyl peroxide paata with
butyl bwuylphthaJaU
Baaaoyl peroxide paita with
inert pUaocuaro
B«nioyl paroude granulaa
mtli tntft plaatxozef
H Bill* ,,,|-
Bamoyi parotid* liquid emulator*
with loan pUeticuan
y iTiiunibanmyl parotide In
dUxityl phthjJiu
p-cfejofobaiuoyl p»rau4e with
•lUaooe fluid
DacaAoyl peronde - granular
nUd
Lauroyl p*nmd« - gruiuJv
•olid
PBUrfonyl ppnujdc - tolid below
WMlO-CI
Proptonyl prroude in hi(h
bailing hydroc«rfaon Ml vent
dl.laloylp.ruid>
HyBtipvBildn
tort -butyl hyrimfwrotid* -
Uquld
t.
JO
70
90
70
«a
70
15
100
70
«s
100
70
89
100
70
86
100
70
89
100
70
W
100
M
M
100
50
70
100
«0
70
81
SO
70
86
SO
88
90
89
70
89
100
130
149
1«0
Mr.
169
13
169
1 4
02
130
21
04
130
21
04
130
21
04
130
21
04
149
2 1
04
130
2 1
0.4
2800
29
09
310
1»
09
130
34
09
130
34
09
490
09
710
07
130
21
04
700 90
'lasj 91.1
.'15 114
32 2»
10-h>.
lull lile,
•c.
94
94
72
72
72
72
72
72
79
79
62
62
172
Trade njmes ind designations
Axtoc (60% pMt«)
Cm-tat TOP
Norm DBF
C»do«TS-W
l.uprrco CST
Norm UUP S »
Apcnrt •>(>•>
Azfc-c HP 1. BP 1C
C«ilo« BTP
Lupvrca ATC
Narox bvnzoyl ptruxide p«irt«
Gu-ox-BZP
BPSOT
ApOMet 550, A[x>«ct 555
Artec BP-2, BP2C
Norox BZP-200. I1ZP 250
Carol QZA, Carox 55A
BPO p«at»« 46-705,4«-70«
BZQ.50. BZQ-55
BP-50. BP.55
Azt«c BP-FR
C«dox BSP-50. Cadox BSP-55
Luperra AFR. Lupereo ANS
B«noxB-50
BPO put* 46-715
BZQ.50. BZQ-40
C«do« BFF-50, Cadox BFF-70
Cadet beruoyl peroxide- 78 wet powder. Ctultft beluoyl p«roxlde-78 r'P
(free flowing wet powder)
Cado»40E
A^toe(90%pa
Cadet tauroyl peroxide
Alperox-F (flake)
Norox lauroyl peroude
UP 389
LYP-9TFl9a«el
Aztec pelargonyl perpxide
Aztec propionyl peroxide
ApowtSOO
Aj»wi'l'.»70i70't-c<.nc 1, Ap*i^-l''*liH|a ri'iiil,- ;<) .MX 'HI
THHP7C1. UM'm«i
TBH-IW.TIIII.HO, THH 70. THH tiO
M^nirlM-
twer/
supplier1
127
693. 7H2
771
ti!»3, 7H2
K.I3
771
U74A
127
byi.7H2
833
771
906
669
674A
127
771
906
917
1134
669
127
693,782
833
771
917
1134
603. 782
693, 782
693.782
127
693,782
1134
127
833
1134
669
674A
127
782
833
771
669
1134
127
127
674A
I>74A
IJ7
li'H ,M/
H t 1
/ /I
1 1 14
(Mil
All ruU II'* djUmtMtlofn <•""• Md* In batuene it concentrations of 0 I to 0 2H, unless othenctur«rt/iufX>lt«rt of organic pcroxtdct vtl) be found In lahle A-7
-------
Table A-5 (Continued). FREE RADICAL INITIATOR CHART
Commercial tan*
N|*eaeie»Met
•..UJ-lrtrttnu-lhyl butyl
hydrot«-roxid>. llquxl 86%
Cumene hydroperoxide
2.5-djirtfthylhi'Xaj»e-2.S-
dihydrupvroxlde, eolid
DlUfipropyUtrriMlw hydroparoxjde
p-menlfiMrw hydroperoxide
UonepelolkM
Acetyl acetone peroxide
Methyl ethyl ketone peroxide*
in dimethyl phthalete
Newketone perojnde
Phlegmeuzed aohltion
Cyelortexanone peroxide*.
crynutjline uottd of pexte
turn in dibucyl phthaJau
bu ' l-hyd/oxycyclohex>l>
peroxide
Dtacetonc alcohol peroxide
Oitunc tat petoudet
Succinic end peroxide-
US* wild
MonopafaiycarboAjtM
oo't-hutyl r*,i*apropyl
monoprroKv carbonate
U*rt -hutyliNTOxy uopropyl
carbonate - 98* liquid
F«oiy diurboiulei
bo.'4 t-butylcyclohexyl)
pt-roiy diatrbonet*
dl leHC-hutyl) peroxy-
diritrUniMU* -
rf\ liquid
Hjlf IHi it selected ttmperilwei'
•c.
130
146
160
130
130
14>
160
-
-
100
119
130
Soefoov
note1
See foot.
note*
100
115
12S
Hi
115
See foot-
note*
70
85
100
85
100
UK
B5
100
115
30
40
50
30
45
60
Hr.
11 0
26
07
1130
670
190
61
-
-
960
31 0
136
960
310
136
200
10
69
16
04
573
87
14
370
58
18
80
14
3
U.14
100
1 4
10-hr.
hill life.
•c.
131
15H
154
-
-
13O1
105
130
r »i
66
99
98
42
45"
45-
Trade names and designations
Lupenol215
Apo»et930
Cumpne hyciroperoxode
Cunvn* hydropcroiioe. 46-727
Luciuol cunu-rw hydroperoxide
Art*c2.ft-4tifTM-thylrM xen* 2 fk-dihydj-operoxlde
Luprroft 2,5-2,5
U8P-«11
Dimopropylh«nieDe
Ketllox UH
p-menthuru' hydropenixide
Apoeet707
Pereedox 40
Lupenol 224
MEK-P40
Norox Azox
Apowt 600. 001 . 602, 630. 720 Ifire-rs.muuit)
Aztec MEKP 60. 60 F. 60 XF, 30 DAP
Cadox M-105. MAP-30. F-85 (6re-re«uitejit)
Lupersol DDM.DeluX. DNF ifire-rvtardant), DSW (fire-reuuTlarit),
DUA-30. Delu
Norox W-60 lfire-reurt«nt), FS-IOO (fire-retartant}, MEKP. MEKP-5,
MEC.Mi.KP-5
MEK 46-700, 46-704, 4R-721, 46-716, tu: . and FR 46-714
Hi Point 180, Quickset, Hi Point PD-1, FR-222 (fire-reaintant), Sprayset
ReOloxKllUS andUK)
Perojumon Kl (other countries)
MEK-60, MEK-FAST. SUPER-MEK. MEK-RED, MEK-30, MEK-15,
MEK-SAKE (Sre-rewidanti
Apoeel707,720
Superox 31 (aolution)
MEK-UR1
Norox Azox
MEK-60
Aztec cyciohexanone peroxjae pane (45%)
Norox HCll-SO
CP-85, CP-50
Apoeet671
Aztec bud hydroxycyclohexyl) peroxide
Norox KP-90
Percedox 48 (nre-realxunt)
Aztec Chemlcala
Luodol succiruc ead peroxide
Luperaol TB1C
PPG Induatnea
Aztec BP1C
Lucidr.l
Percadox 16 (98% powder)
Lupernol 226
t,uprn«)l 225 M fin hydnjcarbont
Tn^ooox .SUP. Tn^onui SBP-C75 (in hydrocarbon)
Manirlac-
tuter/
supplier*
833
674A
504
917
833
127
£13
1134
604
739
504
674A
693,782
833
669
771
674A
127
693. 782
833
771
917
1134
739
6«9
674A
917
669
771
669
127
771
669
674A
127
771
093,782
127
833
833
809
127
M3
693. 782
833
833
782
half !lf*» diUenatnal ton*, wiui1 marie In hprimi*
Maiunt of iwmifar turi*rr./Mi|i|il (ITS nf orgnnlr perm
tUl formulations -irr- mU(uri»«. of several |,
Hllf lift dele-mined In tr I ethyl phoipfwU
1 at fonrr-ntrfltlons of 0 I In 0 ?M, unless olln-rxlsi' nnlprl
Irli". wl I I he fmnil In UMi> A 1
crnxlde «nfl hydrapprovlrlp '.truiturcs having dlflnri'nt li.i I ( MVP
205
-------
Table A-5 (Continued). FREE RADICAL INITIATOR CHART
H*M IH*. * MhcM ttmo.tlturn'
CowMfclal fom
Dtevtyl oeroiydiearbbflata
dkydorwxyl parojrydlcaronaata
dllaopropyl peroxy-
dicarbonata-
dicarbooau-
99* wild
dl (B-propyl) peroxy-
diearbonate
99* liquid
dl (aec-butyl) peroxy-
• 99% liquid
di (2-ethylhexyl) peroxy-
dlcarbonate-
99* liquid
Urt.-butyl pmxyeoMale
art. -butyl penoymaJeic
add
MWtautjrl perocyuobutyrita
ten.'buryl parexypivaleta -
liquid in muaral ipinta
ten-butyl peroxynaooocaAoata -
liquid in mineral rpuita
tart-butyl paroxybenzdata—
liquid
liquid
aentxyiheuJM
'ta^ri^'*''*1^1''"
•c.
40
60
60
46-
60*
30
41
60
40
60
60
40
SO
60
40
SO
60
40-
SO4
40
60
60
86
too
116
130
70
U
100
70
M
100
SO
70
81
40
60
70
100
116
130
70
U
100
100
115
110
90
100
110
120
Ml.
42 t
100
24
70
36
090
886
106
1.6
396
138
033
174
066
580
169
063
149
31
0.83
1086
2.90
089
88.0
125
19
0.33
68]
122
2.8
2»0
3.6
06
20.0
1.6
04
25.3
1.7
0.47
180
31
06*
72
10
016
100
16
027
110
37
1 1
034
10-hr.
halt lilt,
•c.
60
43
46'
46'
36
35
•15*
35
43'
41
44'
102
88
70
66
47
106
M
100
n
Trade niniai and d«i|iutioni
L
-------
Table A-5 (Continued). FREE RADICAL INITIATOR CHART
ComurcUl lom
Pwoiyaalara Cool d
Urt butyl pvro«y(2-«thyl-
heianoato), liquid -97ft
(t-butyl pvroftoata)
t*rt -butyl pero*y-3,3.y
tnmvOiyl hexanoate (t-butyl
peroxyuonanoate)
di-u>rt -butyl diperoxyphthalat*
in dj butyl phthalat*
Muad pvraatan
PoiyfuneUnnal
Mtalyl Kyi M>"U**
Atxttyl ryetotMiyl
aulfonyl parottda
Acetyl awe heptylauHonyl parorada
Tartar? >IKylpa>xaUJl
2,2 bta (tarvbutylpcroxy)
buUUM
1,1 bu (t-butylp«roxy>
cyclohnuM
Ethyl-3, 3-bu (t-butyl-
peroxy) butyrate
1,1 bw ft-butytp«roxy)
3^^-tnm«thylcydoheui)«
n-butyM,4-bU(Urt -butylpMroxy)
valcrate
H*« IH« •) teltctcit t.mpeiilwei'
•c.
70
Sft
100
70
100
120
100
116
130
70
BO
110
-
40
90
30
40
50
95
126
90
100
110
IDE
120
130
85
100
lie
100
Hr.
130
22
04
7000
147
IS
iao
26
04
500
60
065
-
20
04
130
24
06!
290
08
140
40
1 17
180
3 I
098
270
38
071
330
10 -til.
hill till,
•c.
73
103
106
«3
-
38>
31
93
110
92
107
Tr.de nim«i and desi|niti«ii
Aponet44S
Ap««lt 445 P ' 501* in OOP)
Apowt 445 S <50a 10 nunorti cpinta)
AzU*c t-butyl prrorttMU
A*t*-c t liut> 1 p.-rorto*te (&<«• ID OOP)
Lucxfal I butyl ptToctoatA
Luprm.l I'DO (50* in OOP)
LupiTMol CMS (60^- IQ mineral »pmu)
EitfKraK 2H
Enptrox 2MPD (50^ JD DOP)
E«prrux 2HMD (60% In mineral ipinta)
Tngonoi 21
TVigonoi 21 OP-50 16O% in DOP)
Tngonox 2 1C-60 160% in mineral ipinU)
TBO-97
TBO-60
Tn«onox42
Apoaet420
A^tecdi-t-butyl diperoryphthalata
Lupcr>ol KDB
Parcadoi K.SM
Apowt469
Luperoi 22KP (in plaAldzcr)
Trifonoi ACS-M28 (in plajQour)
Luperaol 199P(50%acQv« peroxide la plaEtldzer)
Apowt322
TX-22
USP-400P
USP-333
Luperool 231 (92% nun active peroude)
Luperco 231-X1. (40% acuve peroude on inert filler)
Percadox 29/40 (40% active peroxide on inert filler)
Percadox 29-B-76, 29-C-75
Pareadox 1 7/40 (40% powrder in calcium carbonate)
MjnullC-
hjrfr/
iuppher*
C74A
127
(O3
1134
782
693, 782
693. 782
669
SS9
782
674A
127
833
892,782
674A
83J
782
S33
674A
669
1134
1134
833
833
693,782
693.782
693,782
All h*lf Itfi; (Jetflrmtnatlon^ W<
NaM.fl of Mnufictur*rf /)uppM*
3ttelf Mft tn bm«m.
TP rrwdp In benzene at toncpntrat Ions of 0 1 to 0 ?M , unless otherwise not*'*!
pf of orgjntc peroxides will few found In \ab\* A-/
207
-------
Table A-6. COLORANTS CHART
1
S
| VwliU, hUreoiu. Rtds
Centric lumtt
(tUINACHfDONEr^
QU1N \ritIDONR vt»l*i m«roan
CfUlNACRUXWK KCU y*llv* *h«d*
PARA HCDnMdiuniUxiMprMl
CHLORINATED PARA tlfhi rvt
BON (2B-BagkltklifhtrW
BON (2B^T* Skit) medium rwi
LITHOL nUBINE bluuh rad
BON KfBINE C«-biui*h rad
N* C« UTHOL6 light n^.mvMfi
B« LITHOL awdium ml
PIGMENT SCARLET bluuh nrf
MAUOER LAKE «liuniM rod
ALIZARINE MAROON m*rooo
HEUO BORDEAUX xitfooo
TH 10 INDIGO
THIOINDICO
THIOlMll(XXrf>lI>U>pp.raurMjn
TOI.UIUfNR mvx»n - light r*d
PTMATONEM
UrOJLAZINE^Ut
DfOXAZINE vutM
DIOKAXINE VK.IM
METHYL vtolM
RED LAKE C light ~fA
HOMOLOG-RED 1 .ARE C ycllowuli rW
HCOUAKEH light r*d
PVKAZOLONE nwdiumrad
l'YRAZOLONKHM)x^llnw-h«l,
DIANIKIDINI. n^diuir r*d
NAI'HTHOl.dkrk light f«l
NAPTHO1, HKI). mvdiuM r«J
N AHTHOt Hfll. mMlium rw)
N APTMOL RKO, Muiirti rarf
33
< F Colour Index —
If 2nd Edition
* - names and
numbers'
'ig VM> IB 1MOO
PigR*d t liO'Q
Pig R*J 48, 1 58«5
Pi«R«iS2 15*60
PigR*d4S 15630
PigIUd60 16105
Pig Rod H3 53000
Pi| Vio 5. 560AS
Pi* MM. 14830
Pig R*d 88, 73312
PiCVttJH73M5
I'tg Kod'J mitO
Pig Red 11, 12J»1
Pig Vio 2,40176
Pif Vio 23,61119
Pig Vio IB
Pif Vio 34
P»|Vw> 3,32536
Pi| Rod S3 1S6W5
Pi|K*d£l 1SHOO
Pig Hod 3M,^ 11 20
P.«IW37^UD5
Pij< Hod 41 21 .MX)
Pm Hj-d 17 1JTK1
Pig Rod 170
l'i| fed 210
Pig KM) 7 1 «2U
Pi< K*d 160
Thermoplastic »*
CD
«*
F
C
11
'
E
F
P
P
*
E
t-
>
k
F
F
P
y
P
P
F
p
'
f-
p
P
p
p
o
V
p
!'
p
E
P
-e
F
f
E
>
o
u
H
h
I1
h
E
e
1
^
t
h
ofinaled polyether **
-=
c
>s
f
P
P
P
*•
^elhylene — low density
o
>
^
••
e
1
'•
M "
p
p
E
t
F
h
^ethylene — high densify
o
>
F
I'
E
E
F
P
K
o
o.
o
I-
*
P
E
E
P
F
P
*•
C
0
o
"
1'
V
11
p
p
p
J
•'
11
1'
V
P
*
o
0.
OJ
I
OJ
o
,
f
"
'
E
T
E
=
iq
ra
•ex
E
o
-
*
>
1-
K
e
»
|
^
h
E
L
1-
t
11
•o
5«
b
>
t.
'•
F
F
V
E
f
Thennosets1
S
0
b
F
h
f
>
|
f
»
lyl phthalale
>
'
1
f
^
'
h
nol formaldehyde
j=
•
>
*
»
•
"
p
•c
0
o
>
^
h
'•
'
*
f
!<
f
f
*
F
I-
K
»
f
F
f
olyurethane (elastomers and foams)
F
*
h
"
1
1
F
f
f
h
h
f
>
^ 1
^
h
f
*
K
F
t.
K
(C
should irte thu Colour !nd*»x dps Inflations whenever po^-i»hlc wlipn { or rp'.pnmhmj wMh Mippl (c
Vrocr
K«y E ' Colorant f^wlly U widely used to color r*",in mdt( ,itrd I Colorant hfl-, I imlfH u*.
Uied, p*»rform*nf« ^houl(l h*1 ch»**V^d In ^pccltlr, applUAt inn f - Tolor^nt family not ri'toinrx-M
»p of varl a t ions in fldiounf ^nd t /[IP tif mipur 11 i*-s ( out a itu>d
re-, in i ndif .1 tfl Before it
tor ir.e in rc'.io indnatp*i
for acfUls, rolorants Must b^ tested before u',tnq
froa Ont colorant supplier tit another.
Chlertiutxt poly»tri»r H not usiull/ colored
Reprinted from the October 1974 issue of Modern Plastics Encyclopedia. Copyright
1974 by McGraw-Hill., 1221 Avenue of the Americas, New York, N.Y. 10020. All
rights reserved.
206
-------
Table A-6 (Continued). COLORANTS CHART
[ Orf*nk PifnMts 1
| Violet i, Maroons. Reds (Coni'd)
>•
o
NAPTHOL K»:iJ.tvw«.«Uj*rUMi.
NAPTHOL RH». y»llM* .h-J. r*d u Mh
NAPTHOI. KE». Mo* .h*d» r*d b- tail
ANTHHA9.U1NONE nt
IHOINIX>UNONKr*d
H1ACRED 2 A1UM1N11K LAtCEroodfwtS
FDACRED 3 ALUMINUM LAKE
FD*C HEL) 4fi ALUMINUM LAKF
FD4C VIOLET 1 ALUMINUM LAK£
food vtolM 2
PERYLENE
PERYUENE
PERYLENE
PERYLEVE RED, medium r*d
MONO-AZO RED, blue •hwta red
MONO-AZO RED, blu« tnd yellow
MONO-AZO RED, Mm *nd y.llo*
VATRED.modiuraml
VAT PINK
ANTHKAQUINONK r-W ANltilDIDB
lifht y*llo*
(JIARYUDE YELtOW AAMV TYCt,
light ts«n*p*r*m
D1ARYUDE YELLOW ORTHOTOLUIUIDE
DIARYLIDE YELLOW, HR. mcdjuJn r*tU>w
HANfiA YELLOW
lOGfrnnu-o— It medium yellow
D1ARYUDE ORANGE
DIARYUDEORANCE
yx
MONOAZOOKANUK
OIANMIDINE *•*«(•
HK ANTIIANTIfHONK want*
nNAVTHUNR.™..
T
r Colour Indei—
^ 2nd tdition
namct ind
1 number «'
H,,K^», IVla
Pin H«I tnt
P.IIM1M
1618S
4&430
Nntawucned
42MO
PigRwd 123
PijFUd 179 7H30
Pig FUd 149
Pi|R*d 176
Pi»fUdlS5
f*ig Or W 77H78
Pif VM 32
P\|FUd 176
Pi|fUd 194 7 HOD
P..IMIH17UM,
Pi( Y.ll U 21)00
P1CY«II17 21105
P,RV*MI421W
Pil Yell B3
PlgYrllJ 11710
1 116HO
Pt| Or 14
PigfUd 139 144
1 4*5 1M
Pig Or M
Pig YrlliH n't IOO
Pi| >M 1*7
p
E
E
F
F
E
P
P
F
;
F
J1
F
p
K
E
E
E
''
P
P
P
F
£
F,
I-
F
F.
P
E
P
P
P
E
E
t
F
P
-
F
F
F
>
w
F
*
F
>
F
E
P
P
p
E
E
F
t
F
F
F
ed polyethei1-
•R
0
j=
L
o
ene—low density
^*
fc 0
..
f
p
F
P
*
P
P
P
'
F
r
F
1
t
*
f
P
E
E
E
'
F
F
P
F.
>
F
F
F
ene— high density
^
o
h
^
F
F
F.
F
P
F
F
F,
E
F
F
F
P
t
F
h
'
"
ji
»
F
*
F
F
F
P
F
F
F,
F
F
F
F
P
F.
F
t
F
'
r
~o
>
>
>
i'
F
F
h
P
P
''
>-
O
h
I'
"
p
p
p
ne- general purpose
o
F
F
>
h
E
P
F
F
F
F:
'
F
F
F
f
*
*
re— impact resistant
5"
^
t
F
P
F.
K
T
*
1
p
e
L
F
^>
^
F
F
F
F
V
L
E
E
*
P
H
^
t.
f
F
L
f>
F
F
F
>
*
*
F
I
F
t
K
t
E
F
^
E
E
E
E
L
f
P
I-
E
F
E
P
f
I
F
*
>
K
i
Thermo ids'
1
t
|._
F
F
h
F
F
t.
^
-
rmaldehyde
•o
o
molding compounds
1 £ s
^
t i h
"""I
*
f
i
1
F
^_
i
f
E 1
E
E
1 F
r
r
F
F
F
'
1
r
F
'
F : r
F
F
P
1,
'
T
v
F
fc
F
F
F
f
F
~
_
,
t
—
f ^
F
I
11
t
1
f
f
*
'
f
f
F
F
*
olyureihane (elastomers and loams)
~p~j
f
h-
1
E
'
'
'
F
r
*
F
F
F,
T~
E
1
i- i f i >
F F
E
F
F
y
V
»
F
F
E
E
E
E
t F
|
1 1
L
Prmrmnrs should U^<* th^ Colour Influx df^tqnatiorts whfncv*1
K«y: C • Colorant family tt widely nsfd to color re*,In fndf
for acttalt, colorants Mist b* tested before uttnq dcrau
fro* on* colorant supplier to «noUwr
Chlorinated polytthcr 1s not usually colored.
when (orror>|M>ndtn'
atp») f Colorant hd-,
P * Colorant family not
1th ' tippl icr',
id-'d
of vflrUtfons in amount ami type of tr.iput I r ics (utit^iiMd
209
-------
Table A-6 (Continued). COLORANTS CHART
6
s
IB
-
O
i
<5
Bli»-Gr»ft
I
i
Generic nwnts
PYRANTHONE ar*flt*
GR PERINONE <*•««*
SOINUOL1NONE yvllow
SOINDOLINONE ywllffw
FLAVANTHHONE yellow
ANTHRAPYRIM1DINE yellow
ANTHRAPYRlMIDlNEy.llow mHiurti v*llo»
FD4C YELLOW - 8 ALUMINUM LAKE
odd V*UQ-W *
FOAC YELLOW '« ALUMINUM LAKE
AZOIC YELLOW light r«)icm
AZOIC YKI.U>W medium y*l|'*»
PLAVANTHHONK ?*tl«w
MONOAZO YKI.LOW light y.llw
NICKKUAZO YELLOW gr«.n.«h v.llow
FDACBLUE 1 ALUMINUM LAKE
foodMu«2
fOACBLl/E 2 ALUMINUM LAKE
(MO bin* 1
PHTHALOCYANTNE grwn
PHTHALOCYAND-fE gran
PTA PMA TONERS blue, frara
PIGMENT GREEN B dark given
INDANTHRONK
1NDANTHRONE
AZOIC HHOWN
•OffK HIJWK
AZO yvlt'tn' «•! fr»*n MIM, W69HOO
hi Br 2&
ri|filk7T7UM
S.,1 Hlu.' it
SolOr,) 1 ll'JJO
Hoi Yvi 14 120')-,
Sol Hnl 27 Ml 26
S.4H«) i VWIO
KolBUl.JHIM,
So
f
t
r
F
*
E
E
E
E
P
f.
a
p
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h
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K
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E
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fc
K
f.
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K
K
t
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F
F
F
F
F
F
F
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f.
u
o
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u
h
F
E
F
F
t
Y
F,
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f-
fc
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I
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u |
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r
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t
f.
f
k.
h
K
E
^
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£
E
V
f
T Polyethylene— high density
E
*
_
F
E
E
'•
L
F.
K
f
f
F
I-
K
E
F
F
E
£
f
fc
- Polyprcpy'tne
L
f
h
E
F
L
E
f
t
t
F
b
h
E
F
F
E
E
1 *
r
i*
LJ
0
a.
