Plastic Industry

I- Petrochemical Industries

Petroleum and petrochemical industries have dramatically

transformed our life by providing the major basic needs of rapidly
growing, expanding and highly technical civilization. In general,
petroleum is the basic source in different sectors such as energy,
industry, transport, and as feedstock for synthetic fibers, synthetic
rubbers, polymers, plastics, explosives, agrochemicals (pesticides or
fertilizers), dyes, lubricants, paints, etc. Moreover, modern
petrochemical industry fulfills the requirement of a large number of
products which are frequentlybeing used. They are also closely linked
with the socio-economic aspiration of people from automobiles to
telecommunication, construction to home appliances, healthcare to
personal care, etc. In this section, we will introduce simple information
about the most important product of petrochemical industries; plastic.

Plastics:

Plastics are materialsformed from any synthetic or semi- synthetic

organic compounds that are malleable and can be moldedinto
solid objects. Thus they belong to organic materials which are, as
you know, compounds contain carbon and hydrogen in their
structures. Due to the ability of carbon atoms

1
 Chapter 3 Chemical Industries and their environmental impacts

to form long chains via covalent bonds, millions of organic compounds

are known.

The word “Plastic” is derived from the Greek word “plastikos”,

which means able to be shaped. Plastic materials consist of long chain
molecules (polymers) that available in many colors or in transparent
form. The term "polymer" derives from a two Greek words; “poly” that
means "many", and “mer” that means "part"), and refers to high
molecular mass compounds whose structures are composed of multiple
repeating units called monomers. For example, polyethylene is a
polymer that is composed of “-CH2- “, and Polyvinylchloride is
composed of “-CH2-CHCl- “

Due to their low cost, ease of manufacture, and some other

applicable properties,plastics are used in countless products and
application. More than 80% of the chemical industry concentrates on
producing polymers, and plastics. They are not only used in packing,
but also in numerous other things such as paper clips, appliances,
furniture, bottles, CD and cassette boxes, disposable cups, electrical
connectors, electronic enclosures, eyeglasses, ID cards, instrument
panels, jars, lenses, microwavable packaging, name tags, outdoor signs,
pallets, pipes, plates, windows and windshields.

2
 Plastic Industry

Properties and classifications of plastics

Plastics have numerous properties that make them superior to other
materials in many applications such as:
1- They generally have strong ability to resist corrosion, water and
chemicals
2- They have low electrical and thermal conductivity
3- They have high strength-to-weight ratio
4- Their colors available in a wide variety and transparent
5- They have good mechanical, and good durability but low
density
6- They also have low cost and they are easy to manufacture
7- Theyhave low toxicity.
Plastics can be classified in many different ways such as
classification according to the process used in their synthesis:
condensation, polyaddition, and cross-linking plastics. Another
classification is based on the chemical structure of their backbone and
side chains: acrylics, polyesters, silicones, polyurethanes, and
halogenated plastics. Others classification is based on their physical and
mechanical properties such as: (conductive and non-conductive
plastics), (hard and soft plastics), (thermoplastics and thermosetting
plastics). Here, we will consider the final classification.

3
 Chapter 3 Chemical Industries and their environmental impacts

Thermoplastics and thermosetting plastics

Depending on their thermal behavior, plastics can be divided into
two general categories:
Thermoplastics: they are the plastics that, when heated, do not undergo
chemical change in their composition. Thus they can be reshaped again,
i.e. they can soften on heating and harden on cooling because of weak
van der waal's forces. They have either linear or branched structure and
can be amorphous or semicrystalline materials. In addition, most of
them are high molecular weight polymers with chains associated either
through weak Van der Waals forces such as polyethylene (PE), or
through strong dipole-dipole interactions and hydrogen bonding; or
even stacked aromatic rings such as polystyrene (PS). Polypropylene
(PP) and polyvinyl chloride (PVC) are also considered thermoplastics.
Depending on the resin, thermoplastics can serve low-stress
applications such as plastic bags or high-stress mechanical parts.

