| | Reference Document on Best Available Techniques in the |
| | 4,04 | | MB | Production of Polymers |
| | 314 | | stron |
| | 5413 | | ID | JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS) |
| | 2007 | | rok |
| | EXECUTIVE SUMMARYI |
| | PREFACEXI |
| | SCOPE .XXIII |
| | 1 GENERAL INFORMATION ON THE PRODUCTION OF POLYMERS. 1 |
| | 1.1 Definition 1 |
| | 1.2 Structure 1 |
| | 1.3 Properties 4 |
| | 1.3.1 General properties 4 |
| | 1.3.2 Thermal properties . 4 |
| | 1.4 Main uses 5 |
| | 1.4.1 Fields of application. 5 |
| | 1.4.2 Processing technologies . 6 |
| | 1.5 Main products 6 |
| | 1.5.1 Polymers based on crude oil 6 |
| | 1.5.2 Polymers based on renewable resources 8 |
| | 1.5.3 Biodegradable polymers 8 |
| | 1.6 Production and market . 9 |
| | 1.6.1 General 9 |
| | 1.6.2 Germany 14 |
| | 1.6.3 France 16 |
| | 1.6.4 Spain 18 |
| | 1.6.5 Belgium. 20 |
| | 2 GENERAL PROCESSES AND TECHNIQUES APPLIED IN THE PRODUCTION OF POLYMERS |
| | 21 |
| | 2.1 Raw materials and raw material requirements . 21 |
| | 2.2 Energy . 22 |
| | 2.3 Chemical reactions . 22 |
| | 2.3.1 Polymerisation (chain growth reaction) . 23 |
| | 2.3.2 Polycondensation (step growth reaction) . 25 |
| | 2.3.3 Polyaddition . 26 |
| | 2.4 Production processes 26 |
| | 2.4.1 Suspension polymerisation 26 |
| | 2.4.2 Bulk polymerisation. 27 |
| | 2.4.3 Emulsion polymerisation . 28 |
| | 2.4.4 Gas phase polymerisation 29 |
| | 2.4.5 Solution polymerisation . 29 |
| | 2.4.6 Summary of processes . 30 |
| | 3 POLYOLEFINS 31 |
| | 3.1 General information . 31 |
| | 3.1.1 Polyethylene. 31 |
| | 3.1.2 Polypropylene (PP) 34 |
| | 3.2 Applied processes and techniques in the production of polyolefins. 36 |
| | 3.2.1 Alternative processes . 36 |
| | 3.2.2 Low density polyethylene 38 |
| | 3.2.3 High density polyethylene . 43 |
| | 3.2.4 Linear low density polyethylene 50 |
| | 3.2.5 Polypropylene 52 |
| | 3.3 Current emission and consumption levels 61 |
| | 3.3.1 Low density polyethylene (LDPE). 61 |
| | 3.3.2 LDPE copolymers (ethylene-vinylacetate copolymer (EVA)). 62 |
| | 3.3.3 High density polyethylene (HDPE) 63 |
| | 3.3.4 Linear low density polyethylene (LLDPE) 65 |
| | 3.3.5 Polypropylene (PP) 66 |
| | 3.3.6 Economic parameters for the production of polyethylene . 67 |
| | 4 POLYSTYRENE . 69 |
| | 4.1 General information69 |
| | 4.1.1 General purpose polystyrene (GPPS) .70 |
| | 4.1.2 High impact polystyrene (HIPS) 70 |
| | 4.1.3 Expandable polystyrene (EPS) .71 |
| | 4.2 Applied processes and techniques in the production of polystyrene 72 |
| | 4.2.1 Process overview72 |
| | 4.2.2 General purpose polystyrene (GPPS) process 75 |
| | 4.2.3 High impact polystyrene (HIPS) process78 |
| | 4.2.4 Expandable polystyrene (EPS) process 81 |
| | 4.3 Current emission and consumption levels 84 |
| | 4.3.1 General purpose polystyrene (GPPS) .84 |
| | 4.3.2 High impact polystyrene (HIPS) 86 |
| | 4.3.3 Expandable polystyrene (EPS) .88 |
| | 5 POLYVINYL CHLORIDE .91 |
| | 5.1 General information91 |
| | 5.2 Applied processes and techniques in the production of polyvinyl chloride94 |
| | 5.2.1 Raw materials .94 |
| | 5.2.2 VCM supply, storage and unloading 94 |
| | 5.2.3 Polymerisation95 |
| | 5.2.4 Stripping .98 |
| | 5.2.5 Drying99 |
| | 5.2.6 Sieving and grinding.99 |