>'
f
Y
Y
J-
t
1
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*
9
r
r
F
P
P
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o
3
£
r
0
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F
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t
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f-
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i
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Phenol tormsldehyde
F
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5
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t
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h
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t
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- -1
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t
f
F
E
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K
>
1
Processors should «se the Colour Index designations whenevpr possible whpn rorresponding with suppliers about sppcifir colorant^
2Key: £ * Colorant family is widely used to color resin indicated r - Colorant has limited U-.P in resin indicated Rpforp it ts
used, performance should be checked in sppfific application. P = Colorant family not rpromnipndrrt for IISP in resin indicated
For acetals, colorants must be tested before usinq because of variations in
-------
Table A-6 (Continued). COLORANTS CHART
5
<
i
j
tagrpncpifMms
'
i
i
i
»
i
•»
i
<
1
1
1
1
5
i
6
Gttwric names
ANTMKAgUlNONE
yrltow rW, grmn, 6Ju« brown
ACRTATE wtfte mlor rang*
A< lU.CHKOMfc AND DIRECT
•rid* orJ«r ring*
BASIC DYKS wvl* color r«np.
MGKOSINtt AND (NUUL1NES
wid* color r»ng«
ANILINE BLACK
•pint noiubl*
TITANIUM OIOXU)E
ZIKCiULFIDE
LfTHOPONE
ZINC oxioe
CAOMlL-M SULFOSELENIDE
nuruwi red OTATif*
CADMIUM MERCURY ouraon, r*d, or*of«
IRON OXIDE mwoon. n-1. light red
ULTRAMARriVE REP
CHROME TIN P.nk
ULT«AM*«I«P,«<
L'lTHAMAKINK VIOLKT
MAWANrHKvu.lH
CAI'MIUH MUI Hit*. y.Hy*
CHKOMK „.„„,.,„.
( HHOMI-' y. llu- ihwi.tr »i.[«nEi
"'"•»»»ATt »-.,,.
MOLVftUA rfc or«ng* « V.IIJ4, 77600
Pin Or^i 776u|
77606
Pil YellJb 779S1
P,^.I.U777W(
Thermoptjstlct*
GO
p
P
E
E
E
E
fc
E
I
fc
>
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p
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P
L
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r.
f
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i
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P
P
f
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e
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P
P
P
r
F
t
P
fc
^
ellufosfcs
K
>
p
j-
t
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K
E
E
F
fc
K
>
K
''
k
P
K
t
i
Q.
•o
O
E
£
r
t1
r
f
F
f
E
E
E
t
fc
'
'
P
>
i-
*
h
olyethylene — low density
-
p
f
p
p
\>
fc
E
t
*
fc
h
K
'
>
f
k
E
olyethylene— high density
"
P
f
P
P
''
E
E
K
fe
K
'
K
'
R
1-
fc
t-
a.
"a
"
I'
11
''
''
"
t
E
I
fc
*•
*
fc
f
fc
>
fc
E
c
ro
U
"o
>
t
''
P
*
E
P
E
1
fc
F
*
*
h
P
11
!•
VI
o
p
r
p
p
E
fc
>
'-
k
^
F
P
>
olysryrene— general purpose
i-
>
11
p
'
p
E
r
F
'
f
t
*
F
>
f
i
h
olystyrene- impact resistant
i-
'•
r
11
'•
p
1
E
t
fc
K
1
—
t
1
*•
f
F
'
I
C
'
*•
p
1*
f
1
E
t
^
>
f
_
r
fc
t.
V
^
*'
1
13
C
'
^
h
Ttwmosets* *.
o
E
•
l-
r
^ i h
|
fc
E
fc
*
f
'
K
t
*
fc
f
fc
fc
L
*"
E
fc
fc
fc
E
K
fc
f-
h
1
ol loimaldehyde
ester or afhyd
one nioldirg compounds
2 , S ,-5 = , g.
h r ' v
c
p
i
'' i f-
p r
p p p i f i p
P t , > P j P
r » ^ 1
'
f-
r fc
E
E
^
t ^
fc
fc
*
'
h
1-
f
K
,,jt
^-_—
*
'
fc
l
E
f
!•
—
i
':
(.
1
-(_-
^
t t
f
h
t-
v
f
^
L
h
!__
*
f
E
E
t
1
>
'
!
-
»•
__
K
f
f
L_
urethane (elastomers and loams)
o
>
f
1
f
E
F
fc
—
>
'
^
'
Processors should use the Colour Ind^x
oni whenever possible when coi-rpspondinq with suppliers about sr>ecifir rolnr^nt
Key: E r Colorant family K widely i/sfrf to color resin indlc^tert T
Used, p*rfonn*nr«» should b«* rhptted In sprclflr appHrat'on, P ' Colo
For 4crtAM, coforanM ffw/st h^ testfd hfforj? mfrnj bocAm/1 of v^
from on* colorant tuppltvr to another.
ChtoMnaUd poly*th«r tt not utually colortd
Colorflnt hai limited U'.P *n rp'.ln irirl u fltrd
rant family not ret otuiipnifc'd for U^P in rpsin
ons in amount ^nrJ type nf tmpurjtlps * ori
211
-------
Table A-6 (Continued). COLORANTS CHART
[ iMXiaucpisiMnt* tcwr«
i
'
|
1
Generic name*
IKON OXIDE buff, brown
umbm
TITANIUM PIGMENTS brown
COBALT ALUM IN ATE blu*
CHROME COBALT-ALUMINA turquotue
IRON BLUE bluf
MANGANESE Wu«
TITANIUM PIGMENTS blu*
ULTRAMARINE BLUE blo«
ULTRAMARINE GREEN gr»«n
CHROME GKEKN gr*"
CHROMIUM GXIDfc dull Kr«*n
HYDRAfED CHROME OXIDE jnwn
TITANIUM PIGMENTS light gr*«n
TITANIUM PIGMENTS from
CERAMIC BLACK
IRON OXIDE
METALLIC OXIDE BROWNS
i Kifh heftl itabU)
METALLIC OXIDE BROWNS-FDA
ALUM 1NVM PLASTIC GRADES ulv*r
BRONZE PLASTIC GRADES
ml gold Ibyrllow gold
COPPEH PLASTIC GRADES c0PP*r> r»d
BIHMl/TH COATKU MICA prarly lu«*r
HIKMUTH f-OATI [> TALC p> «Hv luair-
LEAD CAR WON ATfc. 1 bnllii.nl ,*•/)
LEAD CARBONATE U u^iu. t>*»/l
TITANIUM l>H)Xmt'/Mi( A COMPOKirK
PI UOHX>i< KNT
,dy,* „,«.„.. ^-.p.mcl,.. |u|.«.h* „„.,
.punrfv, ^.^Ic-.Wr,.,,,,,,
OITIt AI.HKKiHTKNt-HM U.-u-lui KCH
PHOHPHOM».»CENT«(inc itiifctai
x s> Colour Indei —
« o- 2nd Edition
2 ^ names and
•I :? numbers'
Pi K*d 102
77 tfl
P Br 1 77491 &
77 9-J
P.BBIu-27
77510 & 77520
P (BI33 T7112
Pl( Blue 29
77007
Pig Or U
PifGr]7 7728U
P,iGfll*772»9
Thermoplastics'
i
F,
K
E
t
E
E
h
h
>
F
F
"E
o
I-
E
f
E
I.
¥
F
E
F
E
>
^
*
F
| - Acrylics
E
>
E
F
F
F
E
F
E
F
F
V
p
y
F
E
j r. Ceilulosics
F
P
K
E
P
E
F
E
*
f-
F
V
p
P
P
| CHonnaled polyether*
E
ft
5
z*
p
E
F
t
t
P
'
E
F
E
>
P
t'
P
*
P
I
*
o
J,
0
CL
S-
K
F-
L
t
f
E
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t
t
K
'
*
V
>
a
1
c
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t
F
F
t
>
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E
f
K
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>
K
Q
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a.
l-
F
P
••
*
t.
p
F
F
>
>
(•
^
t
t-
^
K
-^ Polyc^rbonale
F
p
L
f
1-
\
V
E
F
>
^
f>
'*
*'
P
f
>
£-_
O
a
l>
E
"
f-
F,
'
*
P
E
P
t-
>
p
1
'•
r
>
0
F
F
f
1
>-
'
L
K
f
E
E
K
E
*
V
t-
h
E
I"
I
c
f
"o
>
>
F
*
t
f-
'
'
t
E
E
t
F
K
1-
t
Y
P
K
1C
|
>
F
t
F
L
V
t-
K
1
*
E
L
^
I-
Y
t-
T
^
t
*
LI*
k
F
K
F
^
'•
p
>
F
E
E
E
t
E
*.
V
*
Y
I
F
Tnermosets*
o
F
F
f
^
V
h
p
F
t-
E
*
F
1-
P
v
V
"a.
:
«j
-C
(U
'rt 1
E
a
"o
1
|
•D
O
'
V
•a
ra.
E
a
CM
O
E
4J
0
E
r
V , V ' V
F
"
*
'
)>
:-
t
1
F f>
f
E
F
f
1-
^
Y
»•
V
f
h
H
'-
O
1
F
F
t
Y • >
i
t.
i__
> 1 i
t | F j t
1
E
1
E
E
E
*
t
>
F
f
'
1-
P
£
_1.
'
fc
t
t.
L
E|E
t
E
F
F
P
L
E
E
F
F
L
F
t-
F
F
*
*
>
I
F
£
ra
5
"o
f
t
K
F
F
1
f
Y.
Y.
t
E
E
C
F
F
F
F
F
1
>
1
i-
Processor* should usp the Colour lnd*»x designations whenever possible when corresponding with suppliers about specific colorants
Key: E * Colorant fanii ly is widely used to color re sin indica ted. f ' Colorant: has limi tpd u'-e in res i n i nrtir n tf r! Before it ir.
used, perforiswnce should be checked in specifie spplirfltton. P - Colorant family nof remiwipiulpd for use in rpsm tndiratpd
For acetals. colorants must be rested before using because of variations in amount and type of impurities contained in roloranls
f^>n one colorant suppllei to another.
ChlorfMtod pol)*tn*r i* not usually colored.
212
-------
Table A-7. MANUFACTURERS/SUPPLIERS OF MATERIALS LISTED IN CHARTS
II
1IA
12
13
14
16
16
17
18
20
21
22
23
74
25
26
26A
26B
27
28
29
30
31
32
33
34
35
36
'17
37A
38
3»
AAA Piaxt.o* (Equipment Co
AK Armi-n fnc
W Armstrong CWk l_n
97 Armt-tronK Pr'x.ucXM Co , Inc
<>H Aro Corp
AKCO/Putynvn Inc 90 Arrow Induxlne., Inc
1H7
1HH
1M«
1H9A
IW
iai
I9'J
i^t
145
ASC Induhtnci Inc 101 Arv.-yG,r|i I arntou* Div ]47
ASKA i
Aarlite Inc •
Abbott Machinery Div US Packajrtnu Corp 1
Acctorht»mic.i! r<, Inr 1
Acme Pla-tUCi M*. him rv ( nrp 1
Acmt Re*in Co 1 nit '-f ('PC Inurniiuonal
Adam* & Atxooaft Inc >
01A Anahi Chi mir.il Indu^trifH Co
OIB Astthi I)nw Lul
0!C A-ahi M.-( o Ltd
02 As.«*ht Yuki.i^i Kn^-j (\, , 1 ul
03 AshUnd Chtmicjf Ci Uiv
Rjofimn^ f'o
04 As.sociaudUnd Mf« Ltd
Ltd
VshUnd Oil &.
Adann Bros PU-lic 105 Aeronautic !ndu-.tnev Inc
Aden. Work* 107 Atlantic l.ammnLfs, On Oak Industrie-), Inc
Advanced Machine Planning, Inc 1
08 Atlantic Powd.-rcd Metals Inc
Air Products 4 ChemicaU Inc 109 Atla-s Coatings Corp
Air-Vac Inc HO Atltu Hvdrauiic Div Hu stone- Walker Davib
Akron Extruders ^ub Bo.tnn-EmeMon. Inc 111 Atlas Machine & Tool Corp
Akio Chemie bv 1
Akio Chemie GmbH 'Inientabi 1
Akza Chemi* U K Ltd . Inwrstab Div 1
Akzo Plastic* nv
Alambres Dommicanon C por A
A.-BeIndusine-«.fnc I
Albu Corp I
Albright & Wilson, Ltd , Industrial Chemicals 1
Div
Alcan Metal Powders Div Alcan Aluminum
12 Atlas Minerals & Ch^-micaK Ih
13 Atlas Vac Machine IM Plom-t
14 Autojector, Inc
15 Automatic Packaging M^chiner
16 \utomatic Timing & Controls,
17 Automation De\icr* Inc
18 Automation Product^, Inc
19 Auto-Place, Inc
20 Autotron, Inc
21 Auto- Vac Co
ESH. [nc
1'roduLt, Corp
vCo
nc
Corn 122 A\ecor, Inc
Alchem Plastic*, Inc 123 Aviaplastique, S A iRAPl
Alcolac, Inc 1
At f ram me Corp
Aillince Mold Co \1\ild, n« Equipment Oiv
Alllod Chomical Corp Plu-tiri Div
Alltwl Ch«mit*.l Corp , Spwci-lty Chemical*
Div
Allied Color Indu.rn.- Inc
Allwood Hydraulu frets Co
24 Avnet Machinery f)iv Avnct, I
25 Avnet Shaw Div Avmilnc
'2fi A Inc
.in** inc
40 Alnof Instrument Co 132 BP ChemicaU Internarionwl CK Plasrics Dept
42
43
44
45
40 A.
46
47
48
50
51.
52
53
M
55
56
S7.
58
58
60
61.
61A
62
63
64.
65.
67.
M
69
70
73
74
715
?4
,'n
r*i
M)
M
"
••
'HI
Alpin* Am*rtf.4n Corp 115 Bailey, J W , Math me ry Lul
Alu/runumCo of Amenc*. :
Anuco, Inc
Amacotl Machinery, Inc
AlDMl Ltd 1
Amoo Plastic Precentors Inc Colorant Div
American Acrylic Corp
Anwncan Barm*K Corp
Am*nc*n Chemical Corp
Amencan Cvioamid Co [nduatnal Chemicals
& Plut.c. Div
Amtncan Cvanamid Co, Elantomer* & Poly-
mer Additrv« Oept
Amencan C>anamid Co Die* & Chemicals
Dq»
Amenean Cvanamid Co . PI a* tic* Div
,1fl Sakelite, La
37 Batte-lite Xvlonit*- Ltd
38 Baker Costor Oil Co , Product U
39 Baker Perfcina. Inc
40 Barber-Colmsin Co , Indimru
Div
41 Barnes Engineering Co
42 Barr Potymer Systents fnc
43 Battenfeld Corp of Amenta
44 !3auflano& Figh
45 Baychem Corp , Verona Div
4fi Bayer AG
47 Beckman Instruments Inc
48 Beetle Plastics Inc
49 Bekum Majichmenfabriktn Gm
evclopmeni
1 Instruments
bH
American Hoech.it Corp 150 Beldmg Chemical Indi.st.rK>.*
Amencan Hoechul Corp Film Div 151 Beloit Coi"p Plnitiot Machinery Div
Aflkencftji Hoechit Corp , Chemicals & Pieties 152 Berdon. Inc
Div
Amencsn Hvdrothtvm Com , Sub Ecolopcal
Sci*n« Corp
Amenc*n In>tniment Co Dt\ Travpnol Labo-
ratonei. Inc
Amencan Insulator Corp
Amcncan Packa^nng Corp
Amenean PoUtntrs. Inc
Amencan P\nmlin Corp
Amencan Renoht Corp
Amencan Re-m Corp
Amencan Stuebbe Div , Dem«a PlaNtic Machi-
nery
'T Bfrrge-, C W Maehinenf^bnk
M Herrifl f-'oam Product.-, Co
55 Btrstrotf Hermann Maschi
iTransmare-: Corp U S Kt'p >
56 B*tol Machines, Ltd
57 Rielloni Con-uruiiom Italiane
58 Billion 5 A
59 Bm-DicJtor Co
60 BipeMnternauonai Inc , 'Sn(c^
61 Black CU«.«on Ca , Uilts Dtv
62 Blane Chemical Dis , Rcichh
Inc
63 Bletbcrzcr Berewprk^ Union
American The rmopl untie* Cnrp 164 Bogert "Machin* Corp tU i r
An,»nch*m Inc KG)
Am«» BC Co
66 Bohnv. Or Th KG
Am-rttrk/lnntniriifntimnd ContrnU 166 Boiling, ^wwurl, & Co Uw
Anvx» Chrrnti «l- Cnrn
Div
AmpMwi Co ( fk UK t>< KI.I* M uhim-rv (jrnu|>
AfihiFMr'TeV "> n r»l» r^ ( ,inliH
Ap4.hr Koriin l'i 4J,ui« 1).\ \1illni...t.T Unv*
(.'orp
A|Th. ,( Kl'.uu,. - Ir.,
\lifl,. tt n,-i ,-i >.
Ari|.li.-.l -M -i, itn.r,.r|i
A.)u>t urn H-vim...
ArVurn M.i^.'KKtcntiibrik
Arpjs t'hrmuttl ( <>rp MwlHv Mix
ti7 B^lMn t- m--r"(,n Inc
6'J Iktnitn t h. f»ir,il ''orp I'ln r.n
70 Hordt-n I'h.-mii il Dis fiord, n
71 Bor« Wurn. r Corp ( hi fimuN
"14 hr.il^ndfr <' W In .rniirii-ni,-
,'ft Hnidl.-, & Tumid I I.I
7fi Hr,,iid.-ahurK' r ./on. (urn S(n.-n
t nhttu
77 Hniiiilv^ii). l-il.r- I'n-hi<^( .»
7H Hriti-h l . i in.'-. 1 Id
7N lirili-.h liiiiii-truit I'l. ^ IK - 1 i
Du ,11 ^ -:il,-,r,,, kinuolrul
M Krti'-lui^v^.in h.mu il- 1 Id
rt| Mr.M>kli. Id t- n^iii.. mi,; 1 iUir,,
H2 ltr.»>k . In-iruuv. in DI-. >r n» r.
Ht Broun \f,u)iiii,' Du K*r
Inti-rwlo Auto-
.plH^iicD.v
|N<
Hhtftita
limns, hin
1 Knvinrcnnif
.iriix I,,r
.n H.tiriL t'K
i. i.
1
N.uitM Div
19M
jyy
200
201
207
209
J10
21 1
..12
213
214
^15
216
217
218
219
221
222
223
224
22 b
^27
22H
229
2'tO
2J1
2).J
234
^)4A
2.JS
236
2J7
238
239
..40
241
242
243
244
245
246
248
249
251
252
253
J55
257
258
259
260
261
262
263
264
265
267
267A
268
'fiHA
2fiQ
271
27 J
^7!
'74
_' T'iA
.'76
JTH
' rlt
JM)
•y|
.^ J
-"- t
_^J
2H.SA
JH«
Huchcrfeiiy'T l.i«( "
Hu«I.Ko/l'<.lvil>ini li.v
Hy.ld I'l., 'IK iT'Kt.nuliiv
ttuhl«-r Mr-,- (rnnl,n.(r I (,|
Bulov.i Wi.tdi' •.
Hiilli'r Mfn ' <• ^'iliri.i !h\
CDI l)i -r" r '""*
riHA f
Canjs Ch»-n»cH) Co In,
Carver r"n-d b Inc
Cartall, Inc
Celan--^ Hla-tics ( «.
Cement A-,^ -to-- I'rr.duct- I ••
Certain T. .-d Product orp PL.st.^Oiv
Chaw>Ch«micil ( «rp
Chf-mi trorr f orp Innr^.itin < hi rni< ds On
( hi'inLrron ( <>ru ' )r i MI n < In inn •! 1 )i
C'hem*-trnn < orfi I'l^iti. n Div
Cht-mical (• jnn-K.-utiM i u \
ChemifHl (J. v'-l'j],in, ti' ( , rj,
Chumtcal ProduM ( NIJ,
fJifmictil ^ jl"- f o
<"hempl*-x ( o
Chevron Chemical Co
ChlssoCorp
ChromH Con-
Cincinnati Dt'vi*lrj|mient Jit Mln ' '-
Cincinnati Milatron Au-tri.i dfndH
Cincinnati \1ilacronrhernual-, Im
Cincinnati Mila.ron f'ljvic- M^.hmerv Div
Cities S-jnite Co
Cities Service Co Plasm •, On.
Claremont PuUchemicjl '.'orp
Clifton rUdraulicPre^Lo
Clopav Corp
Clow Corp Fistic-. Div
Colonial Koloniti- Co
Color Chip Corp
Colorco, Inc
Conunerci.il x»Uent.s Corp
Compo Indi-.'nc^ Inc
Conap, Inc
Conoco Chemical-. Di\ Continental Oil Co
Conolite Du Woodatt Iniluscrii--, Inc
Con rac Corp Crnmpr Di\
Consowtld Corp
Const mccione^ Margant 3 L
Continental Ot, Co
Continental Pla-ticx lndu-.tru«, Inc
Control Proc,-- Inc
Cooke Color & Chr-niici! Oiv Reichhold
Chcmicnli inc
Co-.no PI i-nc- Co
r»,rv,opl«-M<*^ K 1
f'ottrell l».p>.r< •> Inc
m« Mtl,
( re- line 1'ln n< ^ Pi[j.< ( ., Im
1 'fl'-t e" O.llll t "T\l
f'nm^o Im
fmi«[!t..n & Kn,,wl. 1 ,,<\, I'L.-ti,- I !,|.,r Ih'v
( rown h'n,'!ii' i r. d Mni<>mii^ Div i i<>wn 1 nn-
I'},W» In,
Cnmn I'rn.liu t- ( nrjj
( >t,vi n A Id r 1. i! 1. ! or (>
l'u|,],l, ^ 1 ntl. <1 l'.|- 111.
l'iirr\ An- Mutilin^ & 1 iitiinut in^ (''i
( urtin II, i\- D l o
1 ttiMt-n A. N. »Uix 1 1.1
t'llxl.iml'),. nm ,M „ l,u
1 llM.munhil I>U
Custnin t niMjh.unittnj,' Curfi
''il^tom K.-,n- In,
DSM
*Ttepn'n±pd from the October
right 1974 by McGraw-Hill.,
All rights reserved.
1974 issue of Modern Plastics
1221 Avenue of the Americas,
Encyclopedia.
New York, N.r
Copy-
100^0
213
-------
Table A-7 (Continued). MANUFACTURERS/SUPPLIERS OF MATERIALS LISTED IN CHARTS
2NAA Hfti Nippm Ink & Ch<-«nirnl Inc
'2H7 Uti Nifrt*.nT"h\..C<)
.tHH DiiMi'l I.tH
.FtO l>in Corp l,bl
2*14 Hurt ,H<'uo.ni"> Inr Owm.cn I Group
2M7 |t«vu"< Nitmw Co
'2«*N (IMMK frank I), To, Sub Hwkwf**. tn.
rm- Inr
2*N tltttl* M''U-f ft StippK C«
100 DMVI- HundiiMr-tmuldinK/Hobbft Du Cromp
101 lint cot ,,rp pHthHfpng Film Div
r,02 lint (Jo ( it-.- ( orp
IMVII & KirhardMin.ini
|t«*otr P|H»tic* Corp
I ((-(-or I-uminulcM, Inc
(V. hi* Hlaokliu-Corp
IWrfiHd P,a«Uc«Co.lnc
IVT,u.~« Inc
Doknron Du . SHmuvl Moore & Co
IVIto Chirajro Inc rind R*« Div
!W-m it hun-t-ofltirhnik GmbH
IVnki K*edku Kojryo K K
Design Center. Inc
D*\ con Corp
[Vw Foam fnrfuov*r Oi*iniciil Corp
MuwrtwfmctlCorp
l»ow Corntng C'jrp
I)r*b«rt Sohr,* M*»chin,«nfwbrik
llrntruK" r n(fl(i««rinK Co
Uriiiii-t |)ijw G & W Induatnea
Ett»t Co<«oi Chedutul* Co
Eastman fhemical ProducU'
Kgan Machinery Co
Elcctnc Trading Co
Electro-Flex Heat, Inc
Electro-Mcchano Co
Emerson 8t Cummg, Inc
Em*er Werttc AG
Emen Industries Inc
Engel Ludwig. KG
Engineering Plontiot Inc
Fngmt-enng PlaxtiCH Ltd
tneirwennp Plastic Machirwrv Co
Enka GlBnii-toff Pldanc NX' Sngineenng Pla»-
tm Dept
En* Foundry Co
Erorxl !ndu*triv>«
Fi-do PijHti^ Muchm^ry, Ltd
Kxiu-x Inu'rniHion,il inc Copotymer Product*
t ««ex Wire Corp
Kthvl Corp ln,[u-tnnl Chi-mirul). l>tv
KthvlCorp f'olvner D.v
Furopran Plu^'r Mwchin^ry MfK ('<>
Fv»rm Chtrm»tic« Inc
Kilril*TM, Ine
f »iv
ruhruoii 1'nxluax Div K««i*-J'ttfu r Indun
fru-H.lnc
rumco I'lddtir-n MIg Co , Div ramilianCorp
^wrrrU'tv th% I'sW <'.*]»
r/.-t Il.-Mi t li nit ra Milt Co
hi di r.il Mo^ul I nrp , Column I Pltn.Uo> Uiv
KrMow-* Corp
Ketb-n A Guilleautm- Uwlektra AG
rVnwul, Inc
KerifUMon. Jamm. & Son». Ltd
(H4
l<»r,
40!