Fig. 1: Different structures of polymer molecular

4
 Plastic Industry

Thermosetsor thermosetting plastics: they are polymers with

three-dimensional, cross-linked, networked structures in which the
polymeric chains are held together by cross-links (strong covalent
bonds). These plastics do not soften on heating and they are hard, strong
and more brittle. Thus, they cannot be reshaped or reused. The
thermosetting process significantly improves the material‟s mechanical
properties, and enhances its chemical resistance, heat resistance and
structural integrity. Thus, thermoset plastics are often used for sealed
products due to their resistance to deformation.
The following tables represent very important comparison between
thermoplastic and thermoset plastics and their most important
applications:
Table 1. Comparison between thermoplastic and thermoset plastics
Features Thermoplastic Thermoset
Thermoplastics are formed by Thermoset plastics are formed by
soften the polymeric pellets with cross-linking the polymers in
heat in a completely reversible which irreversible chemical bonds
way and without forming any are formed.
Curing additional chemical bonds. This The cross-linking process
Process allows thermoplastics to be eliminates the risk of the product
remolded and recycled without re-melting when heat is applied,
changing the material‟s physical making thermosets ideal for high
properties. heat applications such as
electronics and appliances.

5
 Chapter 3 Chemical Industries and their environmental impacts

 There are multiple resins that  Thermoset plastics significantly

offer various performance improve the material‟s mechanical
benefits, but most materials properties, providing enhances
commonly offer high strength chemical resistance, heat
Benefits and shrink-resistance. resistance, and structural integrity.
 Based on the resin, they can  Thermoset plastics are often
serve low-stress applications used for sealed products due to
such as plastic bags or high- their resistance to deformation.
stress mechanical parts.

 Highly recyclable  More resistant to high

 Aesthetically-superior temperatures than thermoplastics
finishes  Highly flexible design
 High-impact resistance  Thick to thin wall capabilities
Pros  Remolding/reshaping  Excellent aesthetic appearance
capabilities  High levels of dimensional
 Chemical resistant stability
 Hard crystalline or rubbery  Cost-effective
surface options
 Eco-friendly manufacturing

 Generally more expensive  Cannot be recycled

Cons than thermoset  Difficult to surface finish
 Can melt if heated  Cannot be reshaped

6
 Plastic Industry

Table 2: Common examples of thermoplastics and their uses

Example Uses

Polyethylene (PE) A wide range of inexpensive uses including supermarket

bags, and plastic bottles.

Polypropene (PP) Food containers, appliances, and car fenders (bumpers).

Nylon (Polyamide) Synthetic fiber, substituted for silk (in silk stockings),
tufted carpet, and machine gear wheels.

Polyvinylchloride Plumbing pipes and guttering, shower curtains, window

(PVC) frames, flooring, and erotic clothing.

Polyethylene Carbonated drinks bottles, jars, plastic film, and

terphethalate (PET) microwavable packaging.

Table 3: Common examples of thermosets and their uses

Example Uses

Vulcanized rubber Tires, gloves and tubing

Bakelit Electrical insulators and plastic wear.

Polyester Glass-reinforced plastics and fiber-glass

Epoxy Adhesive and in fiber reinforced plastic such as glass

reinforced plastic and graphite-reinforced plastic.

Acrylonitrile butadiene Electronic equipment cases (e.g., computer monitors,

styrene (ABS) printers, and keyboards).

7
 Chapter 3 Chemical Industries and their environmental impacts

Environmental impacts of plastics industry

Plastics are very stable and therefore stay in the environment a long
time after they are discarded, especially if they are shielded from direct
sunlight by being buried in landfills. Plastic pollution is the
accumulation of plastic products in the environment that adversely
affects wildlife, wildlife habitat and humans.It can afflict land,
waterways and oceans. Living organisms particularly marine
animalsare strongly harmed by their presence in water. The most
obvious form of pollution associated with plastic packaging is wasted
plastic sent to landfills. Moreover, plastics also cause a big chemical
burden on the environment, since they release significant of toxic
chemicals during theirproduction such as:
- trichloroethane - acetone
- methylene chloride - styrene
- methyl ethyl ketone - toluene

Other serious pollutants are that generated during the production of

the plastic resin itself. Manufacturing PET resin generates more toxic
emissions (nickel, ethyl-benzene, ethylene oxide, benzene) than
manufacturing glass. Producing a 0.5 kg PET bottle generates more
than 100 times the toxic emissions to air and water than the same size
bottle made of glass would produce.