| | 5.2.7 VCM recovery100 |
| | 5.2.8 Water treatment 100 |
| | 5.3 Current emission and consumption levels 101 |
| | 5.3.1 Industry standards.101 |
| | 5.3.2 Emissions102 |
| | 5.3.3 Energy consumption.103 |
| | 5.3.4 Emission data from an example S-PVC plant 103 |
| | 6 UNSATURATED POLYESTER 105 |
| | 6.1 General information105 |
| | 6.2 Applied processes and techniques in the production of unsaturated polyesters107 |
| | 6.2.1 Raw materials .107 |
| | 6.2.2 Process safety hazard issues .109 |
| | 6.2.3 Plant layout and operation 109 |
| | 6.2.4 Storage.110 |
| | 6.2.5 Polycondensation110 |
| | 6.2.6 Curing114 |
| | 6.3 Current emission and consumption levels 115 |
| | 6.3.1 Emission and comsummption data from example plants .117 |
| | 6.3.2 Sources of environmental impact .117 |
| | 7 EMULSION POLYMERISED STYRENE BUTADIENE RUBBER119 |
| | 7.1 General information119 |
| | 7.2 Applied processes and techniques in the production of emulsion styrene butadiene rubber 122 |
| | 7.2.1 Preparation of rubber bales.123 |
| | 7.2.2 Oil extension.124 |
| | 7.2.3 ESBR latex .124 |
| | 7.2.4 Technical parameters125 |
| | 7.3 Current emission and consumption levels 126 |
| | 8 SOLUTION POLYMERISED RUBBER CONTAINING BUTADIENE.127 |
| | 8.1 General Information127 |
| | 8.1.1 Polybutadiene (butadiene rubber, BR)128 |
| | 8.1.2 Solution styrene butadiene rubber (SSBR).129 |
| | 8.1.3 Styrenic block copolymers (SBC) 130 |
| | 8.2 Applied processes and techniques 131 |
| | 8.2.1 Purification section.132 |
| | 8.2.2 Polymerisation section132 |
| | 8.2.3 Hydrogenation section132 |
| | 8.2.4 Blending section .133 |
| | 8.2.5 Solvent removal and recovery 133 |
| | 8.2.6 Technical parameters for typical solution plants 135 |
| | 8.3 Current emission and consumption levels 136 |
| | 9 POLYAMIDES 137 |
| | 9.1 General information . 137 |
| | 9.2 Applied processes and techniques in the production of polyamides 139 |
| | 9.2.1 Polyamide 6 . 139 |
| | 9.2.2 Polyamide 66 . 142 |
| | 9.2.3 Spinning techniques . 146 |
| | 9.3 Current emission and consumption levels 151 |
| | 9.3.1 Production of polyamides 151 |
| | 9.3.2 Spinning of polyamides . 151 |
| | 9.3.3 Potential sources of pollution in polyamide processes. 151 |
| | 10 POLYETHYLENE TEREPHTHALATE FIBRES 159 |
| | 10.1 General information . 159 |
| | 10.2 Applied processes and techniques in the production of PET fibres . 161 |
| | 10.2.1 Continuous polycondensation based on dimethyl terephthalic acid (DMT) 161 |
| | 10.2.2 Continuous polycondensation based on terephthalic acid (TPA). 162 |
| | 10.2.3 Continuous solid state post condensation. 163 |
| | 10.2.4 Batch solid state post condensation 164 |
| | 10.2.5 Batch polycondensation based on DMT 166 |
| | 10.2.6 Production of spinning chips 167 |
| | 10.2.7 Production of staple fibres . 167 |
| | 10.2.8 Production of filament yarns 168 |
| | 10.3 Current emission and consumption levels 170 |
| | 10.3.1 Continuous polycondensation based on DMT, TPA and batch DMT-BPU processes 170 |
| | 10.3.2 Post condensation processes 171 |
| | 10.3.3 PET processing 171 |
| | 11 PRODUCTION OF VISCOSE FIBRES 173 |
| | 11.1 General information . 173 |
| | 11.2 Applied processes and techniques in the production of viscose fibres. 174 |
| | 11.2.1 Processes and products. 174 |