104
tm
406
407
40H
409
41.1
414
415
416
Krrrn forp Color I)i\
Kirn<('-ii*-*< Hi*
ri>rr<.('hiv <»l (-vrr,»(\,rp
H.rr>. M.irlnti.. Co
MUoi'l,M.i<^ in.
r«
I iU-riti' Corp
rma.r (lit N-.rth Anwnc«n R.*kwell
f OrifHiufH Inr
hir, .f,,n. I'N^Hc- ( o Div Firfslum
Ktx r < o
fin-ti.nf SMiihelic FiU rfi Co
t-iM-M/.n.- iviitli.-tic KubU-r A 1 «ex C
ri'vdi. r Hl.m MiJ.tmK K^uipnu-nt
ruft-^r A poricr Co
ri-rh.-r N i, ntific C n
r IM LIT i «ith Pla-ttn- Machine!, Inc
Hrxipltxt Inc
H»-x O-Ua-r. Inc . Pluctio Di\
Hint Vote To
KInrin, Ltd
FliinrncflHmn Co
Forrt ^^o^o^ Co Pftml & Vu
hormica Corp
Kornuca. Lta
In°c m
J'nrtm Pln-tiCR, Inc
Foster Grunt Co
Fo«tona-Fannon, Inc
Foiboro Co
hox VaUe Dewlopment Co
rranklm Fihr, -LamiWx Corp
Freeman Oivrriciil Corp, Suh M H Robert^oii
French Oil Mill Machinery Co
ivl Operation^
Di\ Monogram Industrie!
SOI
502
V)!
S04
Vi-
SOM
fill
512
513
514
516
rru-wkfA Moepfner GmbH 121
Fnlvam .S p A 524
Fro^ndenbcrBer Ma^chinin & Apparuiehau *,'£*>
GmbH r»2ft
Fu(WChvmica.lCo "i27
Fuller Co 02H
Fur.-ire ^iantict, Inc ^'.'^
furukawa El*ctnc Co 5 10
GAP Corp "iSl
fj R F Cowtpjijoni MocfJiiiiachf- S p A ^'!^
f.KN Minder Ltd c> JJ
GSE, Jnc ft'M
Gummaftux, Inr
Gwrdtn Sut« Chemical W^
dttrdnfr Lfiboratory, Inc T j^A
Gart Mfg Co 536
Olman, Herman A , Co 536A
Om-O-Lite Pla-stio- Corp 537
General Color Co , Div H Kohnitainm Co 5 W
(rCT^ral Engineering Co 5 ^
freneral Eiectnc Co InduMnal Control Prod- 5-iO
ucts Div 541
General Elettnc Co , Industrial Salrs Uiv 542
General £iectric Co , Insulating Materials 544
Dept 546
General Electric Co , Laminated Products ^47
Ucpt 550
General Electric Co , Engineering Polymers 55;
Product Dept 553
G^OTrfl Electric Co . Plastics Div z,^
General Klectric Co Norvl Operauons 554
General Electric Co . Silicone Products Dept 554 \
General Electric Plastic NV 555
Genera) ro,im Plastics Corp 55,3
General Industnes Co 557
General Instrument Corp . Semi Conductor 555
0» 559
f>t,t;rai Mill-. Chemicalrt Inc ^(j
trt-ncral rMa*Uo>Curp
General Plagues Mfg Co 561
Gem-fit Tire & Hubber Co . Chemical Plantio. -)b,
D"v 5*1
dentran.Inc 5^4
(rt-trv Mdchint- & Mold, Inc -^7
Gi/ford-HillCo.Inc
Oilman Brot. Co SQR
<(l«mort,'an Pit** fit 1-oumirv Co ^(,y
*tio. inc 57ii
Clastic Corp ^71
Glulif.-n Ptgim ntn, SCM C orp 572
(.litU-rex ( >,r\, ^ t
(.lolml Prur-ir. Fquipmcni, Inc ^74
(ilotJci'-U-r I,fiLtiri4*crini/ Co Inc
«l«» f,75
l,,,™l h, niiiitlH Inr
',i,ltMJ-itl A Mfluitic i'owilt-r., Inc *,7f,
(Ml (,i»lrirn U !• ( h. iiiinil Co r,7T
4*i? 1/iMxly.ir Ai n,«|ii,rt ( ttrp t[7H
4*14 t.itfidvt (tr Tir<- & UutiU-r t inni I In r)h i
47J (,nit,-WH 4(o ll,ni-...ii ( hfmK»l lln vi^A
471 (,rio-WH 4(,i r II tv Hulil»-r !)u .,K |
474 i.r»r,, V, II & ('„ , llniin ( lit imii.1 On '„,
ITS l,niii-SSH «t I n M.trtt, 1^1, mu.il III v -^-,
471, (.rnh.mi r>iKiit«rui|i( i,r|i ,^i,
477 (,r. 1,1 l..itf- < hi mn.tl C'urp •,„;
47« i.rfat luki-i rrKjndry hand Co, Min,'r«l 1'rod- r>««
urti- Div 1^(4
479 (.uanlmn Thi rrtirul Cttrp 51^)
479A UunrdiMn KUrUic Mfg Co
4.'1
422
42'1
4M
427
42M
429
4.-I1
432
43'J
4't4
435
436
437
4:18
439
440
44 1
442
444
444A
444B
445
445A
446
446A
446B
447
44H
i49
450
4SI
452
4*>7
45K
4SH
460
461
462
46.1
4A4
0,,1( Oil n» mwnl. Ti> C,,|» Ailhriti\,-.
HIT! " ll.-li-n~t I'n.lutl. lilt
llni.kt Inr
!li,l! (T Oi
Hnlhkii.ini, III-In, ,1,
li»-:ull .l,,i 1'i,,.,K-s lilt
llnrr, I In,
Hiirshn* ( li.-iiii.i.l Ci, Hit kr.inifvOiK.
Hirt, k ( n Inr •-„!, lliniiit.nd Ihnmr,
llnrtt-v lltihMI Inr .I'lA-tioDiv
H»r»irk( n< muni Corp
Hn-iin* 1'l.i-licx Inc
Hu.iithl*-nip Kf-ine, Inc
HilLtrd Indu-trirs Inc
Hill-McOinnn Hit P,-nn»>lt Corp
Hilton Dui-CSt-micalCo
Hitnchi Chi-micnICo Ltd
llntih- Mtc To Dati--Standard Div
Hobhr \S uliams Machinery Ltd
Hoke Inc
Hommel 0 Co
Hnni-t*,!! Apparatus Controlt
Honntttill Industrial Dlt
Hookfr CiifmicolCurp
Hontpr B,ill i Hu hdv. ard Honon Co
Hnuthton r h , t Co
Hmturil lndu-,tnt-«, Inc
Howfll liiiiu-int-B, Inc
Hull ( orp
Iliimphri'vOirmiiiiltCuni
Hunknr l.ttlim il/inen, Inc
Hupfirli] Bros
llu'H Injtrtiijii MulilniK^.ii-ms I I/I
llvdr.tti Int.
[lit Travfnul Lab . Inc
Htsol Div Dexter Ctirp
i IBM
ICI America, Inc
ICI Lankro Fla«ticl«r« Lu)
ICI Ltd Plastics Dlt
1K1>- Corp Suli Amcncan -Silk Lab»i MIg (
ITT fhortipson Plw-tic, Uiv
ITT V ulcan tloctnc
IdemitAU Petrochemical Co
Idt-ntification Service Corp
Ikegal Iron Works. Ltd
Illig Adolf Mav;hin«nbau
Inper-ill Kand/Negn Bow D,v
Incoe Corp
Indet, Inc
Indol Chemical Co
Induisa Corp
Industrial Chemical i D>e Co Inc
Industrial Olelectl iCb Inc
Industrial Nuclconic-s Corp
Industrial Plastic SL IVanng Sales Dlt
Inou-tnal Pla-tici-abnc«tors Inc
Industrial Temperature Control Co
Induatnal Timer Corp
Industrie \Vcrke KrtrUruche \ (, Packak
Machinery Ilu
Infrfirt-d Induttrifs Inc Elearonit:?,
lnsu°atmxT.brican,rs ol "Jew (• ngland. Inc
InUTn.ttirinnl Kain Dit , Hrilidav Inns
Ami-ric,! Inc
InternaiKin.il Industri ,1 Products Corp
Inl. rm I h. micil. ltd
Inl.-rtJlitstlfs ( i,rp , ( ninnn rci.il Krsins Du
lnltrst,ih Ltd
lonm ( hi mica! Co , Uit ul Svbron Corp
Irrt.n Ira
Ulnh.iM Stiniryn KJI h.i ltd, Inu-rnnli
s.,1, . l(,pt
lf|iik.iv.,,liinu Hitriimi lleiitt IniluKlrns
I HI liiilii.in..l SLiihin, ,v In.
Mandr in 16-ins ( ti
|snl,t S p A
I--,la \Vt rki AG
Inn rilirt.ro
.1 n,, Mly Ci
i I .!
l.ltl
J.ipjn tli, I Wt.rks I td
Jar. ikil orv
.Itfltr-on I h. inir.il C.i Inc
.It Ilu i \llt. ( n
.1. t tir. ,,m Plitstich K.ilph .Mnt- Co
,)ii«rn,»Ut-l. rn Mills Co "lj-tlc r abnc In-
,l|lhn^ Miintillc
John-on I'lnmio Marhmtrt Div I*. -.'
Carp
214
-------
Table A-7 (Continued). MANUFACTURERS/SUPPLIERS OF MATERIALS LISTED IN CHARTS
Ml
Wl
904
5*5
Mo
W7
**IU
401
">04
SOS
S06
607
SOU
MO
na
til
015
616
«17
619A
no
621
«27
MO
631
•32
632A
6328
635
636
637
838
639
6*0 '
641
642
643
644
645
646
Mg
'MS
660
651
662
064
666
M7.
IM
ett
662
M6
MM
M,
MX
DM
»7u
«72
674A
675
«77A
678
662
6HJ.
68S
686
*r!7
ivv
it»5
fix
TlXI
:oi
Jordon Valve l/iv Kidurxh Induncruw. Inc
Kalle Aktii naf~*ll-«-haft
KaflfKMfurhi ( rn-mical lndu«tn*-a Co . !•**!
Kard ( 'iifti
KauvKik, Ml|| Co
Kaufman *>A
K.CIU-. VWl.m.-. loc
Kay rrt.-.' h. m.i.,1- li»
KnlOn-muMl! o
K*-l!.-v Pirk. rinii 1 h.-mic.il Corp
Ker.nch Pftroch. mi (Jr«uni, \tnu-nal« Uiv
Kornybk Corp
Kr§» LVirp
(trail*. At l>n*ins '.inhll
K/auM Mafl*, f vp
Krei.r, Oeorn Jr 1m
Kn>tal Krak Inc
Kroll Equiprntnl (.„
Kruno. Titan r.mhH
KJODO* Tiun A,b 'Norway, ,-iub NL InduM-
tn*»
LF£ Corp , Proce« Controls Uiv
LNP Corp
Land Instrument* Inc
Landuli C>r !nc
Lftakro ChemtcaU. Ltd
Lttfx fiber Industrie*
Lati Indudtria Thennopladtica S p A
Lawter Chernical*. Inc
Uwton, C A , <.ne liu
Lumar OIIILB) MlK Ijo . Inc
1 unwca K *,
MA->»(iA
MKKt n»n,u,.l 1 , !,„
M 4, 0 I'l,,.,,,. I'rr.i,,,,..
MKPI.,.ll,-i 1 o.liiu,- Inc
M 4 T Clien.KjI. In. \p./>!^t- Prnalmf
Machine Tool VV,,rk^ I Ivrhk.m buhrle Ltd
MallilHkrnll 1 h.-mu-jl Work,
Manning P.iiwrDiv Httnmierhill Paper Co
M«trb!«?tw t. "ip
Margoli,. A & ^on.
Marine Pla.tua. !)iv Northfrn Petrochemical
Co
Marhn Ml( Corp
Munrw^nitnn M,-,-r ^CI
Marpli-*. \V \l r rf Hitro Co
Man.chull I'u M,l.'. Lahoratoriea. Inc
MM*onitf Corp
NlHI^UMhitH Mi-itric Work-, Ltd Pla*tiCM
\l ilriv 1 ontniU Co
M n & It ,k,T 1 id
M.*\n^r.l PI ,.|i.- In, I)n Ch.-K-aindiiMri.-M
M,h, -v,,i Cn, on,., If,.
M,\,-il rrMl 11 MiS.-iH or|.
M.-nrl t ,,q.
M.'.liu |l,-i,:i, In,
M,,|»n K,i«> KK
Mrr.-,-., !T,.lu,t.
M«-ru Cln-iiiic.il f o
•KU
70«
7(>i>
707
708
70HA
709
710
711
712
714
715
717
71HA
71!0
722
726
727
721!
Ta
Till
7JI
7.12
7.TI
734
7.IB
TU>
lilt
730A
740
741
742
741
744
746
746
747
748
749
740
760A
751
751A
752
753
764
765
757
758
759
760
79!
762
764
764
766
76U
767
7S7A
707 B
76K
76»
7MA
770
771
771
771
,'74 A
775
T7«
774
701
7B2
7SJ
704
785
787
7«8
7n9
790
791
7^5
74(,
797
ftUO
H0.4
H0.°>
MW
Mica Corp
Miclvl M * 1 ,, Inc
MlchlicnnCh. m.r.,1 t oru
Midland Ho.s ( orp MurtiK Muchmery Uiv
Midland H,-.. ( orp , Unit I'liuticn lliv
Mulv.K.1 Ml« Corp
Milwc. hie
Miu
Morgan Indci'lne. Inc
Producta Inc
Moalo Machines Co
Motion Indicatinij Uvvicen, In,.
Mount Vemon MIII-. ,nc
N L Inclliiirn-i Indu.triMl t n,-micttlb Uiv
N L Induatrre-.. Titanium Pixmenu Uiv
NRM Corp aub Condec Corp
NV Chtmi^he rahnek v/h Ur A Haatftrn
NVr Co , Molded Products Ui>
NVF Co , Tecnnical Producw Ui\
National Autonidt.c Too! Co
National (nduttridl Chemical Co
National Tel-ironica Uiv . kastem Air Devices
Co
Natvaj- Co. p
Nelmor Co , Inc , nub Entwwtle Co
Neville Chemical Co
Neviltc-Synthne (Jrganica. Inc
New Arden (_hc-mical Co, c,
InduBtrial Product. Inc
New hngland PU-.IICH Coip
Newbur^ InduKtn^rt Inc
New tnglHnl l,amiri,ii** Co Inc
New Jnr»ey /.me Co . a Gull at vve«t«rn Co
Nict»m
Nippon Mt-,-1 I liernic-..! Ltd
Nippon /Von C'o^ Lul
NoracCo "inc
NordoerK MHcli.nerv orocip 1^-nnord Inc
NorplK 1)1, Univrraul Oil Product*
Northern IVlrocht (oic-al Co
Northland Pla>lic. Inc
Norton Co PI.I.UCH i nvntht tui, Uiv
Norton l.nlirir.itonff. Inc
Noury C'henuc.il C or D
N'ourv & inn ,*, r l.uiide N\
Nouvelle M.ipr,- .-> A
Novamont c orp
Nupla Corp
Nv lene C orp
Nvlon Kngmivrmg. Inc
Nypel. Inc
Olhcinc' Mc-cciniclu- Veron™.
llin Corp l hi-rnic.il Un
)lm Corp
>|jiuon I ti.-riiu.,! llu llvnaU.i. Inc
)rl»t,>K. In,
>r,- & f hi-iiuci.l I oip
H07
HIO
nilA
KUA
»ri
HIS
MIH
rt^TA
H31
»32
HU
^ r,
1 !*>
i.rj
^411
141
«44
H47
S51
fl57
HhO
Hbl
h62
B64
H67
469
1)70
871
87 1A
S71
i(77
H7H
OKI
,-iyi
K45A
M9M
902
90JA
906
908
909
911
•U J
41 1
414
'llr,
918
919
(Halite Cn Lul .
Owi'nx ( .rfninx 1- in, rtflMN ( orp
PUKI'i-nnl ulif I™
?\'i; Indn.tn. - Inr 1 hi-m,c«l Iliv
('PC Indtihtrt, . Ill, 1 oMlinti & K. tinn Ihv
Pncirc PI.I-.1IC Pl|. 1 ..
Pitcihc H, .irw & 1 1,. rnin.j. Inc Plinlic*. Uiv
Pacific Wil.-lHlil. l),l ( orp
PocKaiJi-M,,, Inn, i •. ( ,, (t, , ,| Pr, ntici Uiv
P^k A MHIIC Kc|i.i|,iil.-nt 1 ul
Pin I h'l-mnjl C or,,
P..r.,moi,nl ln,lu,tn, . Inc
Parnall Si v,n- 1 1,1
Pnrllow < orp
Puth, K 1 1,1
P,-^r..,ll ( h.-nnc..[ ( o
P. Iron I orp
P, men Product. M M ' or i.
Penn-tylvani . Indo.rr,,,! , h, mi, ,1 ( orp
Pfnnw.llt ( orp H,.r, h-rn ,lix
rVlinv-jltl ,,r,, 1 o,,,l,,l n,,
I'..n..w.,h 1 ,,r,i PI, r,, , ). p,
IVrrn^u In,
I'tilif In, .f. , Ml , f,, rri,,.«l. Hi f,r
Pll/, r In, \lp\l III
Philip. K^
Photofk II ( ', In,
"I.1.UCS tc|ciipin,'r,i it A-^-...,r,, - , o Ltd
Plastic. Ldniuijuiii! c ,„ p
Plastic Molclrr. -.unpl, Co
PUstitoain (_o,p
Pla.tiniac . r i
Pla.tnnatiori Inc
Pla.timcr a A
Plasti-Vac Inc
PlumhCh.-n.ic.l ( orp
Podell Industrie- in,
Poloron Product-. In,
Polychemicdl Co Lid
Poly >uam Inc
PoK-Pla.rilm. in.
Polymer Dii,^ r-ion Imiu-'rn
Polym.-rMdthin. ry ( ,.|,
Polyh-r Ml.t,iir/ liu
Port, r H K ( „
l'r«Cl»lOli I'olyii.' < In-
I'r4-mi.-r rh.'rrn.f !'( ..m i „
hnniaLj* lh,lt a •, >,,
Purpi.iniM Oi\ f- .-ion Ki ( ore
PylmnPnxiuasC .,
P>rom^.r [riorum. nt( „
P\iH-,-M'r\ lii-triliin nt I <<
(juak.T OHI- (. o t h.Tim its Un
Rdl" Corp
Kmlmtion Tcchnnfii^.", (ni
RHinvillr Co'
R*vS.-U>- M,«n» iituti Inc Kquiptmnt Srtl.'S
K.-,-\, (•'l.-nnmi.- (in
H. tin--.! . HH v |)M Milhn ,-t.T 1 ):i\ v
Iv li ui I'l-.-tu- ,,l 1 in ! Ul
Ki iiJm«M ( h. nit^'l- hu
Kt'ichhi.kl ( h, mi, .1 Im K.-uilnrotl I'L^tu-*
H« it- iihnii--T II -i Snl. - I ,.rp
tit-iniiirtiil I'l t-tii- hu
215
-------
Table A-7 (Continued). MANUFACTURERS/SUPPLIERS OF MATERIALS LISTED IN CHARTS
»JI H. I" AMnruilm liv
!I2 I U. in..., r.s.m ( orp
1T24 K.,, 1'1,,-tH-
tr25 II. -,,n HIM AC
tr_'l> N. -*-... h Iru
(tJI.A K,-,,.,, ,1 tt.rk II K.rmml.T<:ml,ll
9-1* l{ikt(M I'olvnHTs ( i>. Div D.in IndUNlries.
ItK- 10.'-'
9-2KA Hi-i Kino Corp Hl.'J
»2>< K, 7,,l,n,l>n Hc-xo-l 102J
930 Hh. insight AC M««hinbau. llrnt.ch.-i Plasiiot 102,'j
Mjchinen 1026
•»J1 Rn.-inst.ir,l Plastics International, Ltd 1027
912 Rh«-ims*lK- -M.ihlw.Tke MaHchirwnbau HI2S
HIJ Kh.MM Inc , Polvimide Div HI2"
OH Klinn.-I'oul. nc Textile 10"!
115 Rhone Poultry. Soc des U*me<* Chermqvte* 1011
9i6 Richuru*on Co , Polvmeric Systems Div
937 Kid.it Engineering Co 1011,
93B Rikj Koir>°Co
940 Rilxan Corp
1HOA Risho Kogyo Ltd
941 Rnerdi.1.- Color Corp
942 Robertj.ha« Control* Co , Fulton Svlphon Div
941 ruii* rt*h.<»» Control,. Co . Industrial Irtstru
imnuilion IJiv
044 Rohinu'fli, Inc
943 K/K-heleau Tool I Die Co
947 RodR.-m Pla-ttlcw Equipment Uiv Package
94ft Hog'Th Anti-Mdtic ChenucaU, Inc
949 Roger* Corp
950 Rohm & H.,.- Clone Curp
956 Ro^ lund Producu, Inc
967 Royal Pla.nci Corp
9SK Rm l«. John, 4 Soru
959 Ku^aun Corp
960 Ruhh-rmaid InduHtritl Products Corp
Ml Ruco Div . Hooker Chemical Corp
962 Rumianca S p A
9«3 Ru^coe. WJ Co
D63A S f Pla.tio Inc
994 SCL lndu.tr,,-. Inc
9«5 SIOEL
966 SIEMAG. Sieng^ncr Ma&chmcnbau GmbH,
PIjAlicn Proc«n«mi{ Machinery Ucpt
K~ S P R E A
96« S IS Machinery Co , Div New Machine Tool
969 Samafor
970 Sandol Color* & Chemicals
971 Sandretto F Hi
972 Sangamo Electric Co
973 Sangamo Wcston Control*, Ltd
974 Sanjo Seiki Co
974A S«n\u Renin Co , Lid
975 Saiagr Mfj & Sales. Inc
976 SchiwctAcTv Chemical*. Inc
078 Scl.Ln Trtxe- Corp
879 Schramm ribcrglafts Products, Dtv HiRh
Strength Pla«t!c« Corp
980 Schulman. A Inc
982 Scott Bader Co
983 Scolt Paper Co . Foam Div
'MM Scranlun PU^lic Laminating, Inc
'JM4A S.-.IH, Corp
BUS S.^o Corp
'.WA hi-idl Mux-hmcnrMrirlk V.C,
IW7 S, iHinriimiph s*'r\ic« Corp , Heincor Un
!*Xh ,'^ki.ui (himifjl Co. Ltd. roam Product*
llu
9W) H«.n«ou-c Inc
9ftOA M«ntin«irrriul/i ' 1'ittliMKli
U S r«p i
mil 7 K Color Corp
lOlfi "^»ili*r Chfininil Corp
1017 N>1|>! ( xntniU luc
1UIKA S,.m, ln.lii.lrn» Inr
HitHH >*.m,ir Ml^ Co Ltd
Ull'l S,,inm,T llr InK rnt7 Nnchl
10^0 SoiitiiuTs 1'ljiNtic rriHluili- Iliv Whtttitkci
Siuiuldin,; ril^r.. Co ' linurok Dn
S|«-c,jln Pr.xJun*Co
-,«.c.ra I'olvim-r, Inc
.^qunr,- li Co
M .luo MmcrwU C^rp
M Lawrvnr* Hvdrauhc Co
Mailman M H Co
. W
sh..
Sh<-l
sh<-
Six
..
^ rruiin. & Co
ll Cht-micul C "
ll Inu rn.i!i«.n«! Hi
|,h« rd Chi niu-,.1 <
rwin V\illi.im» ri
ii.mi* o
!WH Shiinn Tr-idinjl Co , Ltd
W*A Slim Kl«u < In nucal lndtjr.tn<-s Co Ltd
!ftH Sliin-Kdbc Klutru M.uhiru-rv Co . Ltd
HtUO Minw^U-iilt»Ct> Lui
KHKIA slT.m,. Ht(f|]f>..hn..T Co . Lul
1(K>1 .sh,,-., Vuk,i K K
1002 Shuni.m ('',
lt)0t S^in.! In-truiTuiithiCanitttHi Lul
KMM ^I!H rlmcMIti O.
HWS Sitnc.-Co
1006 MmpUimutic Mf« Co
1007 Siniii-un cJrfinc Co. Uiv Afnvricnn
M.irhtm- Co
HM)H
LOUI
1011
1012
Munch*! FnpintfrmgCo
Suufivr Chi-micnl Co, P
D
10H
10.14
10.16
1017
1040
1041
104.1
1044
1046
H>17
1047A
10-18
1050
1051
1052
105J
1054
1055
1057
LU5H
1059
1060
lOfal
1062
1062A
1063
1CK4
1065
1066
1068
1068A
1069
1070
1071
1072
1073
1074
1076
1077
1078
107H
I079A
I OHO
IOH1
IOH2
10H.I
H1MH
10H7
pectaU\ Chemicals
n
SlauffiT Cht-miral Co . SWSSiliconeH Di\
Supan Chemical Co
Slfp.in ChrTnicat Co , R*»-in D«-pt
bti-rlmfi Inc
bUTlmirComroU Inc , D» Nationul Mfg Co
I (WO
10*J1
.inp-o.imoH
SliKutti lnilu-.tnr.. I'liiHtu MnJum-r> Oiv
tOL'l Snuih rhnrm.iI & Color ( o , Inc
1W4
1015
.
s.,1,11) rh<-tiiu.il->. Inc
Sarrh & Ucvuloprnent
(_orp
Titonu folvmerwt-rk.- GmbH
TiuxttW id C«na.i«, Lid
Tohoku PuUmiTsCo
Tokyo hhibaura Klertnc Co . Chemical Prod
uci^ J)u
Tor.iv InOustru-h. Inc
Tomv s,|lc<,n*- Co , Ltd
To^hibd MiKlunuCo
Tu>uI>uCo Ltd
To\o Kii^.iku Co
Towiinuik.i (America i. Inc . Machinery Ik-pi
Tra-ton. Inc
Trun-.mur« s Corp
TriuluSp A
Truhor Mfg Co
Tm.-l'Uxj Ini
TiMnti Chi-inicalh lliv , Knu-ry Industnrn
Turnn I t.
11SSA
llb«
1170
1171
1172
117J
1174
1174A
1 17a
1I75A
1175B
1176
1177
1177A
117M
ns
\ht>
1H1
1M2
1HI
11K4
11 M.'i
11 Mb
11M7
1 1MH
llrl!l
11**0
1191
11'.1-2
1191
11>*4
11'15
lluh
1 I'lT
I r»N
1 14*1
12(10
1OT2
1201
1-2(14
I2ur,
1206
\ Div
l.'mtika Ltd
I lin- r«al Clll I'r.^lija- Co f !,<
( pi-.lin Ti, ( 1'H !Jr
L.pjuhrt Li> 1'<,I\(M, r ( r,. inual- Ijiv
Vnlih«nill,\ I n,l--'l M- r"iii(; ' ., <,\ N J
\ .,,, l>,,rn I'lj-lK- Madnri. r\ < o Utv \ H"
1 Jorn Co
Vrtnderbill H T Co VanhLny O^pt
V« Kicnl Chi-'mic'tl Corp
\« iur'>n Corp , C h,-micaifc I)|\
\ .TC..III Sac fi
V,.r,on All.u-fl PTPS« Co
\ uki-r^ Ihv , S|»>rr> Rand Co^
\ ictury trit>n«vririg Corp
Vimm Corp
Vmvlplex. Inc
Vistron Corp , Film Div
\ istron Corp Sub Sundard Oil Corp of Ohio
Voltek. Inc
WER Industrial Uiv Emerson Electric Co
Wahj»h Metal Prtxlucti Co
V\ acker.Chi'mie GmbH
'.Vako Pure Chenuial Industries. Ltd
Wakefield t npneenng, Inc
Wallace & TVrnan DM , Pennwalt Corp
Ward. Blenkinsop & Co Ltd , Accui Chem'
cals-U S rep )
Ware Chemical Corp
Warren Conpotventi Corp
Watson-Sundard Co
Wayne Machine & Die Co
Weather Measure Corp
\Veed Instrument Co
Wehco Plas'ics, Inc
Welding Engineers, Inc
Weldotron Corp
W,.]r.x Inc
Wcllman Inc , Plastics Div
Werner & Pflfidenr Corp
\V ^st Instrument Div . Cjulton InHustn.-s ln<
Wehlern HlfcintlCH CM
Wemmghouse Kiuctric Corp, Inriu.trial I'l.i-
tic. Uiv
rlaTi Div
W.-.tUke Pl»»tics Co
W,-»ton Chemual, Div Borg Warner ( orp
Whn« Chemical Co
ttlnllock It.c
Div
Whitlak.-r Corp Mnl Rez Div
WhMUk. rforp. K & I) Div
Whlttrtktr Corp Tin rrnopla-uc-s I)u
W liquid K.Iain L.lliv LmiTson Electric («
Williams Inurnational.Inc
Williams-Whin- & Co
Wilson Instnimint, Div Acco
Wilson \l.inn, Div. Wilson PharmaciulM
Uilsonl'rulucisCo.Dii ll»n Indusln. s In
Div
Witci, Chi mical Corp Organics Div
Wiuo Chemic.il Corp . Polymer Div
W'-^all In.lustrn-s Inc
\Vr"i;lil, PM Kl.-ctr.caICo
XCr L Corp
Y»r«nyCorp
'/* us Indust, 'ul 1'ru.luctM, Inc
Zurn Imliwlnn, KEMCO Div
216
-------
APPENDIX B
PRODUCTS
217
-------
Table B-l. PRODUCTS OF THE PLASTICS AND RESINS INDUSTRY
Acetal resins
Acetone-formaldehyde resins
Aery1 amide resin
Acrylami de-acrylic acid copolymer
Acrylic resins
(includes acrylic emulsion polymers, acrylic latex)
Acrylonitrile-butadiene styrene resin (ABS)
Adipic acid-tetraethylene pentamine paper resin
Alkyd resins (phthalic acid resins)
(includes alkyl molding compounds)
Alkylphenol-acetylene resins
Aniline-formaldehyde resins
3utyl phenol-formaldehyde resins
Cellophane
Cellulose resins-
Coumarone-indene resins (coal tar resins) (petroleum resins)
Cresol-formaldehyde resins (unmodified)
Cresylie-acid-formaldehyde resins (unmodified)
Diallyl phthalate resins
Dicyandiamide resins
Dimethyl hydantoin-formaldehyde resins
Epoxy resins
modified
unmodified
Ethylene-maleic anhydride copolymer resins (EMA resins)
Ethylene-vinyl acetate copolymer resins (vinyl acetate-ethylene copolymers)
Fluorocarbon resins (polyfluoro ethylene resins)
Furan resins (Furfuryl alcohol resins)
Glyoxal-formaldehyde resins
Hydrocarbon resins (coal tar resins) (petroleum resins)
lonomer resins (SurlyrT^
Ketone-aldehyde resins
Maleic resins
218
-------
Table B-l (Continued). PRODUCTS OF THE PLASTICS AND RESINS INDUSTRY
Melamine-formaldehyde resins (Amino resins)
Methyl vinyl ether - maleic anhydride copolymer resin (Gantrez^
Methyl vinyl ether - mono butyl maleate copolymer resin
Methyl vinyl ether - mono ethyl maleate copolymer resin
Methyl vinyl ether polymer resin
Phenol-formaldehyde resins
Phenol-resorcinal-formaldehyde resins
Plastisols
Polyamide resins (Nylon resins)
Polybutene-1 resins (polybutylene)
Polybutylene terephthalate
Polycarbonate resins
Poly (1,4-cyclo hexylene dimethylene terephthalalate/isophthalate) copolymer
Polyester resins
saturated (excludes resins for polyester fibers)
unsaturated (includes alkyd molding compounds)
Polyethylene resins (polyolefin resins)
hiqh density
low density
Polyimide resins
(includes polyimide, poly(ester-imide), and polyamide-imide types)
Polyphenylene oxide resins (PPO) (Polydimethyl o-phenyl)
Polyphenylene sulfide resins
Polypropylene resins (polyolefin resins)
Polystyrene resins
(straight and rubber-modified - may include certain styrene copolymer
resins and elastomers)
Polysulfone resins
Polyterpene resins (terpene phenol resins)
Poly(tetramethylene terephthalate)
Polyurethane foam
Polyurethane resins (miscellaneous)
(includes adhesives, molding resins, sealants, etc.)
Polyurethane surface coating resins
Polyvinyl acetate resins
Polyvinyl alcohol resins
219
-------
Table B-l (Continued). PRODUCTS OF THE PLASTICS AND RESIN INDUSTRY
Polyvinyl butyral resins
Polyvinyl chloride resins
Polyvinyl chloride-acetate copolymer resins
Polyvinyl chloride-propylene copolymer resins
Polyvinyl chloride-vinylidene chloride copolymer resins
Polyvinyl formal resins
Polypropylene-ethylene copolymer resins
Resorcino!-formaldehyde resins
Rosin and rosin ester
Silicone resins
Styrene-allyl alcohol resins
Styrene-acrylonitrile copolymer resins (SAN resins)
Styrene-butadiene copolymer resins
latex
resin
Styrene-divinyl benzene copolymer resins
Styrene-maleic anhydride copolymer resins
Thermoplastic resins
Triazone resins
Urea-formaldehyde resins (Ammo resins)
Vinyl 1,2-Polybutadiene resins
l-Vinyl-2-Pyrrolidinone-styrene copolymer resin
Vinyl toluene-acrylic copolymer resin
Vinyl toluene copolymer resin
220
-------
APPENDIX C
COMPANIES AND PRODUCTS
221
-------
Table C-l. ACETAL RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Celanese Corp.
Celanese Plastics Co., div.
E. I. du Pont de Nemours & Co.,
Inc.
Plastics Products and Resins
Dept.
Bishop, TX
Parkersburg, WV
48 (105)
729 (765)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually.
Source: Directory of Chemical Producers, 1976.
Table C-2. ACETONE-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(10f) Ibs)
Reichhold Chems., Inc.
Union Carbide Corp.,
Chems. and Plastics Div.
Andover, MA
Detroit, MI
Bound Brook, N.J.
J0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually.
Source: Directory of Chemical Producers, 1976.
222
-------
Table C-3. ACRYLAMIDE RESIN PRODUCERS1
Company
American Cyanamid Co.
Indust. Chems. and Plastics
Div.
Location
Longview, WA3
Mobile, AL
Springhill, LA
Wall ing ford, CT
Kalamazoo, MI1*
Capacity1
Gg(105lbs)
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually
3An expansion of acrylamide resins capacity to 90 million pounds per year is planned
for completion in 1976
''A new acrylamide resins plant has come onstream since January 1, 1976
Source: Directory of Chemical Producers, 1976.
223
-------
Table C-4. ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
ADCO Chem. Co. Inc.
Alco Standard Corp.
Alco Chem. Corp, div.
American Aniline & Extract Co.,
Inc.
American Cyanamid Co.
Indust. Chems. and Plastics
Div.
Anderson Dev. Co.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,div.
Resins & Plastics Div.
AZS Corp.
AZS Chem. Co. Div.
BASF Wyandotte Corp.
Colors and Chems. Group
Beatrice Foods Co.
Beatrice Chem. Div.
Polyvinyl Chem. Indust.,
Div.
Borden Inc.
Borden Chem. Div.
Thermoplastic Products
Newark, NJ
Philadelphia, PA
Calvert City, KY
Azusa, CA
New Orleans, LA
Wallinaford, CT
Adrian, MI
Calumet City, IL
Fords, NJ
Los Angeles, CA
Newark, NJ
Atlanta, GA
Kearny, NJ
Wilmington, MA
Bainbridge, NY
Compton, CA
Demopolis, AL
Illiopolis, IL
Leominster, MA
224
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
Celanese Corp.
Celanese Coatings &
Specialty Chems. Co.
subsid.
Celanese Resins Div.
Wica Chems. Div.
Chem. Processors, Inc.
Chem. Products Corp.
Cook Paint & Varnish Co.
De Soto, Inc.
The Dexter Corp.
Midland Div.
Dock Resins Corp.
E. I. du Pont de Nemours &
Co., Inc.
Biochems. Dept.
'Fabrics and Finishes Dept.
Belvidere, NO
Charlotte, NC
Los Angeles, CA
Louisville, KY
Newark, CA
Charlotte, NC
Seattle, WA
Elmwood Park, NJ
Detroit, MI
Houston, TX
Milpitas, CA
North Kansas City, MO
Berkeley, CA
Chicago Heights, IL
Garland, TX
Cleveland, OH
Hayward, CA
Rocky Hill, CT
Waukegan, IL
Linden, NJ
Belle, WV
Chicago, IL
Flint, MI
Par!in, NJ
Philadelphia, PA
South San Francisco, CA
225
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
E. I. du Pont de Nemours &
Co., Inc. (Continued)
Plastics Products and Resins
Dept.
ELT Inc.
Baltimore Paint and Chem.
Corp., subs id.
H. B. Fuller Co.
Polymer Div.
Gen. Latex and Chem. Corp.
Gen. Mills, Inc.
Gen. Mills Chems., Inc.,
subsid.
Indust. Chems. Operations
The B. F. Goodrich Co.
B. F. Goodrich Chem. Co.,
div.
Guardsman Chems., Inc.
Hanna Chem. Coatings Corp.
Hanna Chem. Coatings Co.,
subsid.
Hart Products Corp.
Hercules Inc.
Organics Dept.
E. F. Houghton & Co.
Hugh J.-Resins Co.
Inmont Corp.
Parkersburg, WV;
Baltimore, Md.
Atlanta, GA
Blue Ash, OH
Ashland, OH
Cambridge, MA
Charlotte, NC
Dal ton, GA
Kankakee, IL
Avon Lake, OH
Grand Rapids, MI
Columbus, OH
Birmingham, AL
Jersey City, NJ
Clairton, PA
Carroll ton, GA
Philadelphia, PA
Long Beach, CA
Anaheim, CA
Detroit, MI
226
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
S. C. Johnson & Son, Inc.
Kewanee Indust., Inc.
Millmaster Onyx Corp.,
subsid.
Refined-Onyx Div.
Marcor Inc.
Montgomery Ward & Co.,
subsid.
Standard T Chem. Co., Inc.,
subsid.
Minnesota Mining and Mfg. Co.
Chem. Resources Div.
Mobay Chem. Corp.
Verona Dyes tuffs Div.
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
Morris Indus. Inc.
Lanson Chem. Co., div.
Morton-Norwich Products, Inc.
Morton Chem. Co/, div.
National Starch and Chem. Corp.
N L Indust., Inc.
Indust. Chems. Div.
Norris Paint & Varnish Co.
Northeastern Labs, Co., Inc.
Nyanza, Inc.
Hamilton Chem. Div.
The O'Brien Corp.
Fuller-O'Brien Corp.,
subsid.
Racine, WI
Lyndhurst, NJ
Staten Island, NY
St. Paul, MN
Bayonne, NJ
Pittsburgh, PA
East St. Louis, IL
Ringwood, IL
Meredosia, IL
Philadelphia, PA
Salem, OR
Melville, NY
Ashland, MA
South Bend, IN
South San Francisco, CA
227
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
Onyx Oils & Resins, Inc.
Philip Morris, Inc.
Polymer Indust., Inc.,
subsid.
Adhesives and Liquid
Coatings Div.
Textile Chems. Div.
PPG Indust., Inc.
Coatings and Resins Div.
Purex Corp.
K. J. Quinn & Co., Inc.
Polymer Div.
Raffi and Swanson, Inc.
Polymeric Resins Div.
Reichhold Chems., Inc.
Reichhold Chem. Del Caribe,
Inc., subsid.
H. H. Robertson Co.
Freeman Chem. Corp.,
subsid.
Rohm and Haas Co.
Rohm and Haas California
Inc., subsid.
Rohm and Haas Kentucky
Inc., subsid.
Rohm and Haas Tennessee
Inc., subsid.
Rohm and Haas Texas Inc.,
subsid.
Brooker, FL
Newark, NJ
Springdale, CT
Greenville, SC
Circleville, OH
Cheswold, DE3
Oak Creek, WI
Carson, CA
Maiden, MA
Seabrook, NH
Wilmington, MA
Azusa, CA
Detroit, MI
Elizabeth, NJ
South San Francisco, CA
Rio Piedras, PR
Chatham, VA
Saukville, WI
Bristol, PA
Croydon, PA
Hayward, CA
Louisville, KY
Knoxville, TN
Deer Park, TX
228
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS2
(Includes acrylic emulsion polymers, acrylic latex)
Company
Location
Capacity1
Gg(106 Ibs)
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins Group
The Sherwin-Williams Co.
A. E. Staley Mfg. Co.
Staley Chem. Div.
Standard Brands, Inc.
Standard Brands Chem. Indust.
Inc., div.
Tylac Chems., div.
The Standard Oil Co. (Ohio)
Vistron Corp., subsid.
Chems. Dept.
Barex®210 Resin Div.
Sun Chem. Corp.
Chems. Group
Chems. Div.
Sybron Corp.
lonac Chem. Co., Div.
Jersey State Chem. Co., div.
Kerr Mfg. Co., div.
Syncon Resins Inc.
Farnow, Inc., div.
T. F. Washburn Co., div.
Union Carbide Corp.
Chems. and Plastics Div. ,
Chicago, IL
Cleveland, OH
Huron, OH
Reading, PA
San Francisco, CA
Chicago, IL
Cleveland, Ohio
Kearny, NJ
Lemont, IL
Cheswold, DE
Cleveland, OH
Chester, SC
Birmingham, NJ
Haledon, NJ
Romulus, MI
South Kearny, NJ
Chicago, IL
Bound Brook, NJ
Institute and South
Charleston, WV
229
-------
Table C-4 (Continued). ACRYLIC RESIN PRODUCERS''
(Includes acrylic emulsion ploymers, acrylic latex)
Company
Location
Capacity1
Gg(106 IDS)
United Merchants & Mfgs., Inc.
Valchem - Chem. Div.
USM Corp.
Crown-Metro, Inc., subsid.
Yenkin-Majestic Paint Corp.
Ohio Polychemicals Co., div.
Langley, SC
Greenville, SC
Columbus, OH
J0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e,
greater than $1,000 sales annually or more than 1,000 Ibs. annually
3 A new acrylic resins plant is planned.
Source: Directory of Chemical Producers^ 1976.
230
-------
Table C-5. ACRYLONITRILE-BUTADIENE-STYRENE RESIN AND
STYRENE-ACRYLONITRILE COPOLYMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Borg-Warner Corp.
Borg-Warner Chems.
Plastics Div.
Dart Indust. Inc.
Chem. Group
Plastic Raw Materials
Sector
Rexene Polymers Co.
Dow Chem. U.S.A.
Foster Grant Co., Inc.
The Goodrich Co.
B. F. Goodrich Chem. Co.,
div.
Carl Gordon Indust., Inc.
Hammond Plastics Div.
Monsanto Co.
Monsanto Polymers & Petro-
chems. Co.
Union Carbide Corp.
Chems. and Plastics Div.
Uniroyal, Inc.
Uniroyal Chem., div.
Ottawa, IL
Washington, WV
Joliet, IL
Gales Ferry, CT
Midland, MI
Pevely, MO
Torrence, CA
Leominster, MA
Louisville, KY
Worcester, MA
Oxford, MA
Addyston, OH
Muscatine, IA
Bound Brook, NJ
Baton Rouge, LA
Scotts Bluff, LA
TOTAL
19 (200)
120 (265)
25 (55)
30 (65)
32 (70)
450 (100)
9 (20)
n.a.
14 (30)
n.a.
n.a.
145 (320)
57 (125)
14 (30)
91 (200)
672 (1480)
*0n stream as of January 1, 1976
Producers considered manufacture materials ir commercially
greater than $1,000 sales annually or more than 1,000 Ibs.
Source: Directory of Chemical Producers, 1976.
salable amounts, i.e.
annually
231
-------
Table C-6. ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
ADCO Chem. Co., Inc.
Allied Chem. Corp.
Specialty Chems. Div.
American Cyanamid Co.
Indust. Chems. and Plastics
Oiv.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
div.
Resins and Plastics Div.
AZS Corp.
A Z Products, Inc., div.
AZS Chem. Co. Div.
Ball Chem. Co.
Resin Div.
Barrett Varnish Co.
Beatrice Foods Co.
Beatrice Chem. Div.
Parboil Co., div.
Bennett's
Bisonite Co., Inc.
McDougall-Butler Div.
M. A. Bruder & Sons, Inc.
Cargill, Inc.
Chem. Products Div.
Newark, NJ
Los Angeles, CA
Toledo, OH
Azusa, CA
Los Angeles, CA
Newark, NO
Pensacola, FL
Valley Park, MO
Eaton Park, FL
Atlanta GA
Glenshaw, PA
Cicero, IL
Baltimore, MD
Salt Lake City, UT
Buffalo, NY
Philadelphia, PA
Carpentersville, IL
Lynwood, CA
Philadelphia, PA
232
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS'
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co.,
subsid.
Celanese Resins Div.
Chem. Processors, Inc.
Chem. Products Corp.
Conchemco Inc.
Baltimore Operations
Kansas City Operations
Cook Paint & Varnish Co.
Degen Oil & Chem. Co.
De Soto, Inc.
The Dexter Corp.
Midland Div.
Dock Resins Corp.
E. I. du Pont de Nemours & Co.,
Inc.
Fabrics and Finishes Dept.
Belvidere, NJ
Los Angeles, CA
Louisville, KY
Seattle, WA
Elmwood Park, NJ
Baltimore, MD
Kansas City, MO
Detroit, MI
Houston, TX
Mil pitas, CA
North Kansas City, MO
Jersey City, NJ
Berkeley, CA
Chicago Heights, IL
Garland, TX
Cleveland, OH
Hayward, CA
Rocky Hill, CT
Waukegan, IL
Linden, NJ
Chicago, IL
Flint, MI
Fort Madison, IA
Parlin, NJ
Philadelphia, PA
South San Francisco, CA
Toledo, OH
Tucker, GA
233
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Elliott Paint & Varnish Co.
Armstrong Paint Co., div.
ELT Inc.
Baltimore Paint & Chem.
Corp., subsid.
Emkay Chem. Co.
Essex Chem. Corp.
BFC Div.
Exxon Corp.
Exxon Chem. Co., div.
Exxon Chem. Co. U.S.A.
Foy-Johnston, Inc.
The P. D. George Co.
Gilman Paint & Varnish Co.
W. R. Grace & Co.
Hatco Group
Hatco Polyesters Div.
Grow Chem. Corp.
Boysen Paint Co., subsid.
Guardsman Chems., Inc.
Handschy Chem. Co.
Farac Oil & Chem. Co., div.
Hanna Chem. Coatings Corp.
Hanna Chem. Coatings Co.,
s ubs i d.
Hugh J.-Resins Co.
Inmont Corp.
Chicago, IL
Baltimore, MD
Elizabeth, NJ
Sayreville, NJ
Houston, TX
Cincinnati, OH
St. Louis, MO
Chattanooga, TN
Col ton, CA
Oakland, CA
Grand Rapids, MI
Riverdale, IL
Columbus, OH
Birmingham, AL
Long Beach, CA
Anaheim, CA
Cincinnati, OH
Detroit, MI
Greenville, OH
Los Angeles, CA
234
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd moding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Insilco Corp.
The Enterprise Companies,
di v.
Frisch & Co., div.
Internat'l Minerals & Chem.
Corp.
Chem. Group
Commercial Solvents Corp.,
s ubs i d.
McWhorter Chems. Co.
Div.
Interplastic Corp.
Commercial Resins Div.
lovite Chems., Inc.
Jones-Blair Co.
Kelly-Moore Paint Co.
Kohler-McLister Paint Co.
Koppers Co., Inc.
Organic Materials Div.
Kyanize Paints, Inc.
Lawter Chems., Inc.
Stresen-Reuter Div.
Lilly Indust. Coatings, Inc.
Marcor Inc.
Montgomery Ward & Co. ,
subsid.
Standard T. Chem. Co.,
Inc., subsid.
McCloskey Varnish Co.
Wheeling, IL
Paterson, NJ
Carpentersville, IL
Minneapolis, MN
Matteson, IL
Dallas, TX
San Carlos, CA
Denver, CO
Bridgeville, PA
Everett, MA
Bensenville, IL
Indianapolis, IN
Montebello, CA
Chicago Heights, IL
Staten Island, NY
Los Angeles, CA
Philadelphia, PA
Portland, OR
235
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 IDS)
Midwest Mfg. Corp.
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
Benjamin Moore & Co.
Morris Indust. Inc.
Lanson Chem. Co., div.
Napko Corp.
N L Indust., Inc.
Indust. Chems. Div.
A. P. Nonweiler Co.
Norris Paint & Varnish Co.
The O'Brien Corp.
Fuller-O'Brien Corp.,
subsid.
Onyx Oils & Resins, Inc.
C. J. Osborn Chems., Inc.
Perry & Derrick Co.
Pervo Paint Co.
Plastics Engineering Co.
Polychrome Corp.
Cellomer Corp., subsid.
Burlington, IA
Cleveland, OH
Edison, NJ
Kankakee, IL
Rochester, PA
Cleveland, OH
Los Angeles, CA
Mel rose Park, IL
Newark, NJ
East St. Louis, IL
Houston, TX
Philadelphia, PA
Oshkosh, WI
Salem, OR
Baltimore, MD
South Bend, IN
South San Francisco, CA
Brooker, FL
Newark, NJ
Pennsauken, NJ
Dayton, KY
Los Angeles, CA
Sheboygan, WI
Newark, NJ
236
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
PPG Indust., Inc.
Coatings and Resins Div.
Pratt & Lambert, Inc.
Red Spot Paint & Varnish
Co., Inc.
Reichhold Chems., Inc.
Sterling Div.
Reliance Universal Inc.
Chem. Coatings and Resins
Group
Resinous Chems. Corp.
Resyn Corp.
H. H. Robertson Co.
Freeman Chem. Corp., subsid.
Rohm and Haas Co.
Circleville, OH
East Point, GA
Houston, TX
Oak Creek, WI
Springdale, PA
Torrance, CA
Buffalo, NY
Evansville, IN
Azusa, CA
Detroit, MI
Elizabeth, NO
Houston, TX
Jacksonville, FL
South San Francisco, CA
Tuscaloosa, AL
Sewickley, PA
Brea, CA
Clinton, MS
High Point, NC
Houston, TX
Louisville, KY
Roanoke, VA
Salem, OR
Somerset, NJ
Sunnyvale, CA
Virginia Beach, VA
Zion, IL
Linden, NJ
Linden, NJ
Chatham, VA
Saukville, WI
Philadelphia, PA
237
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Sapolin Paints, Inc.
Schenectady Chems., Inc.
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins Group
The Sherwin-Williams Co.
Sullivan Chem. Coatings
Sybron Corp.
Jersey State Chem. Co., div.
Syncon Resins Inc.
Farnow, Inc., div.
T. F. Washburn Co., div.
Synres Chem. Corp.
Shanco Plastics & Chems.,
subsid.
Textron Inc.
Indust. Product Group
Spencer Kellogg Div.
Kelly-Pickering Chems.
Dept.
Union Camp Corp.
Chem. Products Div.
Valspar Corp.
Midwest Synthetics Co., div.
Brooklyn, NY
Schenectady, NY
Chicago, IL
Cleveland, OH
Reading, PA
San Francisco, CA
Chicago, IL
Cleveland, OH
Dayton, OH
Detroit, MI
Emeryville, CA
Garland, TX
Gibbsboro, NJ
Newark, NJ
Chicago, IL
Haledon, NJ
South Kearny, NJ
Chicago, IL
Anaheim, CA
Elkhart, IN
Kenilworth, NJ
Tonawanda, NY
Baltimore, MD
San Carlos, CA
Valdosta, GA
Rockford, IL
238
-------
Table C-6 (Continued). ALKYD RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Westinghouse Electric Corp,
Insulating Materials Div.
Whittaker Corp.
Whittaker Coatings and Chems.
Mol-Rez Div.
Yenkin-Majestic Paint Corp.
Ohio Polychemicals Co,, div.
West Miffin, PA
Minneapolis, MN
Columbus, OH
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-7. ALKYL PHENOL-ACETYLENE RESIN PRODUCERS2
Company
Polymer Applications, Inc.
Location
Tonawanda, NY
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Pi rectory of Chemi cal Producers, 1976.
239
-------
Table C-8. ANILINE-FORMALDEHYDE RESIN PRODUCERS2
Company
Union Carbide Corp.
Chems. and Plastics Div.
Location
Bound Brook, NJ
Capacity1
Gg(106 Ibs)
lQr\ stream as of January 1, 1976
Producers considered manufacture materials in commercailly salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-9. BUTYL PHENOL-FORMALDEHYDE RESIN PRODUCERS1
Company
Magna Corp.
Location
Houston, TX
Capacity1
Gg(106 Ibs)
X0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
240
-------
Table C-10. CELLULOSE RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Dow Chem. U.S.A.
Eastman Kodak Co.
Eastman Chem. Products,
Inc., subsid.
Tennessee Eastman Co.,
div.
Marcor Inc.
Montgomery Ward and Co.,
subsid.
Standard T Chem. Co.,
Inc., subsid.
Tenneco Inc.
Tenneco Chems., Inc.
Foam and Plastics Div.
Midland, MI
Kingsport, TN
Linden, NO
Nixon, NJ
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
241
-------
Table C-11. COUMARONE-INDENE AND HYDROCARBON RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Chemfax, Inc.
De Soto, Inc.
Exxon Corp.
Exxon Chemicals Co., div.
Exxon Chem. Co. U.S.A.
The Goodyear Tire & Rubber
Co.
Chem. Div.
Hercules Inc.
Organics Dept.
Neville Chem. Co.
Northwest Indust., Inc.
Velsicol Chem. Corp.,
subsid.
Reichhold Chems., Inc.
Newport Div.
Schenectady Chems., Inc.
Gulfport, MS
Chicago Heights, IL
Baton Rouge, LA3
Beaumont, TX
Baton Rouge, LA
Clairton, PA
Nest Elizabeth, PA
Anaheim, CA
Neville Island, PA
Marshall, IL
Gulfport, MS
Rotterdam Junction, NY
L0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
3An expansion which will increase "Escorez" hydrocarbon resins capacity to 200
million pounds per year is scheduled for completion in 1977.
Source: Directory of Chemical Producers, 1976.
242
-------
Table C-12. CRESOL-FORMALDEHYDE RESINS PRODUCERS2
(Unmodified)
Company
Location
Capacity1
Gg(106 Ibs)
The Bendix Corp.
Friction Materials Div.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems. Div.
East
The Budd Co.
Plastic Products Div.
Georgia-Pacific Corp.
Chem. Div.
Reichhold Chems., Inc.
Varcum Chem. Div.
Schenectady Chems., Inc.
Union Carbide Corp.
Chems. and Plastics Div.
Troy, NY
Bainbridge, NY
Fayetteville, NC
Brigeport, PA
Conway, NC
Lufkin, TX
Detroit, MI
Niagara Falls, NY
Rotterdam Junction, NY
Schenectady, NY
Bound Brook, NJ
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
243
-------
Table C-13. CRESYLIC ACID-FORMALDEHYDE RESIN PRODUCERS2
(Unmodified)
Company
Location
Capacity1
Gg(106 Ibs)
The Budd Co.
Plastic Products Div.
Monogram Indust., Inc.
Spaulding Fibre Co.,
subsid.
Napko Corp.
Reichhold Chems., Inc.
Varcum Chem. Div.
Schenectady Chems., Inc.
Bridgeport, PA
De Kalb, IL
Tonawanda, NY
Houston, TX
Detroit, MI
Niagara Falls, NY
i Rotterdam Junction, NY
i Schenectady, NY
X0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-14. DIALLYL PHTHALATE RESIN PRODUCTS'
Company
Allied Chem. Corp.
Specialty Chems. Div.
FMC Corp.
Chem. Group
Tndust. Chem. 'Div.
Location
Los Angeles, CA
Toledo, OH
Baltimore, MD
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
244
-------
Table C-15. DICYANDIAMIDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
American Cyanamid Co.
Indust. Chems. and Plastics
Div.
Apex Chem. Co., Inc.
De Paul Chem. Co., Inc.
ICI United States Inc.
Mgf. Div. for Specialty
Chems. and Dyes & Textile
Chems.
Kewanee Indust. Inc.
Millmaster Onyx Corp.,
subsid.
Refined-Onyx Div.
United Merchants & Mfgs., Inc.
Valchem-Chem. Div.
USM Corp.
Crown-Metro, Inc., subsid.
Wallingford, CT
Elizabethport, NO
Long Island City, NY
Dighton, MA
Lyndhurst, NJ
Langley, SC
Greenville, SC
J0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually
Source: Directory of Chemical Producers, 1976.
Table C-16. DIMETHYL HYDANTOIN-FORMALDEHYDE RESIN PRODUCERS'
Company
Glyco
Chems., Inc.
I
Location j
Capacity1
Gg(106 Ibs)
i
Williamsport, PA <
lQr\ stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
245
-------
Table C-17. EPOXY RESIN PRODUCERS2
(Unmodified)
Company
Location
Capacity1
Gg(106 Ibs)
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co.,
subsid.
Celanese Resins Div.
Ciba-Geigy Corp.
Plastics and Additives Div.
Resins Dept.
Dow Chem. U.S.A.
Polychrome Corp.
Cellomer Corp., subsid.
Pratt & Lambert, Inc.
Reichhold Chems., Inc.
Resyn Corp.
Seton Co.
Wilmington Chem. Corp.,
div.
Shell Chem. Co.
Polymers and Detergent
Products
Union Carbide Corp.
Chems. and Plastics Div.
Louisville, KY
Toms River, NJ
Freeport, TX
Newark, NJ
Buffalo, NY
Andover, MA
Azusa, CA
Detroit, MI
Houston, TX
Linden, NJ
Wilmington, DE
Deer Park, TX
Taft, LA
11 (25)
27 (60)
34 (75)
n.a.
n.a.
15 (32)
11 (25)
2 (4)
45 (100)
3 (6)
TOTAL 148 (327)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
246
-------
Table C-18. EPOXY RESIN PRODUCERS2
(Modified)
Company
Location
Capacity1
Gg(106 Ibs)
Adhesive Products Corp.
Allied Chem. Corp.
Specialty Chems. Div.
Allied Products Corp.
Acme Chems. Div.
American Can Co.
M&T Chems. Inc.,
subsid.
Furane Plastics, Inc.,
subsid.
Applied Plastics Co. Inc.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
di v.
Resins and Plastics Div.
Bennett's
Carboline Co.
Moran Paint Co., subsid.
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co., subsid.
Celanese Resins Div.
Ciba-Geigy Corp.
Plastics and Additives Div.
Resins Dept.
Cook Paint & Varnish Co.
Degan Oil & Chem. Co.
Dennis Chem. Co.
Bronx, NY
Los Angeles, CA
Toledo, OH
New Haven, CT
Los Angeles, CA
El Segundo, CA
Valley Park, MO
Salt Lake City, UT
Xenia, OH
Belvidere, NJ
Los Angeles, CA
Louisville, KY
Mclntosh, AL
Detroit, MI
Houston, TX
North Kansas City, MO
Jersey City, NJ
St. Louis, MO
247
-------
Table C-18 (Continued). EPOXY RESIN PRODUCERS2 (Modified)
Company
Location
Capacity1
Gg(106 Ibs)
De Soto, Inc.
The Dexter Corp.
Hysol Div.
Midland Div.
Dow Chem. U.S.A.
Elliott Paint & Varnish Co.
Armstrong Paint Co., div.
Essex Chem. Corp.
BFC Div.
The Flamemaster Corp.
Chem-Seal Corp., div.
Guardsman Chems., Inc.
Hardman Inc.
Hexcel Corp.
Rezolin Div.
Inmont Corp.
Isochem Resins Co.
Lawter Chems., Inc.
Stresen-Reuter Div.
Marcor Inc.
Montgomery Ward & Co.,
subsid.
Standard T Chem. Co.,
Inc., subsid.
Midwest Mfg. Corp.
Berkeley, CA
Chicago Heights, IL
Garland, TX
City of Industry, CA
Olean, NY
Cleveland, OH
Hayward, CA
Rocky Hill, CT
Waukegan, IL
Torrance, CA
Chicago, IL
Sayreville, NJ
Sun Valley, CA
Grand Rapids, MI
Belleville, NJ
Chatsworth, CA
Cincinnati, OH
Greenville, OH
Lincoln, RI
Bensenville, IL
Chicago Heights, IL
Dallas, TX
Staten Island, NY
Burlington, IA
248
-------
Table C-18 (Continued). EPOXY RESIN PRODUCERS2 (Modified)
Company
Location
Capacity1"
Gg(106 Ibs)
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
Napco Corp.
North American Philips Corp.
Thompson-Hayward Chem. Co.,
subs id.
Leffingwell Chem. Co.,
subsid.
The O'Brien Corp.
Fuller-O'Brien Corp., subsid.
Onyx Oils & Resins Inc.
C. J. Osborn Chems., Inc.
Owens-Corning Fiberglas Corp.
Resins and Coatings Div.
Plastics Engineering Co.
Poly Resins, Inc.
PPG Indust., Inc.
Coatings and Resins Div.
Reichhold Chems., Inc.
Sterling Div.
Resyn Corp.
Schenectady Chems., Inc.
Cleveland, OH
Kankakee, IL
Pittsburgh, PA
Houston, TX
Brea; CA
South Bend, IN
South San Francisco, CA
Newark, NJ
Pennsauken, NJ
Anderson, SC
Sheboygan, WI
Sun Valley, CA
East Point, GA
Houston, TX
Oak Creek, WI
Torrance, CA
Azusa, CA
Detroit, MI
Elizabeth, NJ
South San Francisco, CA
Sewickley, PA
Linden, NJ
Schenectady, NY
249
-------
Table C-18 (Continued). EPOXY RESIN PRODUCERS2 (Modified)
Company
Location
Capacity1
Gg(106 IDS)
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins Group
Seton Co.
Wilmington Chem. Corp., div.
Shell Chem. Co.
Base Chems
The Sherwin-Williams Co.
Syncon Resins, Inc.
Farnow, Inc., div.
T. F. Washburn Co., div.
Synres Chem. Corp.
Synthane-Taylor Corp.
United States Gypsum Co.
Permalastic Products Co.
subsid.
Valspar Corp.
Westinghouse Electric Corp.
Insulating Materials Div.
Whittaker Corp.
Whittaker Coatings and Chems.
Wooster Universal Div.
Chicago, IL
Cleveland, OH
Reading, PA
San Francisco, CA
Wilmington, DE
Deer Park, Texas:
Chicago, IL
South Kearny, NJ
Chicago, IL
Kenilworth, NJ
Betzwood, PA
LaVerne, CA
Gypsum, OH
Detroit, MI
Trenton, NJ
Minneapolis, MN
West Miff!in, PA
Wooster, OH
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
3A new 200 million pound-per-year epoxy resins plant is planned; construction is
expected to begin in late 1976 and be completed in late 1978
Source: Directory of Chemical Producers, 1976.
250
-------
Table C-19. ETHYLENE-MALEIC ANHYDRIDE COPOLYMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Monsanto Co.
Monsanto Indust. Chems. Co.
Luling, LA
Texas City, TX
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976
251
-------
Table C-20. ETHYLENE-VINYL ACETATE COPOLYMER RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Air Products and Chems., Inc.
Polymer Chems. Div.
Allied Chem. Corp.
Specialty Chems. Div.
Borden Inc.
Borden Chem. Div.
Thermoplastic Products
Dow Chem. U.S.A.
E. I. du Pont de Nemours &
Co., Inc.
Plastics Products and Resins
Dept.
Polymer Intermediates Dept.
National Distillers and Chem.
Corp.
Chems. Div.
U.S. Indust. Chems. Co.,
div.
Union Carbide Corp.
Chems. and Plastics Div.
Union Oil Co. of California
AMSCO Div.
Calvert City, KY
Middlesex, NJ3
Orange, TX
Bainbridge, NY
Compton, CA
Demopolis, AL
Illiopolis, IL
Leominster, MA
Midland, MI
Orange, TX
Seneca, IL
Seneca, IL
Tuscola, IL
Institute and South
Charleston, WV
Charlotte, NC
La Mirada, CA
stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually
3An expansion of ethylene-vinyl acetate copolymer resins which doubled capacity has
come on stream since January 1, 1976
Source: Directory of Chemical Producers, 1976.
252
-------
Table C-21. FLUOROCARBON RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Allied Chem. Corp.
Specialty Chems. Div.
E. I. du Pont de Nemours
& Co., Inc.
Plastics Products and Resins
Dept.
ICI United States Inc.
Plastics Div.
Marcor Inc.
Montgomery Ward & Co.,
subs id.
Standard T Chem. Co.,
Inc., subsid.
Minnesota Mining and Mfg.,
Co.
Commercial Chems. Div.
Pennwalt Corp.
Chem. Div.
Elizabeth, NJ
Parkersburg, WV
Bayonne, NJ
Staten Island, NY
Decatur, AL
Calvert City, KY
*0n stream as of January 1, 1976
Producers considered manufacture materials in comrnercailly salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
253
-------
Table C-22. FURAN RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
American Can Co.
M&T Chems. Inc., subsid.
Furane Plastics, Inc.,
subsid.
Ashland Oil, Inc.
Ashland Chem. Co., div.
Chem. Products Div.
Combustion Engineering, Inc.
C-E Cast Indust. Products
Div.
Core-Lube, Inc.
CPC Internal11 Inc.
Acme Resin Co., div.
Delta Oil Products Corp.
Eronel Indust.
ESB Inc.
Atlas Minerals and Chems.
Div.
Hercules Inc.
Haveg Indust., Inc.,
subsid.
Marshall ton Operation
Hill & Griffith Co.
Mar-Cam Div.
Internet'1 Minerals &
Chem. Corp.
Aristo Internet'1 Corp.,
subsid.
Foundry Products Div.
Los Angeles, CA
Hammond, IN
Muse, PA
Grovelane, IL
Forest Park, IL
Milwaukee, WI
Hawthorne, CA
Mertztown, PA
Wilmington, DE
Hickory, NC
Detroit, MI
254
-------
Table C-22 (Continued). FURAN RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Koppers Co., Inc.
Thiem Corp., subsid.
Kordell Indust.
Occidental Petroleum Corp.
Hooker Chems. and Plastics
Corp., subsid.
Durez Div.
Reichhold Chems., Inc.
Varcum Chem. Div.
United-Erie, Inc.
Milwaukee, WI
Oak Creek, WI
Mishawaka, IN
Kenton, OH
North Tonawanda, NY
Niagara Falls, NY
Erie, PA
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-23. GLYOXAL-FORMALDEHYDE RESINS PRODUCERS1
Company
Location
Capacity1
Gg(106 Ibs)
National Starch and Chem. Corp.
Proctor Chem. Co., subsid.
U.S. Oil Co.
Southern U.S. Chem. Co., Inc.
subsid.
USM Corp.
Crown-Metro, Inc., subsid.
Salisbury, NC
Rock Hill, SC
Greenville, SC
^n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
255
-------
Table C-24. IONOMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
E. I. du Pont de Nemours & Co.
Plastics Products and
Resins Dept.
Orange, TX
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-25. KETONE-ALDEHYDE RESIN PRODUCERS2
Company
Sun Chem. Corp.
Chems. Group
Chems. Div.
Location
Chester, SC
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-26. MALEIC RESIN PRODUCERS'
Company
Synres Chem. Corp.
Location
Kenilworth, NJ
Capacity1
Gg(10'J Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers. 1976.
256
-------
Table C-27. MELAMINE-FORMALDEHYDE RESINS PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Allied Chem. Corp.
Specialty Chems. Div.
American Cyanamid Co.
Indust. Chems. and Plastics
Div.
Organic Chems. Div.
Formica Corp., subsid.
Ashland Oil, Inc.
Lehigh Valley Chem. Co., div
Resins and Plastics Div.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems. Div.
West
Cargill, Inc.
Chem. Products Div.
Celanese Corp.
Celanese Coatings and
Specialty
Chems. Co., subsud.
Celanese Resins Div.
Commercial Products Co.
Cook Paint & Varnish Co.
Dan River, Inc.
Dock Resins Corp.
Toledo, OH
Azusa, CA
Kalamazoo, MI
Wallingford, CT
Charlotte, NC
Evandale, OH
Calumet City, IL
Fords, NJ
Los Angeles, CA
Kent, WA
Springfield, OR
Carpentersville, IL
Lynwood, CA
Philadelphia, PA
Louisville, KY
Hawthorne, NJ
Detroit, MI
North Kansas City, MO
Danville, VA
Linden, NJ
257
-------
Table C-27 (Continued). MELAMINE-FORMALDEHYDE RESINS PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Georgia-Pacific Corp.
Chem. Div.
Guardsman Chems., Inc.
Gulf Oil Corp.
Gulf Oil Chems. Co., div.
Indust. and Specialty
Chems. Div.
Hart Products Corp.
Koppers Co., Inc.
Organic Materials Div.
Mobil Oil Corp.
Mobil Chem. Co. div.
Chem. Coatings Div.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Albany, OR
Columbus, OH
Conway, NC
Coos Bay, OR
Louisville, MS
Lufkin, TX
Russellville, SC
Savannah, GA
Taylorsville, MS
Vienna, GA
irand Rapids, MI
High Point, NC
Lansdale, PA
Shawano, WI
West Memphis, AR
Jersey City, NJ
Bridgeville, PA
Kankakee, IL
Addyston, OH
Chocolate Bayou, TX
Eugene, OR
Santa Clara, CA
Springfield, MA
258
-------
Table C-27 (Continued). MELAMINE-FORMALDEHYDE RESINS PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
National Starch and Chem. Corp
Proctor Chem. Co., subsid.
Onyx Oils & Resins, Inc.
Owens-Corning Fiberglas Corp.
Resins and Coatings Div.
Perstorp U.S. Inc.
Plastics Engineering Co.
Plastics Mfg. Co.
PPG Indust., Inc.
Coatings and Resins Div.
Reichhold Chens., Inc.
Reliance Universal Inc.
Chem. Coatings and Resins
Group
Renroh Inc.
Riegel Textile Corp.
H.I.T. Chems. Div.
Salisbury, NC
Brooker, FL
Newark, NJ
Newark, OH
Florence, MA
Sheboygan, WI
Dallas, TX
Circleville, OH
Oak Creek, WI
Andover, MA
Detroit, MI
Malvern, AR
South San Francisco,CA
Tacoma, WA
Tuscaloosa, AL
White City, OR
Brea, CA
Clinton, MI
High Point, NC
Houston, TX
Louisville, KY
Roanoke, VA
Salem, OR
Somerset, NJ
Sunnyvale, CA
Virginia Beach, VA
Zion, IL
New Bern, NC
Ware Shoals, SC
259
-------
Table C-27 (Continued). MELAMINE-FORMALDEHYDE RESINS PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Rohm and Haas Co.
Scher Brothers, Inc.
Scott Paper Co.
Packaged Products Div.
The Sherwin-Williams Co.
Skelly Oil Co.
Chembond Corp., subsid.
Sou-Tex Chem. Co., Inc.
Sun Chem. Corp.
Chems. Group
Chems. Div.
Sybron Corp.
Jersey State Chem. Co., div.
Synthane-Taylor Corp.
Synthron, Inc.
United Merchants & Mfgs., Inc.
Valchem - Chem. Div.
t
U.S. Oil Co.
Southern U.S. Chem. Co., Inc
subsid.
Univar Corp.
Pacific Resins & Chems.,
Ind., subsid.
hiladelphia, PA
lifton, NJ
hester, PA
Mobile, AL
)leveland, OH
Newark, NJ
pringfield. OR
tount Holly, NC
tester, SC
Haledon, NJ
Betzwood, PA
LaVerne, CA
Ashton, RI
Morganton, NC
Langley, SC
East Providence, RI
Rock Hill, SC
Newark, OH
Portland, OR
Richmond, CA
260
-------
Table C-27 (Continued). MELAMINE-FORMALDEHYDE RESINS PRODUCERS1
Company
Location
Capacity1
Gg(106 Ibs)
Virginia Chems. Inc.
Indust. Chems. Dept.
Westinghouse Electric Corp.
Insulating Materials Div.
Weyerhaeuser Co.
Portsmouth, VA
West Miff!in, PA
Longview, WA
Marshfield, WI
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually.
3A methylated melamine-formaldehyde resins plant is planned, completion is scheduled
for 1976.
Source: Directory of Chemical Producers, 1976.
261
-------
Table C-28. METHYL VINYL ETHER-MALEIC ANHYDRIDE COPOLYMER RESIN PRODUCERS1
Company
GAP Corp
Chem.
Products
Location
Calvert City, KY
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
2Producers considered manufacture materials in commercailly salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-29. METHYL VINYL ETHER-MONO BUTYL MALEATE COPOLYMER RESIN PRODUCERS'
Company
GAP Corp
Chem.
Products
Location
Calvert City, KY
Capacity1
Gg(10G Ibs)
X0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs. annually
Source: Directory of Chemical Producers, 1976.
Table C-30. METHYL VINYL ETHER-MONO ETHYL MALEATE COPOLYMER RLSIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
GAP Corp.
Chem. Products
Calvert City, KY
J0n stream as of January 1, 1976
2Producers considered manufacture materials in commercailly salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
-------
Table C-31. METHYL VINYL ETHER POLYMER RESIN PRODUCERS'
Company Location Gg(TOMbs)
GAF Corp.
Chem. Products Calvert City, KY
lQr\ stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
263
-------
Table C-32. PHENOL-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Allied Chem. Corp.
Specialty Chems. Div.
American Cyanamid Co.
Formica Corp., subsid.
Ashland Oil, Inc.
Lehigh Valley Chem. Co., div.
Resins and Plastics Div.
The Bendix Corp.
Friction Materials Div.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems.
Div. - East
Adhesives and Chems.
Div. - West
The Budd Co.
Plastic Products Div.
Carboline Co.
Moran Paint Co., subsid.
The Carborundum Co.
Polymers Venture
Champion Internat'l Corp.
U.S. Plywood Div.
Clark Oil & Refining Corp.
Clark Chem. Corp., subsid.
Los Angeles, CA
Toledo, OH
Evandale, OH
Calumet City, IL
Fords, NJ
Newark, NJ
Pensacola, FL
Troy, NY
Bainbridge, NY
Demopolis, AL
Diboll, TX
Fayetteville, NC
Sheboygan, WI
Fremont, CA
Kent, WA
La Grande, OR
Missoula, MT
Springfield, OR
Bridgeport, PA
Xenia, OH
Niagara Falls, NY
Anderson, CA
Blue Island, IL
264
-------
Table C-32 (Continued). PHENOL-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
CPC Internet11 Inc.
Acme Resin Co., div.
De Soto, Inc.
Gen. Electric Co.
Plastics Business Div.
Engineering Plastics
Product Dept.
The P.O. George Co.
Georgia-Pacific Corp.
Chem. Div.
Gulf Oil Corp.
Gulf Oil Chems. Co., div.
Indust. and Specialty
Chems. Div.
Hercules Inc.
Haveg Indust., Inc.,
subsid.
Marshall ton Operation
Heresite & Chem. Co.
1C Indust., Inc.
Abex Corp., subsid.
Friction Products Group
Forest Park, IL
Berkeley, CA
Chicago Heights, IL
Garland, TX
Pittsfield, MA
St. Louis, MO
Albany, OR
Columbus, OH
Conway, NC
Coos Bay, OR
Crossett, AR
Louisville, MS
Lufkin, TX
Russellville, SC
Savannah, GA
Taylorsville, MS
Vienna, GA
High Point, NC
Lansdale, PA
Wilmington, DE
Manitowoc, WI
Troy, MI
265
-------
Table C-32 (Continued). PHENOL-FORMALDEHYDE RESIN PRODUCERS1
Company
Location
Capacity1
Gg (106 Ibs)
Inland Steel Co.
Inland Steel Container Co.,
di v.
Inmont Corp.
The Ironsides Co.
Kewanee Indust., Inc.
Mill master Onyx Corp.,
subsid.
Refined-Onyx Div.
Knoedler, Alphonse & Co.
Knoedler Chem. Co.,
subsid.
Koppers Co., Inc.
Organic Materials Div.
Lawter Chems., Inc.
Masonite Corp.
Alpine Div.
Monogram Indust., Inc.
Spaulding Fibre Co.,
subsid.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Napko Corp.
Alsip, IL
Anaheim, CA
Chicago, IL
Cincinnati, OH
Elizabeth, NJ
Grand Rapids, MI
Greenville, OH
Huntington, IN
Los Angeles, CA
Morganton, NC
Columbus, OH
Lyndhurst, NJ
Lancaster, PA
Petrolia, PA
South Kearny, NO
Gulfport, MS
De Kalb, IL
Tonawanda, NY
Addyston, OH
Chocolate Bayou, TX
Eugene, OR
Springfield, MA
Houston, TX
266
-------
Table C-32 (Continued). PHENOL-FORMALDEHYDE RESIN PRODUCERS5
Company
Location
Capacity1
Gg(106 Ibs)
Occidental Petroleum Corp.
Hooker Chems. and Plastics
Corp., subsid.
Durez Div.
Onyx Oils & Resins, Inc.
Owens-Corning Fiberglas Corp.
Resins and Coatings Div.
Pioneer Plastics Corp.
Chem. Div.
Plastics Engineering Co.
Polymer Applications, Inc.
Polyrez Co., Inc.
Raybestos-Manhattan, Inc.
Adhesives Dept.
Reichhold Chems., Inc.
Varcum Chem. Di v.
Rogers Corp.
Rohm and Haas Co.
Kenton, OH
North Tonawanda, NY
Brooker, FL
Newark, NJ
Barrington, NJ
Newark, OH
Waxahachie, TX
Auburn, ME
Sheboygan, WI
Tonawanda, NY
Woodbury, NJ
Stratford, CT
Andover, MA
Azusa, CA
Carteret, NJ
Detroit, MI
Elizabeth, NJ
Houston, TX
Kansas City, KS
Moncure, NC
South San Francisco, CA
Tacoma, WA
Tuscaloosa, AL
White City, OR
Niagara Falls, NY
Manchester, CT
Philadelphia, PA
267
-------
Table C-32 (Continued). PHENOL- FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Schenectady Chems., Inc.
Simpson Timber Co.
Chems. Div.
Skelly Oil Co.
Chembond Corp., subsid.
Synres Chem. Corp.
Shanco Plastics & Chems.,
subsid.
Union Carbide Corp.
Chems. and Plastics Div.
United-Erie, Inc.
Univar Corp.
Pacific Resins & Chems., Inc.
subsid.
Valentine Sugars, Inc.
Valite Div.
West Coast Adhesives Co.
Westinghouse Electric Corp.
Insulating Materials Div.
Weyerhaeuser Co.
Rotterdam Junction, NY
Schenectady, NY
Portland, OR
Andalusia, AL
Spokane, WA
Springfield, OR
Winnfield, LA
Kenilworth, NJ
Tonawanda, NY
Bound Brook, NJ
Elk Grove, CA
Marietta, OH
Texas City, TX
Erie, PA
Eugene, OR
Newark, OH
Portland, OR
Richmond, CA
Lockport, LA
Portland, OR
West Miffin, PA
Longview, WA
Marshfield, WI
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
268
-------
Table C-33. PHENOL-RESORCINOL-FORMALDEHYDE RESIN PRODUCERS'
Company
Gulf Oil Corp.
Gulf Oil Chens. Co. , div.
Indust. and Specialty
Chems. Div.
Location
High Point, NC
Lansdale, PA
Capacity1
Gg(106 Ibs)
!Qn stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
269
-------
Table C-34. POLYAMIDE RESIN PRODUCERS1
Company
Location
Capacity1
Gg(106 Ibs)
Allied Chem. Corp.
Fibers Div.
Alrac Corp.
AZS Corp.
A Z Products, Inc.,
div.
Bel ding Heminway Co. Inc.
Belding Chem. Indust.,
subsid.
Borden Inc.
Borden Chem. Oiv.
Adhesives and Chems.
Div. - East
The Budd Co.
Plastic Products Div.
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co.,
subsid.
Celanese Resins Div.
Cooper Polymers, Inc.
Crosby Chems., Inc.
Custom Resins Inc.
Dow Badische Co.
E.I. Du Pont de Nemours &
Co., Inc.
Plastics Products and
Resins Dept.
Chesterfield, VA
Stamford, CT
Eaton Park, FL
Grosvenordale, CT
Bainbridge, NY
Phoenixville, PA
Louisville, KY
Wilmington, MA
Picayune, MS
Henderson, KY
Freeport, TX
Parkersburg, WV
8 (18) Nylon 6
1 (2) Nylon 4, captive
2 (5) Non-nylon resins;
2 (4) Nylon 66 and 69
2
1
1
4
7
(2)
n.a.
(5)
(2)
(1)
(9)
(15)
Paper-treating resins
made by condensing a
dibasic acid with a
polyalkalene-polyamine
and subsequently re-
acting this product
with epichlorohydrin.
Nylon 6; Captive
Non-nylon resins3
Non-nylon resins3
Non-nylon resins3
Nylon 6
Nylon 6
45 (100) Nylon 6, 66, 612
2 (5) Non-nylon resins3 for
textiles and adhesives
270
-------
Table C-34 (Continued). POLYAMIDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
El Paso Natural Gas Co.
Beaunit Corp., subsid.
Beaunit Fibers Div.
Emery Indust., Inc.
The Firestone Tire & Rubber
Co.
Firestone Synthetic Fibers
Co., div.
Foster Grant Co., Inc.
Gen. Mills, Inc.
Gen. Mills Chems., Inc.,
subsid.
Indust. Chems. Operations
Hercules Inc.
Organics Dept.
Lawter Chems. , Inc.
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Napko Corp.
Nylene Corp.
Reichhold Chems., Inc.
Etowah, TN
Cincinnati, OH
Hopewell, VA
Manchester, NH
Kankakee, IL
Chicopee, MA
Hattiesburg, MS
Milwaukee, WI
Portland, OR
Savannah, GA
South Kearny, NO
Edison, NJ
Pensacola, FL
Springfield, MA
Houston, TX
Jenkinsville, SC
Andover, MA
1 (2) Nylon 66
5 (10) Non-nylon resins3
4 (8) Nylon 6
7 (15) Nylon 6
11
11
(25)
(24)
(1)
14 (30)
n.a.
2
1
(5)
(3)
Paper-treating resins
made by condensing a
dibasic acid with a
polyalkalene-polyamine
and subsequently re-
acting this product
with epichlorohydrin.
Non-nylon resins3 for
printing inks
1 (3) Non-nylon resins:
Nylon 66,69,610
Captive
Nylon 6
Non-nylon resins3
271
-------
Table C-34 (Continued). POLYAMIDE RESIN PRODUCERS5
Company
Rilsan Corp.
Rilsan Indust. Inc., div.
Shakespeare Co.
Monofi lament Div.
Sun Chem. Corp.
Chems. Group
Chems. Div.
Union Camp Corp.
Chem. Products Div.
Univar Corp.
Pacific Resins & Chems.
Inc., subsid.
USM Corp.
Bostik Chem. Group
Bostik Div.
Location
Birdsboro, PA
Columbia, SC
Chester, SC
Savannah, GA
Newark, OH 1
Portland, OR
Richmond, CAJ
Middleton, MA
TOTAL
Capacity1
Gg(106 Ibs)
5 (12) Nylon 11, 12
<1 (<1 ) Nylon 6
1 (2) Non-nylon resins3
for printing inks
3 (6) Non-nylon resins3
1 (1) Paper- treating resi
made by condensing
dibasic acid with
a polyalkalene-
polyamine and subse
quently reacting
this product with
epichlorohydrin.
1 (2) Non-nylon resins3
<145 (^319)
T0n stream as of January 1, 1976
^Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
3Usually made by condensing vegetable oil acids with polyamines.
Source: Directory of Chemical Producers, 1976.
272
-------
Table C-35. POLYBUTENE-1 RESINS PRODUCERS2
Company
Witco Chem. Corp.
Polymer Div.
Location
Taft, LA
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
2Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
273
-------
Table C-36. POLYBUTYLENE TEREPHTHALATE PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Eastman Kodak Co.
Eastman Chem. Products,
Inc., subsid.
Tennessee Eastman Co.,
div.
GAP Corp
Chemical Products
Gen. Electric Co.
Plastics Business Div.
Engineering Plastics
Product Dept.
(Valo)®)
The Goodyear Tire &
Rubber Co.
Chem. Div.
Kingsport, TN
Calvert City, KY3
Mount Vernon, IN
Point Pleasant, WV
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
3A new polybutylene terephthalate plant is planned; completion is scheduled for
mid-1977
Source: Directory of Chemical Producers, 1976.
274
-------
Table C-37. POLYCARBONATE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Gen. Electric Co.
Plastics Business Div.
Engineering Plastics
Product Dept.
Mobay Chem. Corp.
Plastics + Coatings
Div.
Mount Vernon, IN
Cedar Bayou, TX
New Martinsvilie, WV
68 (150)
n.a.
18 (40)
TOTAL 86 (190)
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers^ 1976
275
-------
Table C-38. SATURATED POLYESTER RESINS PRODUCERS2
(Excludes resins for polyester fibers)
Company
Location
Capacity1
Gg(106 Ibs)
Adhesive Products Corp.
Allied Chem. Corp.
Specialty Chems. Div.
Nypel, Inc., subsid.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems.
Div. - East
The Carborundum Co.
Polymers Venture
Cargill, Inc.
Chem. Products Div.
Cooper Polymers, Inc.
Degen Oil & Chem. Co.
Gen. Electric Co.
Plastics Business Div.
Engineering Plastics
Product Dept.
Gen. Mills, Inc.
Gen. Mills Chems.,
Inc., subsid.
Indust. Chems.
Operations
The P.O. George Co.
The Goodyear Tire & Rubber
Co.
Chem. Div.
Hanna Chem. Coatings
Corp.
Hanna Chem. Coatings
Co., subsid
Henkel Inc.
Textilana, Div.
Bronx, NY3
West Conshonocken, PA
Bainbridge, NY"
Niagara Falls, NY3
Carpentersville, IL
Lynwood, CA
Philadelphia, PA
Wilmington, MA
Jersey City, NJ
Mount Vernon, IN
Minneapolis, MN
St. Louis, MO
"t 5
Point Pleasant, WV\
Birmingham, AL
Hawthorne, CA3
276
-------
Table C-3G (Continued). SATURATED POLYESTER RESINS PRODUCERS2
(Excludes resins for polyester fibers)
Company
Location
Capacity1
Gg(106 Ibs)
Henkel Inc.
Textilana, Div.
The O'Brien Corp.
Fuller-O'Brien Corp.,
subsid
Polymer Applications, Inc.
Reichhold Chems., Inc.
Sterling Div.
Resyn Corp
The Sherwin-Williams Co.
USM Corp.
Bostik Chem. Group
Bostik Div.
Valspar Corp.
Midwest Synthetics Co.,
div.
Hawthorne, CA
South San Francisco, CA
Tonawanda, NY
Sewickley, PA
Linden, NO
Chicago, IL
Newark, NJ
Middleton, MA
Rockford, IL
*0n stream as of January 1, 1976
2Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
3For other uses (excluding oil-free alkyds)
"For films
5A 25% expansion of polyester resins capacity is planned, completion is scheduled for 1976.
Source: Directory of Chemical Producers. 1976.
277
-------
Table C-39. UNSATURATED POLYESTER RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Alpha Chem. Corp.
American Cyanamid Co.
Indust. Chems. and Plastics
Div.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
div.
Resins and Plastics Div.
AZS Corp.
A Z Products, Inc. div.
Barton Chem. Corp.
Cargill, Inc.
Chem. Products Div.
Cook Paint & Varnish Co.
De Soto, Inc.
Diamond Shamrock Corp.
Diamond Shamrock Chem. Co.
Plastics Div.
Eastman Kodak Co.
Eastman Chem. Products,
Inc., subsid.
Texas Eastman Co., div.
Collierville, TN
Kathleen, FL
Perris, CA
Azusa, CA
Perryburg, OH
Wallingford, CT
Calumet City, IL
Los Angeles, CA
Newark, NJ
Valley Park, MO
Eaton Park, FL
Chicago, IL
Carpentersville, IL
Lynwood, CA
Philadelphia, PA
Detroit, MI
Hialeah, FL
Houston, TX
Mil pitas, CA
North Kansas City, MO
Berkeley, CA
Chicago Heights, IL
Garland, TX
Oxnard, CA
Longview, TX
278
-------
Table C-39 (Continued). UNSATURATED POLYESTER RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
The P. D. George Co.
W. R. Grace & Co.
Hatco Group
Hatco Polyesters Div.
Guardsman Chems., Inc.
1C I United States Inc.
Mfg. Div. for Specialty
Chems. and Dyes & Textile
Chems.
Inmont Corp.
Interplastic Corp.
Commercial Resins Div.
lovite Chems., Inc.
Koppers Co., Inc.
Organic Materials Div.
Mobay Chem. Corp.
Plastics + Coatings Div.
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
The O'Brien Corp.
Fuller-O'Brien Corp.
Occidental Petroleum Corp.
Hooker Chem. Corp., subsid.
Hooker Chems. and Plastics
Corp., subsid.
Durez Div.
St. Louis, MO
Bartow, Fl
Col ton, CA
Jacksonville, AR
Linden, NJ
Swanton, OH
Grand Rapids, MI
New Castle, DE
Cincinnati, OH
Detroit, MI
Greenville, OH
Minneapolis, MN
Pryor, OK
Matteson, IL
Bridgevilie, PA
Richmond, CA
New Martinsvilie, WV
Pittsburgh, PA
South Bend, IN
South San Francisco,C
Kenton, OH
North Tonawanda, NY
279
-------
Table C-39 (Continued). UNSATURATED POLYESTER RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Onyx Oils & Resins, Inc.
C. J. Osborn Chems., Inc.
Owens-Corning Fiberglas Corp
Resins and Coatings Div.
Polychrome Corp.
Cellomer Corp., subsid.
PPG Indust., Inc.
Coatings and Resins Div.
Reichhold Chems., Inc.
Sterling Div.
Reliance Universal Inc.
Chem. Coatings and Resins
Group
Resinous Chems. Corp.
Resyn Corp.
H.H. Robertson Co.
Freeman Chem. Corp., subsid.
Newark, NJ
Pennsauken, NJ
Anderson, SC
Valparaiso, Ind.
Newark, NJ
Cheswold, DE3
Circleville, OH
Houston, TX
Springdale, PA
Torrance, CA
Azusa, CA3
Detroit, MI
Elizabeth, NJ
Houston, TX
Jacksonville, FL
Morris, IL"
South San Francisco, CA
Tacoma, WA
Sewickley, PA
Brea, CA
Clinton, MS
High Point, NC
Houston, TX
Louisville, KY
Roanoke, VA
Salem, OR
Somerset, NJ
Sunnyvale, CA
Virginia Beach, VA
Zion, IL
Linden, NJ
Linden, NJ
Chatham, VA
Saukville, WI
280
-------
Table C-39 (Continued). ITJSATURATED POLYESTER RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 IDS)
Rockwell Internat'l Corp.
Automotive Products Div.
Reinforced Plastics
Operations
Rohm and Haas Co.
Rohm and Haas Tennessee
Inc., subsid
Schenectady Cnems., Inc.
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins
Group
The Sherwin-Williams Co.
The Standard Oil Co. (Ohio)
Vistron Corp., subsid.
Chems. Dept.
Filon/Silmar Div.
Syncon Resins Inc.
Farnow, Inc., div.
T.F. Washburn Co., div.
Synres Chem. Corp.
United-Erie, Inc.
United Merchants & Mfgs.,
Inc.
American Plastics Div.
Glascoat Div.
Thalco Div.
USM Corp.
Bostik Chem. Group
Bostik Div.
Westinghouse Electric Corp.
Insulating Materials Div.
Ashtabula, OH
Philadelphia, PA
Knoxville, NY
Schenectady, NY
Chicago, IL
Cleveland, OH
Huron, OH
Reading, PA
San Francisco, CA
Cleveland, OH
Emeryville, CA
Covington, KY
Hawthorne, CA
South Kearny, NJ
Chicago, IL
Anaheim, CA
Elkhart, IN
Erie, PA
Elkhart, IN
Miami, FL
Los Angeles, CA
Middleton, MA
West MiffTin, PA
281
-------
Table C-39 (Continued). UNSATURATED POLYESTER RESIN PRODUCERS2
(Includes alkyd molding compounds)
Company
Location
Capacity1
Gg(106 Ibs)
Whittaker Corp.
Whittaker Coatings and Chems.
Lenoir Div.
Mol-Rez Div.
Ram Div.
Lenoir, NC
Minneapolis, MN
Gardena, CA
*0n stream as of January 1, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
3A new polyester resins plant is planned
"*An expansion is planned which will increase unsaturated polyester resins capacity
to 130 million pounds per year; completion of the multi-million-dollar plant is
scheduled for 1976.
5A new 100 million pound per year unsaturated polyester resins plant is under con-
struction; completion is scheduled for mid-1976.
Source: Directory of Chemical Producers, 1976.
282
-------
Table C-40. POLYETHYLENE RESIN PRODUCERS16
Company
Location
Capacity15
Gg(106 Ibs)
Allied Chem. Corp.
Specialty Chems. Div.
American Petrofina, Inc.
Cosden Oil & Chem. Co.,
subsid.
ARCO/Polymers, Inc.
Chemplex Co.
Cities Service Co., Inc.
Plastics and Special
Products Div.
Cities Service Co., Inc.
Columbian Div.
Dart Indust. Inc.
Chem. Group
Plastic Raw Materials
Sector
Rexene Polymers Co.
Dow Chem. U.S.A.
E. I. du Pont de Nemours &
Co., Inc.
Plastics Products and
Resins Dept.
Baton Rouge, LA
Orange, TX
Calumet City, IL
Port Arthur, TX
Clinton, IA
Lake Charles, LA
Lake Charles, LA1
Odessa, TX
Bayport, TX2
Freeport, TX
Plaquemine, LA3
Orange, TX
Victoria, TX"
100 (353) H; Phillips
11 (25) H
18 (40) L; Allied; PE emulsions
6 (13) L; PE emulsions
68 (150)
182 (400)
141 (310)
86 (190)
H
L; Conventional
L; Du Pont
H; Phillips
125 (275) L; Conventional
297 (380)
50 (110)
300 (660)
79 (175)
163 (360)
211 (465)
104 (230)
109 (240)
L; Conventional;
jointly owned with
El Paso Products Co.
H
L
H; Conventional
L
L; Du Pont
H
L; Conventional
283
-------
Table C-40 (Continued). POLYETHYLENE RESIN PRODUCERS16
Company
Location
Capacity15
Gg(106 Ibs)
Eastman Kodak Co.
Eastman Chem. Products, Inc.,
subsid.
Texas Eastman Co., div.
El Paso Natural Gas
El Paso Products Co., subsid.
Exxon Corp.
Exxon Chem. Co., div.
Exxon Chem. Co. U.S.A.
Gulf Oil Corp.
Gulf Oil Chems. Co., div.
Plastics Div.
Mobil Oil Corp.
Mobil Chem Co. div.
Chem. Coatings Div.
National Distillers and Chem.
Corp.
Chems. Div.
U.S. Indust. Chems. Co.
div.
National Petro Chems. Corp.
Northern Natural Gas Co. .
Northern Petrochem. Co.,1
subsid.
Polymers Div.
Phillips Petroleum Co.
Plastics Div.
Longview, TX
Bayport, TX!
Baton Rouge, LA6
Cedar Bayou, TX7
Orange, TX8
Beaumont, TX-
Deer Park, TX10
Tuscola, IL
La Porte, TX
11
Morris, IL
1 2
Pasadena, TX
114 (250) L; Conventional;
PE emulsions
200 (440) L; Rexall
123 (270)
136 (300)
109 (240)
159 (350)
68 (150)
159 (350)
279 (615)
250 (550)
L; Conventional
L
H
L; Conventional
H; Phillips; jointly
owned with Owens-
Illinois, Inc.
Phillips; includes ,
140 million pounds of
capacity that can be
used for L.
284
-------
Table C-40 (Continued). POLYETHYLENE RESIN PRODUCERS
1 6
Company
Location
Capacity15
Gg(106 Ibs)
Pressure Chem. Co.
Soltex Polymer Corp.
Standard Oil Co. (Indiana)
Amoco Chems. Corp., subsid.
Union Carbide Corp.
Chems. and Plastics Div.
Union Carbide Caribe, Inc.,
subsid.
Pittsburgh, PA
Deer Park, TX
Chocolate Bayou, TX
Seadrift, TX11+
Taft, LA
Texas City, TX
Torrance, CA
Penuelas, PR
TOTAL
1 3
n.a.
200 (440) H; Phillips
68 (150) H
154 (340) L; Phillips
154 (340) H
n.a.
125 (275) L; Conventional
75 (165) L
141 (310) L
4500 (9911)
Notes: H - high density, low pressure
L - low density, high pressure
High density: Specific gravity over 0.940
Medium density: Specific gravity 0.926 to 0.940 (medium density material is
usually in low density)
Low density: Specific gravity 0.925 and lower
In certain instances high density polyethylene capacity could be converted to
polypropylene capacity. Process included under remarks.
xAn expansion is under construction which will increase polyethylene resins capacity
from 275 million pounds to 350 million pounds per year; completion was scheduled for
March, 1976.
2A new 150 million pounds-per-year low density polyethylene resins plant is planned;
construction will begin the third quarter of 1976; completion is scheduled for early
1978.
3An expansion is planned which will increase high density polyethylene resin capacity
to 250 million pounds per year; completion is scheduled for early 1977.
4A new 225 million pounds-per-year high density polyethylene resins plant came on
stream in late 1975.
5A new 150 million pound-per-year low density polyethylene plant is planned; construc-
tion will begin the third quarter of 1976; completion is scheduled for early 1978.
285
-------
Table C-40 (Continued). POLYETHYLENE RESIN PRODUCERS16
6An expansion is planned which will increase low density polyethylene resins capacity
by 220 million pounds to a total of 660 million pounds per year. Completion is
scheduled for mid-1977.
7A 280 million pound per year expansion of low density polyethylene resins capacity is
under construction; completion is scheduled for mid-1977.
8Foster-Wheeler Energy Corp. has been awarded the contract to build a new 240 million
pound-per-year high density polyethylene resins plant; completion is scheduled for
mid-1977.
9Sterns Roger will construct the new 290 million pound-per-year low density polyethylene
resins plant which is planned. Construction was to begin late 1975 with completion
scheduled by late 1977. Output will be used captively.
10An expansion is planned which will increase low density polyethylene resins capacity
from 350 million pounds to a total of 550 million pounds per year; completion is
scheduled for mid-1978.
"H.B. Zachary Co. has been awarded the contract to build a new unit which will increase
high density polyethylene resins capacity by 150 million pounds per year; completion
is scheduled for early 1977.
12A 25 million pound-per-year expansion of polyethylene resins capacity is under con-
struction; completion is scheduled for 1976.
13A 300 million pound-per-year expansion of high density polyethylene resins capacity is
planned; completion is scheduled for 1976.
^A 400 million pound-per-year expansion of low density polyethylene resins capacity is
planned; completion is scheduled for mid-1976.
150n stream as of January 1, 1976.
16Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
286
-------
Table C-41. POLYIMIDE RESIN PRODUCERS2
Company
Location
Type
Capacity1
Gg(106 Ibs)
E. I. du Pont de Nemours
& Co., Inc.
Plastics Products and
Resins Dept.
Gen. Electric Co.
Chem. and Metallurgical
Div.
Laminated and Insulat-
ing Materials Business
Dept.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Standard Oil Co. (Indiana)
Amoco Chems. Corp.,
subsid.
The Upjohn Co.
Polymer Chems. Div.
Newark,DE
Polyimide
Schenectady, NY
Springfield, MA
Joliet, IL
La Porte, TX
Poly(ester-imide)
Polyimide
Polyamide-imide
Polyimide
*0n stream as of January 1, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemcial Producers, 1976
287
-------
Table C-42. POLYPHENYLENE OXIDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Gen. Electric Co.
Plastics Business Div.
Engineering Plastics
Product Dept.
Selkirk, NY
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976
Table C-43. POLYPHENYLENE SULFIDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Phillips Petroleum Co.
Petrochem and Supply
Div.
Phillips, TX
!0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976
288
-------
Table C-44. POLYPROPYLENE RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Dart Indust. Inc.
Chem. Group
Plastic Raw Materials
Sector
Rexene Polymers Co.
Diamond Shamrock Corp.
Diamond Shamrock Chem.
Co.
Plastics Div.
Eastman Kodak Co.
Eastman Chem. Products,
Inc., subsid.
Texas Eastman Co., div.
Exxon Corp.
Exxon Chem. Co., div.
Exxon Chem. Co. U.S.A.
Gulf Oil Corp.
Gulf Oil Chems. Co., div,
Petrochemicals Div.
Hercules Inc.
Polymers Dept.
Northern Natural Gas Co.
Northern Petrochem Co.,
subsid.
Polymers Div.
Novamont Corp.
Phillips Petroleum Co.
Plastics Div.
Shell Chem. Co.
Base Chems.
Polymers and Deter-
gent Products
Standard Oil Co. (Indiana)
Amoco Chems. Corp.,
subsid.
Bayport, TX3
Odessa, TX4
La Porte, TX
Longview, TX;
Baytown, TX'
Cedar Bayou, TX7
Bayport, TX
Lake Charles, LA
Morris, IL8
Kenova, WV9
La Porte, TX10
Pasadena, TX
Norco, LA11
Woodbury, NO
Chocolate Bayou, TX
New Castle, DE
TOTAL
289
64 (140) Captive
73 (160) Merchant
64 (140) Captive
191 (420) Captive
181 (400) Merchant
318 (700) Merchant
73 (160) Merchant
45 (100) Captive
127 (280) Merchant
114 (250)
114 (250)
136 (3000)
Captive
Merchant
-------
Table C-44 (Continued). POLYPROPYLENE RESIN PRODUCERS2
Note: In certain instances polypropylene capacity could be converted to high-density
polyethylene capacity.
*0n stream as of January 1, 1976.
2Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
3A new 150 million pound-per-year polypropylene resins plant is under construction;
completion is scheduled for mid-1976.
**A 10 million pound-per-year expansion of polypropylene resins capacity is planned;
completion is scheduled for 1976.
5An expansion of propylene resins capacity is planned.
6An expansion is being considered which would increase capacity from 420 million
pounds to a total of 750 million pounds per year.
'Arthur G. McKee & Co. has been awarded a contract to build a new 400 million pound
per year polypropylene resins plant; completion of the 100-million dollar project
is scheduled for mid-1978.
8A new 200 million pound-per-year polypropylene resins plant is planned. It will
utilize gas-phase polymerization technology licensed from Germany's BASF AG; comple-
tion is scheduled for mid-1978.
9An expansion of polypropylene resins to 195 million pounds per year is planned;
completion is scheduled for late 1976.
10A new 200 million pound-per-year polypropylene resins plant is planned; completion
is scheduled for late 1977.
1!A new 150 million pound-per-year polypropylene resins plant is planned; completion
is scheduled for late 1977. A second polypropylene resins plant is under construction;
completion of the 150 million pound-per-year plant is scheduled for early 1978.
Source: Directory of Chemical Producers, 1976.
290
-------
Table C-45. POLYSTYRENE RESIN PRODUCERS2
(Straight end rubber-modified)(May include certain styrene
copolymer resins and elastomers)
Company
A & E Plastik Pak Co., Inc.
A & E Plastics Div.
American Petrofina, Inc.
Cosden Oil & Chem. Co. ,
subsid.
ARCO/Polymers, Inc.
BASF Wyandotte Corp.
Colors and Chems. Group
Beatrice Foods Co.
Beatrice Chem. Div.
Polyvinyl Chem. Indust.
Div.
Borden Inc.
Borden Chem. Div.
Thermoplastic Products
Dart Indust. Inc.
Chem. Group
Plastic Raw Materials
Sector
Rexene Polymers Co.
Dow Chem. U.S.A.
Location
City of Industry, CA
Big Spring, TX
Calumet City, IL
Beaver Valley, PA
Jamesburg, NJ
(Styropar®)
Wilmington, MA
Bainbridge, NY
Compton, CA
Demopolis, AL
Illiopolis, IL
Leominster, MA
Holyoke, MA
Joliet, IL
Ludlow, MA
Santa Ana, CA
Allyn's Point, CT
Gales Ferry, CT
Ironton, OH3
Joliet, IL"
Magnolia, AR
Midland, MI
Pevely, MO
Torrance, CA
Capacity1
Gg(106 Ibs)
14 (30) Captive Use
68 (150) Impact polystyrene:
rubber modified
123 (270)
200 (440)
50 (110)
n.a.
n.a. Polystyrene emulsion
n.a. Polystyrene emulsion
n.a. Polystyrene emulsion
n.a. Polystyrene emulsion
n.a. Polystyrene emulsion
25 (55)
18 (40)
5 (10)
16 (35)
54 (120) Polystyrene foam
75 (165) Polystyrene foam
125 (275) Polystyrene foam
n.a. Polystyrene foam
125 (275) Polystyrene foam
5 (10) Polystyrene foam
86 (190) Polystyrene foam
291
-------
Table C-45 (Continued). POLYSTYRENE RESIN PRODUCERS2
(Straight end rubber-modified)(May include certain styrene copolymer resins and elastomers)
Company
Foster Grant Co. , Inc.
Carl Gordon Indust. , Inc.
Gordon Chem. Co. Div.
Hammond Plastics Div.
Hercules Inc.
Organics Dept.
Monsanto Co.
Monsanto Polymers & Petro-
chems. Co.
Morton-Norwich Ptoducts, Inc.
Morton Chem. Co. , div.
Polysar Plastics Inc.
D.C. Div., Polystyrene Plant
Pressure Chem. Co.
Purex Corp.
Reichhold Chems., Inc.
The Richardson Co.
Plastics Group
Polymeric Systems Div.
Location
Chesapeake, VA
Leominster, MA
Peru, IL
Worcester, MA8
Oxford, MA
Oxford, MA
Worcester, MA
Clairton, PA
Addyston, OH5
Decatur, AL
Long Beach, CA
Springfield, MA
Ringwood, IL
Forest City, NC
Pittsburgh, PA
Bristol, PA
Carson, CA
Azusa, CA
Detroit, MI
Elizabeth, NJ
Channel view, TX
Madison, CT
West Haven, CT
Capacity1
Gg(106 Ibs)
68 (150)
55 (120) Polystyrene foam
109 (240) Polystyrene foam
n.a.
n.a.
14 (30)
23 (50)
n.a. Styrene resins,
modified; styrene
copolymers
295 (650)
45 (100)
23 (50)
n.a. Capacity shared with
Addyston, Ohio, plan
n.a. Polystyrene latex
14 (30) Polystyrene resin;
captive use
n.a.
n.a. Polystyrene latex
n.a. Polystyrene latex
n.a. Styrenated resins
n.a. Styrenated resins
n.a. Styrenated resins
18 (40)
n.a.
23 (50)
292
-------
Table C-45 (Continued). POLYSTYRENE RESIN PRODUCERS2
(Straight end rubber-modified)(May include certain styrene copolymer resins and elastomers)
Company
Location
Capacity1
Gg(106 IDS)
Shell Chem. Co.
Polymers and Detergent
Products
Solar Chem. Corp.
A. E. Staley Mfg. Co.
Staley Chem. Div.
Standard Oil Co. (Indiana)
Amoco Chems. Corp., subsid.
Sterling Plastics Corp.
Eastern Sterling Plastics Co.
Sybron Corp.
lonac Chem. Co., div.
Jersey State Chem. Co., div.
Texas Chem. & Plastics Corp.
Union Carbide Corp.
Chems. and Plastics Div.
U.S. Indust. Inc.
E. Helman Co., div.
United States Steel Corp.
USS Chems., div.
Belpre, OH6
Leominster, MA
Kearny, NJ
Lemond, IL
Joliet, IL
Medina, OH
Torrance, CA
Willow Springs, IL
Orange, CA
Windsor, NJ7
Birmingham, NJ
Haledon, NJ
Long Beach, CA
Bound Brook, NJ
Copley, OH
Haverhill, OH
TOTAL
68 (150)
57 (125)
n.a.
n.a.
91 (200)
20 (45)
16 (35)
23 (50)
n.a.
23 (50)
n.a.
n.a.
23 (50)
58 (125)
39 (85)
127 (280)
2315 (5100)
J0n stream as of January 1, 1976.
?Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
3An expansion to 210 million pounds per year of polystyrene resins capacity is planned;
completion is scheduled for 1978.
4A new polystyrene resins plant came on stream in 1975. Completion of a second unit
is scheduled for mid-1976.
293
-------
Table C-45 (Continued). POLYSTYRENE RESIN PRODUCERS2
(Straight end rubber-modified)(May include certain styrene copolymer resins and elastomers)
5A new multimillion dollar plant is under construction which will increase polystyrene
resins capacity by 100 million pounds per year.
6An expansion is planned which will increase polystyrene resins capacity to > 300 million
pounds per year; completion of the first phase is scheduled for 1976 and the second
phase for 1977.
7 A new plant which doubled polystyrene resins capacity to 150 million pounds per year has
come on stream.
8Second plant.
Source: Directory of Chemical Producers, 1976.
294
-------
Table C-46. POLYSULFONE RESIN PRODUCERS2
Company
Minnesota Mining and Mfg. Co.
Commercial Chems. Div.
Union Carbide Corp.
Chems. and Plastics Div.
Location
Decatur, AL
Marietta, OH
Capacity1
Gg(10 Ibs)
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
295
-------
Table C-47. POLYTERPENE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Arizona Chem. Co.
Crosby Chems., Inc.
Hercules Inc.
Organics Dept.
Minnesota Mining and
Mfg. Co.
Chem. Resources Div.
Neville Chem. Co.
Reichhold Chems., Inc.
Newport Div.
Schenectady Chems., Inc
Panama City, FL
Picayune, MS
Clairton, PA
Newark, NJ
Neville Island, PA
Pensacola, FL
Rotterdam Junction, NY
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
Table C-48. POLY(TETRAMETHYLENETEREPHTHALATE)PRODUCERS<
Company
Eastman Kodak Co.
Eastman Chem. Products,
Inc., subsid.
Tennessee Eastman Co.,
div.
Location
Kingsport, TN
Capacity1
Gg(106 Ibs)
1Qr\ stream as of January 1, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976
296
-------
Table C-49. POLYURETHAN FOAM PRODUCERS2
(The following companies react isocyanates or prepolymers with polyols
to produce polyurethan foams. The list is incomplete)
Company
Location
Capacity1
Gg(106 Ibs)
Applied Plastics Co. Inc.
E.R. Carpenter Co., Inc.
Chase Chem. Corp.
Cook Paint & Varnish Co.
Dow Chem. U.S.A.
The Firestone Tire & Rubber
Co.
Firestone Foam Products,
div.
Gen. Latex and Chem.
Corp.
Gen. Motors Corp.
The Gen. Tire & Rubber
Co.
Chemical/Plastics Div.
The B.F. Goodrich Co,
B.F. Goodrich Gen.
Products Co., div.
The Goodyear Tire &
Rubber Co.
Chem. Div.
El Segundo, CA
Conover, NC
La Mirada, CA
Richmond, VA
Russellville, KY
Temple, TX
Pittsburgh, PA
North Kansas City, MO
Ironton, OH
Conover, NC
Corry, PA
Elkhart, IN
Milan, TN3
Thomasville, GA
Ashland, OH
Cambridge, MA
Charlotte, NC
Cucamonga, CA
Dal ton, GA
Dayton, OH
Marion, IN
Orange, CA
Akron, OH
Bakersfield, CA
Logan, OH
Luckey, OH
297
-------
Table C-49 (Continued). POLYURETHAN FOAM PRODUCERS2
(The following companies react isocyanates or prepolymers with polyols to produce poly-
urethan foams. The list is incomplete.)
Company
Location
Capacity1
Gg(106 Ibs)
Kewanee Indust., Inc.
Mi 11 master Onyx Corp.,
subsid.
Apache Foam Products
Co., div.
Midwest Mfg. Corp.
Mobay Chern. Corp.
Polyurethane Div.
01 in Corp.
Designed Products Div.
Pelron Corp.
Reeves Bros, Inc.
Curon Div.
Scott Paper Co.
Foam and Container Div.
Sheller-Globe Corp.
Tenneco Inc.
Tenneco Chems., Inc.
Foam and Plastics
Div.
Textron In.
Indust. Product Group
Burkart/Randall Div,
Belvidere, IL
Linden, NO
Burlington, IA
Santa Ana, CA
Benicia, CA
Brook Park, OH
Fogelsville, PA
Lyons, IL
Cornelius, NC
Orlando, FL
Eddystone, PA
Fort Wayne, IN
Iowa City, IA
Keokuk, IA
Tupelo, MS
East Rutherford, NJ
Hazel ton, PA
Cairo, IL
St. Louis, MO
298
-------
Table C-49 (Continued). POLYURETHAN FOAM PRODUCERS2
(The following companies react isocyanates or prepolymers with polyoles to produce poly-
urethan foams. The list is incomplete.)
Compa ny
Location
Capacity1
Gg(106 Ibs)
United Foam Corp.
United Merchants & Mfgs.,
Inc.
American Plastics Div.
Glascoat Div.
Thalco Div.
The Upjohn Co.
CRP Div.
Polymer Chems. Div.
Witco Chem. Corp.
Isocyanate Products
Div.
Bremen, IN
Compton, CA
Denver, CO
Franklin, NJ
Hayward, CA
Honolulu, HI
Los Angeles, CA
Portland, OR
Shawnee, OK
Elkhart, IN
Miami, FL
Los Angeles, CA
Fairbanks, AK
Torrance, CA
La Porte, TX
New Castle, DE
*0n stream as of January 1, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
3A 25% expansion of polyurethan foam capacity is planned; completion is scheduled for
mid-1977.
Source: Directory of Chemical Producers, 1976.
299
-------
Table C-50. (Miscellaneous) POLYURETHAN RESINS PRODUCERS2
(Adhesives, molding resins, sealants, etc.)
Company
Location
Capacity1
Gg(106 Ibs)
Adhesive Products Corp.
American Cyanamid Co.
Organic Chems. Div.
John L. Armitage & Co.
The Carborundum Co.
Polymers Venture
Degen Oil & Chem. Co.
Gen. Latex and Chem.
Corp.
Henkel Inc.
Textilana, Div.
Hexcel Corp.
Rezolin Div.
ICI United States Inc.
Plastics Div.
Philip Morris, Inc.
Polymer Indust., Inc.
subsid.
Adhesives and Liquid
Coatings Div.
Poly Resins, Inc.
Seton Co.
Wilmington Chem. Corp.,
div.
Witco Chem. Corp.
Organics Div.
Bronx, NY
Charlotte, NC
Elk Grove, IL
Newark, NJ
Richmond, CA
Niagara Falls, NY
Jersey City, NJ
Cucamonga, CA
Hawthorne, CA
Chatsworth, CA
Bayonne, NJ
Springdale, CT
Sun Valley, CA
Wilmington, DE
Clearing, IL
*0n stream as of January, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
300
-------
Table C-51. POLYURETHAN SURFACE COATING RESIN PRODUCERS2
(The following are the major suppliers of urethan coating resins to the U.S. paint
companies. They do not make urethan surface coatings)
Company
Location
Capacity1
Gg(106 Ibs)
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
div.
Resins and Plastics Div.
BASF Wyandotte Corp.
Indust. Chems. Group
Diamond Shamrock Corp.
Diamond Shamrock Chem.
Co.
Process Chems. Div.
Gen. Latex and Chem. Corp.
The B.F. Goodrich Co.
B.F. Goodrich Chem. Co.,
div.
Internat'l Minerals & Chem.
Corp.
Chem. Group
Commercial Solvents
Corp., subsid.
McWhorter Chems. Co.
Div.
Jones-Blair Co.
Mobay Chem. Corp.
Plastics + Coatings Div.
Northeastern Labs. Co.,
Inc.
Occidental Petroleum Corp.
Hooker Chem. Corp.,
subsid.
RUCO, subsid.
Newark, NJ
Wyandotte, MI
Harrison, NJ
Ashland, OH
Cambridge, MA
Cucamonga, CA
Avon Lake, OH
Carpentersville, IL
Dallas, TX
Cedar Bayou, TX
New Martinsvilie, WV
Melville, NY
Hicksville, NY
301
-------
Table C-51 (Continued). POLYURETHAN SURFACE COATING RESIN PRODUCERS2
(The following are the major suppliers of urethan coating resins to the U.S. paint
companies. They do not make urethan surface coatings.)
Company
Location
Capacity1
Gg(106 Ibs)
Reichhold Chems., Inc.
H. H. Robertson Co.
Freeman Chem. Corp.,
subsid.
Synres Chem. Corp.
Textron Inc.
Indust. Product Group
Spencer Kellogg Div.
Union Carbide Corp.
Chems. and Plastics
Div.
Azusa, CA
Carteret, NJ
Detroit, MI
Elizabeth, NJ
Houston, TX
South San Francisco, CA
Tacoma, WA
Chatham, VA
Saukville, WI
Kenilworth, NJ
Bellevue, OH
Institute and South
Charleston, WV
*0n stream as of January 1, 1976.
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
302
-------
Table C-52. POLYURETHAN SURFACE COATING RESINS PRODUCERS2
(The following companies make urethan resins and urethan surface coatings)
Company
ADCO Chem. Co., Inc.
American Can Co.
M&T Chems. Inc., subsid.
Furane Plastics, Inc.,
subsid.
Ashland Oil., Inc.
Lehigh Valley Chem. Co.,
di v.
Resins and Plastics Div.
Ball Chem. Co.
Resin Div.
Beatrice Foods Co.
Beatrice Chem. Div.
Permuthane Div.
Polyvinyl Chem. Indust.
Div.
Stahl Finish Div.
Celanese Corp.
Celanese Coatings and Specialty
Chems. Co., subsid.
Celanese Resins Div.
Chem. Coatings & Engineering
Co., Inc.
Chem. Processors, Inc.
Conchemco Inc.
Kansas City Operations
De Soto, Inc.
Los Angeles, CA
Location
ewark NJ
_os Angeles, CA
Glenshaw, PA
Peabody, MA
Wilmington, MA
eabody, MA
Louisville, KY
Media, PA
Seattle, WA
Kansas City, MO
Berkeley, CA
Chicago Heights, IL
Garland, TX
Capacity1
Gg(106 Ibs)
The Dexter Corp.
Midland Div.
'Cleveland, OH
Wayward, CA
•Rocky Hill, CT
Waukegan, IL
303
-------
Table C-52 (Continued). POLYURETHAN SURFACE COATING RESINS PRODUCERS2
(The following companies make urethan resins and urethan surface coatings)
Company
Location
Capacity1
6g(106 IDS)
E. I. du Pont de Nemours & Co.,
Inc.
Fabrics and Finishes Dept.
Elliott Paint & Varnish Co.
Armstrong Paint Co., div.
ELT Inc.
Baltimore Paint & Chem. Corp.,
subsid.
The Flamemaster Corp.
Chem-Seal Corp., div.
Ford Motor Co.
Gen. Products Div.
The P. D. George Co.
Grow Chem. Corp.
U.S. Paint, Lacquer and Chem.
Co., subsid.
Indpol
Inmont Corp.
Insilco Corp.
The Enterprise Companies,
div.
Isochem Resins Co.
Kohler-McLister Paint Co.
Lord Corp.
Hughson Chems. Div.
Mameco Internat'l
Marcor Inc.
Montgomery Ward & Co.,
subsid.
Standard T. Chem. Co.,
Inc., subsid.
Toledo, OH
Chicago, IL
Baltimore, MD
Sun Valley, CA
Mt. Clemens, MI
St. Louis, MO
St. Louis, MO
Cucamonga, CA
Grand Rapids, MI
Morganton, NC
Wheeling, IL
Lincoln, RI
Denver, CO
Saegertown, PA
Cleveland, OH
Chicago Heights, IL
304
-------
Table C-52 (Continued). POLYURETHAN SURFACE COATING RESINS PRODUCERS2
(The following companies make urethan resins and urethan surface coatings)
Company
Location
Capacity1
Gg(106 Ibs)
McCloskey Varnish Co.
Midwest Mfg. Corp.
N L Indust., Inc.
Indust. Chems. Div.
Norris Paint & Varnish Co,
01 in Corp.
Designed Products Div.
C. J. Osborn Chems. Inc.
Polychrome Corp
Cellomer Corp., subsid.
Poly Resins, Inc.
Pratt & Lambert, Inc.
K. J. Quinn & Co., Inc.
Polymer Div.
Schenectady Chems., Inc.
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins Group
Seton Co.
Wilmington Chem. Corp., div.
Syncon Resins Inc.
Farnow, Inc. , div.
Textron Inc.
Indust. Product Group
Kelly-Pickering Chems.
Dept.
Los Angeles, CA
Philadelphia, PA
Portland, OR
Burlington, IA
Philadelphia, PA
Salem, OR
Rochester, NY
Pennsauken, NJ
Newark, NJ
Sun Valley, CA
Buffalo, NY
Maiden, MA
Seabrook, NH
Rotterdam Junction, NY
Schenectady, NY
Chicago, IL
Cleveland, OH
Reading, PA
San Francisco, CA
Wilmington, DE
South Kearny, NJ
San Carlos, CA
305
-------
Table C-52 (Continued). POLYURETHAN SURFACE COATING RESINS PRODUCERS2
(The following companies make urethan resins and urethan surface coatings)
Company
Location
Capacity1
Gg(106 Ibs)
Trancoa Chem. Corp.
Valspar Corp.
Mid west Synthetics Co., div.
Westinghouse Electric Corp.
Insulating Materials Div.
Witco Chem. Corp.
Organics Div.
Woburn Chem. Corp.
Reading, MA
Rockford, IL
West Mifflin, PA
Clearing, IL
Kearny, NJ
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
306
-------
Table C-53. POLY(VINYL ACETATE) RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 IDS)
ADCO Chem. Co., Inc.
Air Products and Chems., Inc.
Polymer Chems. Div.
AZS Corp.
AZS Chem. Co. Div.
Bennett's
Borden Inc.
Borden Chem. Div.
Adhesives and Chems. Div.
East
Thermoplastic Products
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co.,
subsid.
Celanese Resins Div.
Wica Chems. Div.
Chem. Processors, Inc.
Ciba-Geigy Corp.
Dyestuffs and Chems. Div.
Chas. S. Tanner Co.
subsid.
Colloids, Inc.
Cellate, Inc., subsid.
Conchemco Inc.
Baltimore Operations
Kansas City Operations
Newark, NJ
Calvert City, KY
City of Industry, CA
Cleveland, OH
Elkton, MD
Atlanta, GA
Salt Lake City, UT
Bainhridge, NY
Demopolis, AL
Bainbridge, NY
Conipton, CA
Denopolis, AL
Illiopolis, IL
Leominster, MA
Belvidere, NJ
Bridgeview, IL
Charlotte, NC
Los Angeles, CA
Louisville, KY
Newark, CA
Charlotte, NC
Seattle, WA
Greenville, SC
Franklin, NJ
Baltimore, MD
Kansas City, MO
307
-------
Table C-53 (Continued). POLY(VINYL ACETATE) RESIN PRODUCERS5
Company
Location
Capacity1
Gg(106 Ibs)
Dan River, Inc.
De Soto, Inc.
Diamond Shamrock Corp.
Diamond Shamrock Chem. Co.
Process Chems. Div.
ELT Inc.
Baltimore Paint & Chem.
Corp., suhsid.
Emkay Chem. Co.
Foy-Johnston, Inc.
Franklin Chem. Co.
H. B. Fuller Co.
Paisley Products Div.
Polymer Div.
Gen. Latex and Chem. Corp.
W. R. Grace & Co.
Indust. Chems. Group
Dewey and Almy Chem. Div,
Great Northern Paint & Chem.
Corp.
Grow Chem. Corp.
Boysen Paint Co., subsid.
Danville, VA
Berkeley, CA
Chicago Heights, IL
Garland, TX
Richmond, CA
Baltimore, MD
Elizabeth, NJ
Cincinnati, OH
Columbus, OH
Chicago, IL
Edison, NJ
Forest Park, GA
Atlanta, GA
Blue Ash, OH
Ashland, OH
Cambridge, MA
Charlotte, NC
Dal ton, GA
Owensboro, KY
South Acton, MA
East Paterson, NJ
Lodi, NJ
Oakland, CA
308
-------
Table C-53 (Continued). POLY(VINYL ACETATE) RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Gulf Oil Corp.
Gulf Oil Chems. Co.,
div.
Indust. and Specialty Chems.
Div.
Hanna Chem. Coatings Corp.
Hanna Chem. Coatings Co.,
subs id.
Hart Products Corp.
H & N Chem. Co.
Insilco Corp.
Sinclair Paint Co., div.
Jones-Blair Co.
Kelly-Moore Paint Co.
Kewanee Indust., Inc.
Millmaster Onyx Corp.,
subs id.
Refined-Onyx Div.
Kohler-McLister Paint Co.
McCloskey Varnish Co.
Monsanto Co.
Monsanto Ploymers &
Petrochems. Co.
Benjamin Moore & Co.
Napko Corp.
National Casein of Cali-
fornia
Lansdale, PA
olumbus, OH
Birmingham, AL
Jersey City, NJ
Totowa, NJ
Los Angeles, CA
Dallas, TX
San Carlos, CA
Lyndhurst, NJ
Denver, CO
Los Angeles, CA
Philadelphia, PA
Portland, OR
Springfield, MA
Los Angeles, CA
Mel rose Park, IL
Newark, NJ
St. Louis, MO
Houston, TX
Santa Ana, CA
309
-------
Table C-53 (Continued). POLY(VINYL ACETATE) RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
National Casein Co.
National Starch and Chem. Corp.
Norris Paint & Varnish Co.
Northeastern Labs Co., Inc.
The O'Brien Corp.
Onyx Oils & Resins, Inc.
Philip Morris, Inc.
Polymer Indust., Inc.
subs id.
Adhesives and Liquid
Coatings Div.
Textile Chems. Div.
Raffi and Swanson, Inc.
Polymeric Resins Div.
Reichhold Chems., Inc.
Scholler Bros. Inc.
SCM Corp.
Glidden-Durkee Div.
Coatings and Resins
Group
The Sherwin-Williams Co.
Southeastern Adhesives Co,
hicago, IL
Meredosia, IL
Plainfield, NJ
alem, OR
Melville, NY
Baltimore, MD
South Bend, IN
Brooker, FL
Springdale, CT
Greenville, SC
Wilmington, MA
Azusa, CA
Charlotte, NC
Kansas City, KS
Morris, IL
South San Francisco, CA
Tacoma, WA
El wood, NJ
Chicago, IL
Cleveland, OH
Huron, OH
Reading, PA
San Francisco, CA
Chicago, II
Lenoir, NC
310
-------
Table C-53 (Continued). POLY(VINYL ACETATE). RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Standard Brands, Inc.
Standard Brands Chem. Indust.,
Inc., div.
Tylac Chems., div.
Sybron Corp.
Jersey State Chem. Co., div.
Syncon Resins Inc.
Farnow, Inc., div.
Union Carbide Corp.
Chems. and Plastics Div.
Union Oil Co. of Cali-
fornia
AMSCO Div.
Yenkin-Majestic Paint Corp.
Ohio Polychemicals Co.,
div.
Cheswold, DE
Haledon, NJ
South Kearny, NJ
Institute and South
Charleston, WV
Charlotte, NC
La Mirada, CA
Columbus, OH
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
311
-------
Table C-54. POLY(VINYL ALCOHOL) RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Air Products and Chems. , Inc.
Polymer Chems. Div.
Borden Inc.
Borden Chem. Div.
Thermoplastic Products
E. I. du Pont de Nemours & Co.,
Inc.
Plastics Products and Resins
Dept.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Calvert City, KY
Leominster, MA
La Porte, TX3
Springfield, MA
TOTAL
18 (40)
2 (8)1
45 (100)
14 (30)
79 (178)
J0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
3An expansion which will increase poly(vinyl alcohol) resins capacity to 125
million pounds per year is planned; completion is scheduled for 1977
**0n stand-by
Source: Directory of Chemical Producers, 1976.
312
-------
Table C-55. 'POLY(VINYL BUTYRAL) RESIN PRODUCERS2
Company
E. I. du Pont de Nemours &
Co., Inc.
Plastics Products and Resins
Dept.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Union Carbide Corp.
Chems. and Plastics Div.
Location
Parkersburg, WV
Springfield, MA3
Trenton, MI
Charleston, WV
Capacity1
Gg(106 Ibs)
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
3A new multimillion dollar poly(vinyl butyral) resins plant is planned which will
increase company's capacity by 25%; completion is scheduled for late 1976.
Source: Directory of Chemical Producers, 1976.
313
-------
Table C-56. POLY(VINYL CHLORIDE) RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Air Products and Chems., Inc.
Plastics Div.
Atlantic Tubing & Rubber Co.
Borden, Inc.
Borden Chem. Div.
Thermoplastic Products
Certain-Teed Products Corp.
Continental Oil Co.
Conoco Chems. Div.
Diamond Shamrock Corp.
Diamond Shamrock Chem. Co.
Plastics Div.
Ethyl Corp.
The Firestone Tire & Rubber
Co.
Firestone Plastics Co., div.
The Gen. Tire & Rubber Co.
Chemical/Plastics Div.
Georgia-Pacific Corp.
Chem. Div.
The B. F. Goodrich Co.
B. F. Goodrich Chem. Co.,
div.
Calvert City, KY3
Pensacola, FL1*
Cranston, RI
Illiopolis, IL
Leominster, MA
Lake Charles, LA
Aberdeen, MS5
Oklahoma City, OK
Deer Park, TX
Delaware City, DE
Baton Rouge, LA
Perryville, MD
Pottstown, PA
Ashtabula, OH
Point Pleasant, WV
Plaquemine, LA
Avon Lake, OH
Henry, IL
Long Beach, CA
Louisville, KY
Pedricktown, NJ
68 (150)
28 (50)
28 (50)
182 (400)
66 (145)
490
222 (290)
107 (235)
213 (470)
45 (100)
82 (180)
204 (450)
57 (125)
27 (60)
100 (220)
73 (160)
73 (160)
73 (160)
163 360)
77 (170)
314
-------
Table C-56 (Continued). POLYVINYL CHLORIDE RESIN PRODUCERS'
Company
The Goodyear Tire & Rubber Co.
Chem. Div.
Great American Chem. Corp.
Keysor-Century Corp.
National Starch and Chem.
Corp.
The Pantasote Co. of New York,
Inc.
Eleonora Chem. Div.
Rhodia, Inc.
Rico Chems. Corp.
ROBINTECH Inc.
SHINTECH Inc.
Stauffer Chem. Co.
Plastics Div.
Polymers East
Polymers West
Tenneco Inc.
Tenneco Chems. , Inc.
Organics and Polymers Div.
Union Carbide Corp.
Chems. and Plastics Div.
Location
Niagara Falls, NY6
Plaquemine, LA
Fitchburg, MA
Saugus, CA
Meredosia, IL
Passaic, NJ
Point Pleasant, WV
Brazosport, TX
Guayanilla, PR
Painesville, OH
Freeport, TX7'9
Delaware City, DE8
Carson, CA
Burlington, MJ
Flemington, NJ
Pasadena, TX
Institute and South
Charleston, WV
Texas City, TX
TOTAL
Capacity1
Gg(106 Ibs)
23 (50)
90 (200)
18 (40)
34 (75)
4 (10)
27 (60)
27 (60)
2 (7)
73 (160)
114 (250)
100 (220)
77 (170)
66 (145)
70 (155)
36 (80)
109 (240)
159 (350)
3129 (6892)
*0n stream as of January 1, 1976
'-Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
''A 200 to 300 million pound per year expansion of poly (vinyl chloride) resins
capacity is planned
315
-------
Table C-56 (Continued). POLYVINYL CHLORIDE RESIN PRODUCERS2
''An expansion of poly(vinyl chloride) resins capacity to 150 million pounds per
year is planned; completion is scheduled for 1977.
5An expansion of poly(vinyl chloride) resins capacity to 500 million pounds per
year is planned.
6The 650 thousand-dollar expansion which will increase poly(vinyl chloride) resins
capacity by 25 million pounds per year to a total of 75 million pounds per year
is planned; completion is scheduled for late 1976.
7An expansion which will increase poly(vinyl chloride) resins capacity to 370
million pounds per year is planned; completion is scheduled for January, 1976.
8An expansion which has increased poly(vinyl chloride) resins capacity to 185
million pounds per year has come on stream. An additional expansion which will
increase poly(vinyl chloride) resins capacity to 245 million pounds per year is
scheduled for late 1976.
9Captive use.
Source: Directory of Chemical Producers, 1976.
316
-------
Table C-57. POLY(VINYL CHLORIDE)-ACETATE COPOLYMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg (TO6 Ibs)
Air Products And Chems., Inc.
Plastics Div.
Atlantic Tubing & Rubber Co,
Borden Inc.
Borden Chem. Div.
Thermoplastic Products
The Firestone Tire & Rubber Co.
Firestone Plastics Co., div.
The B. F. Goodrich Co.
B. F. Goodrich Chem. Co., div,
National Starch and Chem.
Corp.
Occidental Petroleum Corp.
Hooker Chem. Corp., subsid.
RUCO, subsid.
The Pantasote Co. of New
York, Inc.
Eleonora Chem. Div.
Stauffer Chem. Co.
Plastics Div,
Polymers East
Polymers West
Tenneco Inc.
Tenneco Chems., Inc.
Organics and Polymers Div,
Calvert City, KY
Cranston, RI
Bainbridge, NY
Compton, CA
Demopolis, AL
Illiopolis, IL
Leominster, MA
Pottstown, PA
Avon Lake, OH
Louisville, KY
Meredosia, IL
Hicksville, NY
Passaic, NJ
Point Pleasant, WV
Delaware City, DE
Carson, CA.
Burlington, NJ
'Flemington, NJ
317
-------
Table C-57 (Continued). POLY(VINYL CHLORIDE)-ACETATE COPOLYMER RESIN PROUDCERS
Company
Location
Capacity1
Gg(106 Ibs)
Union Carbide Corp.
Chems. and Plastics Div.
Institute and South
Charleston, WV
Texas City, TX
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
318
-------
Table C-58. POLY(VINYL CHLORIDE)-PROPYLENE COPOLYMER RESIN PRODUCERS:
Company
Air Products and Chems., Inc.
Plastics Div.
Location
Calvert City, KY
Capacity1
Gg (106 Ib)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
319
-------
Table C-59. POLY(VINY(L CHLORIDE)-VINYLIDENE CHLORIDE COPOLYMER RESINS PRODUCERS7
Company
Location
Capacity1
Gg (106 Ibs)
BASF Wyandotte Corp.
Colors and Chems. Group
Borden, Inc.
Borden Chem. Div.
Thermoplastic Products
Dow Chem. U.S.A.
The B. F. Goodrich Co.
B. F. Goodrich Chem. Co.
Div.
W. R. Grace & Co.
Indust. Chems. Group
Dewey and A!my Chem.
Div.
Morton-Norwich Products,
Inc.
Morton Chem. Co., Div.
National Starch and
Chem. Corp.
Kearny, NJ
Bainbridge, NY
Compton, CA
Demopolis, AL
Illiopolis, IL
Leominster, MA
Midland, MI
Louisville, KY
Owensboro, KY
South Acton, MA
Ringwood, IL
Meredosia, IL
*0n stream as of January 1, 1976
2Products considered manufacture materials in commerciably salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
320
-------
Table C-60. POLY(VINYL FORMAL) RESIN PRODUCERS1
Company
Monsanto Co.
Monsanto Polymers
& Petrochems. Co.
Location
Springfield, MA
Capacity1
Gg (106 Ibs)
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
321
-------
Table C-61. PROPYLENE-ETHYLENE COPOLYMER RESIN PRODUCERS2
Company
Eastman Kodak Co.
Eastman Chem. Products, Inc.,
subsid.
Texas Eastman Co., div.
Location
Longview, TX
Capacity1
Gg (106 Ibs)
:0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
322
-------
Table C-62. RESORCINOL-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg (106 Ibs)
Ashland Oil, Inc.
Lehigh Valley Chem. Co., div,
Resins and Plastics Div.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems.
Div. - East
Adhesives and Chems.
Div. - West
Georgia-Pacific Corp.
Chem. Div.
Koppers Co., Inc.
Organic Materials Div.
National Casein of California
National Casein Co.
National Casein of New Jersey
Adhesives Div.
Polymer Applications, Inc.
Calumet City, IL
Fords, NO
Pensacola, FL
Bainbridge, NY
Diboll , TX
Fayetteville, NC
Sheboygan, WI
Fremont, CA
Kent, WA
Springfield, OR
Albany, OR
Columbus, OH
Conway, NC
Coos Bay, OR
Louisville, MS
Lufkin, TX
Russellville, SC
Savannah, GA
Vienna, GA
Petrolia, PA
Santa Ana, CA
Chicago, IL
Tyler, TX
Riverton, NJ ,
Tonawanda, NY
323
-------
Table C-62 (Continued). RESORCINOL-FORMALDEHYDE RESIN PRODUCERS1
Company
Location
Capacity1
Gg (TO6 Ibs)
Reichhold Chems., Inc.
Schenectady Chems., Inc.
Union Carbide Corp.
Chems. and Plastics Div.
Univar Corp.
Pacific Resins & Chems.,
Inc., subsid.
Tacoma, WA
Rotterdam Junction, NY
Schenectady, NY
Bound Brook, NJ
Portland, OR
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
324
-------
Table C-63. ROSIN AND ROSIN ESTER PRODUCERS'
Company
Location
Capacity1
Gg (106 Ibs)
Arizona Chem. Co.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
div.
Resins and Plastics Div.
Conchemco Inc.
Baltimore Operations
Kansas City Operations
Cook Paint & Varnish Co.
Crosby Chems., Inc.
De Soto, Inc.
Dixie Pine Products Co.,
Inc.
Eastern Color & Chem. Co.
Gil man Paint & Varnish Co.
Guardsman Chems., Inc.
Hercules Inc.
Organics Dept.
Lawter Chems., Inc.
Stresen-Reuter Div.
McCloskey Varnish Co.
The O'Brien Corp.
Buller-O'Brien Corp., subsid,
Panama City. FL
Pensacola, FL
Baltimore, MD
Kansas City, MO
North Kansas City, MO
De Ridder, LA
Picayune, MS
Garland, TX
Hattiesburg, MS
Providence, RI
Chattanooga, TN
Grand Rapids, MI
Brunswick, GA
Burlington, NJ
Hattiesburg, MS
South Kearny, NJ
Bensenville, IL
Los Angeles, CA
Philadelphia, PA
Portland, OR
Baltimore, MD
South Bend, IN
South San Francisco, CA
325
-------
Table C-63 (Continued). ROSIN AND ROSIN ESTER PRODUCERS1
Company
Location
Capacity1
Gg (TO6 Ibs)
Occidental Petroleum Corp.
Hooker Chem. Corp., subsid.
Hooker Chems. and
Plastics Corp., subsid
Durez Div.
Onyx Oils & Resins, Inc.
Reichhold Chems., Inc.
Newport Div.
Rohm and Haas Co.
Schenectacy Chems., Inc.
Syncon Resins Inc.
Farnow, Inc., div.
Synres Chem. Corp.
Shanco Plastics & Chems.,
subsid.
Union Camp Corp.
Chem. Products Div.
Union Carbide Corp.
Chems. and Plastics Div.
Westvaco Corp.
Chem. Div.
Custom Chems. Dept.
Kenton, OH
North Tonawanda, NY
Newark, NJ
Columbia, MS
Houston, TX
South San Francisco, CA
Gulf port, MS
Philadelphia, PA
Rotterdam Junction, NY
Schenectady, NY
South Kearny, NJ
Tonawanda, NY
Valdosta, GA
Bound Brook, NJ
Charleston Heights, SC
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually.
Source: Directory of Chemical Producers, 1976.
326
-------
Table C-64. SILICONE RESIN PRODUCERS2
Company
Location
Capacity1
Gg (TO6 Ibs)
Ashland Oil, Inc.
Lehigh Valley Chem. Co., div.
Northwestern Refining
Co., subsid.
Cargill, Inc.
Chem. Products Div.
The Dexter Corp.
Midland Div.
Dow Corning Corp.
General Electric Co.
Chem. and Metallurgical Div.
Silicone Products Dept.
Isochem Resins Co.
Marcor Inc.
Montgomery Ward & Co.,
subsid.
Standard T Chem. Co.,
Inc., subsid
Morris Indust. Inc.
Lanson Chem. Co., div.
Synres Chem. Corp.
Synthane-Taylor Corp.
Union Carbide Corp.
Chems. and Plastics Div.
St. Paul Park, MN
Philadelphia, PA
Cleveland, OH
Hayward, CA
Rocky Hill, CT
Waukegan, IL
Midland, MI
Waterford, NY
Lincoln, RI
Chicago Heights, IL
Linden, NJ
East St. Louis, IL
Kenilworth, NJ
Betzwood, PA
Sistersville, WV
J0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amount, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
327
-------
Table C-65. STYRENE-ALLYL RESIN PRODUCERS2
Company
Location
Capacity1
Gg (106 Ibs)
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Trenton, MI
^n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers. 1976.
328
-------
Table C-66. STYRENE-BUTADIENE COPOLYMER RESIN PRODUCERS:
Company
Location
Type
Capacity1
Gg (106 Ibs)
American Synthetic Rubber
Corp.
ARCO/Polymers, Inc.
Borden, Inc.
Borden Chem. Div.
Thermoplastic Products
Dart Indust. Inc.
Chem. Group
Plastic Raw Materials
Sector
Southwest Latex Corp.
Dow Chem., U.S.A.
The Firestone Tire &
Rubber Co.
Firestone Synthetic
Rubber and Latex
Co., div.
GAF Corp.
Chem. Products
The Gen. Tire & Rubber
Co.
Chemical/Plastics Div.
The B. F. Goodrich Co.
B. F. Goodrich Chem. Co.,
div.
The Goodyear Tire & Rubber
Co.
Chem. Div.
W. R. Grace & Co.
Indust. Chems. Group
Dewey and Almy Chem. Div
Louisville, KY
Beaver Valley, PA
Illiopolis, IL
Bayport, TX
Freeport, TX
Midland, MI
Pittsburgh, CA
Akron, OH
Chattanooga, TN
Mogadore, OH
Odessa, TX
Louisville, KY
Akron, OH
Owensboro, KY
South Acton, MA
L
L
L
L
L
L
L
L
L
329
-------
Table C-66 (Continued). STYRENE-BUTADIENE COPOLYMER RESIN PROUDCERS2
Company
Location
Type
Capacity1
Gg (TO6 Ibs)
Phillips Petroleum Co.
Rubber Chems. Div.
Standard Brands, Inc.
Standard Brands Chem.
Indust., Inc., div.
Tylac Chems., div.
Union Oil Co. of
California
AMSCO Div.
Uniroyal, Inc.
Uniroyal Chem., div.
Borger, Tex.
Cheswold, DE
Kensington, GA
Charlotte, NC
La Mirada, CA
Scotts Bluff, LA
R (solid)
L
L
L
L
Notes: R - Resin
L - Latex
On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
330
-------
Table C-67. STYRENE-DIVINYLBENZENE COPOLYMER RESIN PRODUCERS2
Company
Dow Chemical, U.S.A.
..... , —
Location
Midland, MI
Capacity1
Gg (106 Ibs)
stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts,
i.e., greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
TABLE C-68. STYRENE-MALEIC ANHYDRIDE COPOLYMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg (106 Ibs)
Atlantic Richfield Co.
ARCO Chem. Co., div.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Channel view, TX
Addyston, OH
Everett, MA
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amount, i.e.,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
331
-------
Table C-69. THERMOPLASTIC RESIN PRODUCERS2
Company
Hastings Plastics Inc.
K. J. Quinn & Co. , Inc.
Polymer Div.
Location
Santa Monica, CA
Maiden, MA
Seabrook, NH
Capaci ty2
Gg(106 Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers. 1976.
Table C-70. TRIAZONE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
American Cyanamid Co.
Organic Chems. Div.
Rohm and Haas Co.
Sun Chem. Corp.
Chems. Group
Chems. Div.
United Merchants & Mfgs.,
Inc.
Valchem - Chem. Div.
U.S. Oil Co.
Southern U.S. Chem. Co.,
Inc., subsid.
Charlotte, NC
Philadelphia, PA
Chester, SC
Langley, SC
East Providence, RI
Rock Hill, SC
*0n stream as of January 1, 1976
^Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
332
-------
Table C-71. UREA-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Allied Chem. Corp.
Specialty Chems. Div.
American Cyanamid Co.
Indust. Chems. and
Plastics Div.
Organic Chems. Div.
Formica Corp., subsid.
Apex Chem. Co., Inc.
Ashland Oil, Inc.
Lehigh Valley Chem. Co.,
div.
Resins and Plastics Div,
The Bendix Corp.
Friction Materials Div.
Borden Inc.
Borden Chem. Div.
Adhesives and Chems.
Div. - East
Adhesives and Chems,
Div. - West
Brown Co.
Cargill, Inc.
Chem. Products Div.
South Point, OH
Toledo, OH
Azusa, CA
Wallingford, CT
Charlotte, NC
Evandale, OH
Elizabethport, NJ
Calumet City, IL
Fords, NJ
Los Angeles, CA
Troy, NY
Bainbridge, NY
Demopolis, AL
Diboll, TX
Fayetteville, NC
Louisville, KY
Sheboygan, WI
Fremont, CA
Kent, WA
La Grande, OR
Missoula, MT
Springfield, OR
Gorham, NH
Carpentersville, IL
Lynwood, CA
Philadelphia, PA
333
-------
Table C-71 (Continued). .UREA-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 IDS)
Celanese Corp.
Celanese Coatings and
Specialty Chems. Co.,
subsid.
Celanese Resins Div.
Wica Chems. Div.
Champion Internat'l Corp.
U.S. Plywood Div.
Chem. Products Corp.
Commercial Products Co.
Cook Paint & Varnish Co.
Dan River, Inc.
De Soto, Inc.
Dock Resins Corp.
Eastern Color & Chem. Co.
Emkay Chem. Co.
Georgia-Pacific Corp.
Chem. Div.
Guardsman Chems., Inc.
Louisville, KY
Charlotte, NC
Anderson, CA
Elmwood Park, NJ
Hawthorne, NJ
Detroit, MI
North Kansas City, MO
Danville, VA
Berkeley, CA
Garland, TX
Linden, NJ
Providence, RI
Elizabeth, NJ
Albany, OR
Columbus, OH
Conway, NC
Coos Bay, OR
Crossett, AR
Louisville, MS
Lufkin, TX
Russellville, SC
Savannah, GA
Taylorsville, MS
i Vienna, GA
! Grand Rapids, MI
334
-------
Table C-71 (Continued). UREA-FORMALDEHYDE RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
Gulf Oil Corp.
Gulf Oil Chems. Co., div.
Indust. and Specialty
Chems. Div.
Hanna Chem. Coatings Corp.
Hanna Chem. Coatings Co.,
subs id.
Hart Products Corp.
Hercules Inc.
Organics Dept.
H & N Chem. Co.
E. F. Houghton & Co.
The Ironsides Co.
Kewanee Indust., Inc.
Mi 11 master Onyx Corp.,
subsid.
Refined-Onyx Div.
Koppers Co., Inc.
Organic Materials Div.
Mobil Oil Corp.
Mobil Chem. Co., div.
Chem. Coatings Div.
Monsanto Co.
Monsanto Polymers &
Petrochems. Co.
Alexandria, LA
High Point, NC
Lansdale, PA
Shawano, WI
West Memphis, AR
Columbus, OH
Birmingham, AL
Jersey City, NO
Chicopee, MA
Hattiesburg, MS
Milwaukee, WI
Portland, OR
Savannah, GA
Totawa, NJ
Philadelphia, PA
Columbus, OH
Lyndhurst, NJ
Bridgeville, PA
Kankakee, IL
Addyston, OH
| Chocolate Bayou, TX
| Eugene, OR
i Santa Clara, CA
Springfield, MA
335
-------
Table C-71 (Continued). UREA-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
National Casein of California
National Casein Co.
National Casein of New
Jersey
Adhesives Div.
National Starch and Chem. Corp,
Proctor Chem. Co., subsid.
Onyx Oils & Resins, Inc.
Owens-Corning Fiberglas Corp.
Resins and Coatings Div.
Perstorp U.S. Inc.
Pioneer Plastics Corp.
Chem. Div.
Plastics Mfg. Co.
PPG Indust., Inc.
Coatings and Resins Div.
Reichhold Chems., Inc.
Varcum Chem. Div.
Santa Ana, CA
Chicago, IL
Tyler, TX
Riverton, NJ
Salisbury, NC
Brooker, FL
Newark, NJ
Kansas City, KS
Florence, MA
Auburn, ME
Dallas, TX
Circleville, OH
Oak Creek, WI
Andover, MA
Azusa, CA
Detroit, MI
Houston, TX
Malvern, AR
Moncure, NC
South San Francisco, CA
Tacoma, WA
Tuscaloosa, AL
White City, OR
Niagara Falls, NY
336
-------
Table C-71 (Continued). UREA-FORMALDEHYDE RESIN PRODUCERS1
Company
Location
Capacity1
Gg(106 IDS)
Reliance Universal Inc.
Chem. Coatings and Resins
Group
Renroh Inc.
Riegel Textile Corp.
H.I.T. Chems. Div.
Rock Hill Printing &
Finishing Co.
Rohm and Haas Co.
Scher Brothers, Inc.
Scott Paper Co.
Packaged Products Div.
The Sherwin-Williams Co.
Skelly Oil Co.
Chembond Corp., subsid.
Sou-Tex Chem. Co., Inc.
Brea, CA
Clinton, MS
High Point, NC
Houston, TX
Louisville, KY
Roanoke, VA
Salem, OR
Somerset, NJ
Sunnyvale, CA
Virginia Beach, VA
Zion, IL
New Bern, NC
Ware Shoals, SC
Rock Hill, SC
Philadelphia, PA
Clifton, NJ
Chester, PA
Everett, WA
Fort Edward, NY
Marinette, WI
Mobile, AL
Chicago, IL
Cleveland, OH
Newark, NJ
Anadalusia, AL
Springfield, OR
Winnfield, LA
Mount Holly, NC
337
-------
Table C-71 (Continued). UREA-FORMALDEHYDE RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 IDS)
Southeastern Adhesives Co.
Sun Chem. Corp.
Chems. Group
Chems. Div.
Sybron Corp.
Jersey State Chem. Co., div.
United-Erie, Inc.
United Merchants & Mfgs., Inc.
Valchem - Chem. Div.
U.S. Oil Co.
Southern U.S. Chem. Co.,
Inc., subs id.
Univar Corp.
Pacific Resins & Chems., Inc.
subsid.
USM Corp.
Crown-Metro, Inc., subsid.
Virginia Chems. Inc.
Indust. Chems. Dept.
Weyerhaeuser Co.
Woonsocket Color & Chem. Co.
Lenoir, NC
Chester, SC
Haledon, NJ
Erie, PA
Langley, SC
Rock Hill, SC
Eugene, OR
Newark, OH
Portland, OR
Richmond, CA
Greenville, SC
Portsmouth, VA
Longview, WA
Marshfield, WI
Woonsocket, RI
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
338
-------
Table C-72. VINYL 1,2-POLYBUTADIENE RESIN PRODUCERS'
Company
Colorado Chem. Specialties
Location
Golden, CO
Capacity1
Gg(106 Ibs)
*0n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976
Table C-73. l-VINYL-2-PYRROLIDINONE-STYRENE COPOLYMER RESIN PRODUCERS'
Company
GAP Corp
Chem.
Products
Location
Calvert City, KY
Capacity1
Gg(106 Ibs)
20n stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
Table C-74. VINYLTOLUENE-ACRYLIC COPOLYMER RESIN PRODUCERS'
Company
Location
Capacity1
Gg(106 Ibs)
The Goodyear Tire & Rubber Co.
Chem. Div.
Akron, OH
'On stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e.
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Directory of Chemical Producers, 1976.
339
-------
Table C-75. VINYL TOLUENE COPOLYMER RESIN PRODUCERS2
Company
Location
Capacity1
Gg(106 Ibs)
Ball Chem. Co.
Resin Div.
Oegen Oil & Chem. Co.
The Goodyear Tire & Rubber
Co.
Chem. Div.
Hercules Inc.
Organics Dept.
Textron Inc.
Indust. Product Group
Spencer Kellogg Div.
Yenkin-Majestic Paint Corp.
Ohio Polychemicals Co., div.
Glenshaw, PA
Jersey City, NJ
Akron, ON
Clairton, PA
West Elizabeth, PA
Bellevue, OH
Columbus, OH
lQr\ stream as of January 1, 1976
Producers considered manufacture materials in commercially salable amounts, i.e,
greater than $1,000 sales annually or more than 1,000 Ibs annually
Source: Pi rectory of Chemical Producers, 1976.
340
-------
TECHNICAL REPORT DATA
(Please read luilructions on ilic ret crsc before completing)
REPORT NO
EPA-600/2-77-023J
2.
. TITLE ANOSUBTITLt
Industrial Process Profiles for Environmental Use:
Chapter 10. Plastics and H(,airiti
i . VI ';klnr
. REPORT DATE
February 1977
6 PrHriJRMIJi.j .;ti.-arjl^i'
u OBGANI/ATION NAME AND ADDRESS
kadian Corporation
8500 Shoal Creek Boulevard
P.O. Box 99^8
Austin, Texas 78766
3. RECIPIENT'S ACCESSION-NO.
1O. PROGRAM ELEMENT NO
1AB015 : ROAP 21AFH-_Q25,
11. CONTRACT/GRANT NO.
68-02-1319, Task
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. ENVIRONMENTAL PROTECTION AGENCY
Cincinnati, Ohio 145268
13, TYPE OF REPORT AND PERIOD COVERED
Initial: 8/75-11/70
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
10. ABSTRACT
The catalog of Industrial Process Profiles for Environmental Use was developed as an
aid in defining the environmental impacts of industrial activity in the United States.
Entries for each industry are in consistent format and form separate chapters of the
study. The Plastics and Resins Industry includes operations which convert monomer or
chemical intermediate materials obtained from the Basic Petrochemicals Industry and
the Industrial Organic Chemicals Industry into resinous polymer products. Fabrica-
tion is not included in this industry, nor is blending or formulation of resin
materials. This chapter provides an overview of the plastics and resins industry
through a summary of information from the open literature describing industrial
practice. Because of the wide range and complexity of the industry, this treatment
necessarily describes only the more important processes and products. This type of
summary eliminates many of the complexities and variations in processing, resulting
in a somewhat simplified picture of the industry. Twenty process flow sheets and
sixty process descriptions have been prepared to characterize the industry. '..Tithin
each process description available data have been presented on input material",
operating parameters, utility requirements and waste streams. Data related to the
subject matter, including company, raw material and product data, are included as
appendices.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Pollution
Plastics
Resins
Monomers
Resin Polymers
Polymerization
Process Description
18. UlSTPllUUnON STAR MI-NT
Release to Public
b.IDENTIFIERS/OPEN ENDEDTERMS
Air Pollution Control
tfater Pollution Control
Solid Waste Control
Drganic Chemicals
Chemical Industry
19. St CURITY CLASS (I'liit Report/
Unclassified
20. SECURITY CLASS ('1 In
Unclassified
COSATI 1 icld.'uroup
07C
13C
111
21. NO. OF
151
22. PRICE
EPA Form 2220-1 (9-73)
341
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