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Tuesday 27 September 2016

Non conventional energy sources

Non-Conventional Sources of Energy: Meaning, Types, Advantages

Energy generated by using wind, solar, small hydro, tides, geothermal heat and biomass is known a non-conventional energy. All these sources are renewable process of energy generation and do not cause environmental pollution.

NON CONVENTIONAL ENERGY SOURCES AND STORAGE DEVICES
 In 1939, Otto Hahn studied the effect of bombardment of fast neutron on uranium.
 The fission of U-235 nucleus by slow neutrons released enormous amount of energy. The energy released is called nuclear energy or fission energy.
 Nuclear fission is defined as the process of splitting of heavier nucleus into two or more smaller nuclei with simultaneous liberation of large amount of energy.
NUCLEAR ENERGY
 When U-235 is bombarded by slow moving neutron, unstable U-236 is formed.
 This nucleus disintegrates into two equal nuclei with the release of huge amount of energy and few neutrons.
MECHANISM OF NUCLEAR FISSION
 Heavy nucleus splits into two or more nuclei.
 Two or more neutrons are produced by fission of each nucleus.
 Large quantity of energy is produced .
 All the fission fragments are radioactive , giving off gamma radiations
 The fission products fall into two groups- one between mass no.80-100 and other 120-150

CHARACTERISTICS OF NUCLEAR
FISSION REACTION
 All the fission reaction are self propagating chain reaction because fission products contains neutrons which further cause fission in other nuclei.
 The nuclear reactions can be controlled ,by absorbing the neutrons using Cd, B or Hf.
 Every secondary neutron released in the fission reaction does not strike a nucleus , some escape into air. Hence a chain reaction cannot be maintained.
 The number of neutrons resulting from a single fission is known as multiplication factor. When it is less than 1 , no chain reaction take place. The process of combination of lighter nuclei to form heavier nuclei, with simultaneous liberation of huge amount of energy.
Example : Fusion reaction in sun

NUCLEAR FUSION
S.No
Nuclear fission
Nuclear fusion
1.
It is a process of breaking a heavy nucleus with projectiles into two or more light fragments with liberation of large amount of energy
 It is a process of  fusion of lighter nuclei  to form heavier nuclei, with simultaneous liberation of huge amount of energy. 
2.
This process occurs with the emission of radioactive rays.
It does not emit any radioactive rays.
3.
It takes place simultaneously at ordinary temperature.
It takes place at very high temperature(106K)
4
It gives rise to chain reaction
No chain reaction
5
Neutrons are emitted
Positrons are emitted
6
It can be controlled.
It cannot be controlled.

DIFFERENCES BETWEEN NUCLEAR FISSION AND NUCLEAR FUSION
 In the nuclear fission reaction , the secondary neutrons emitted from the fission of uranium may hit another uranium nuclei and cause fission producing more neutrons and so on. Thus a chain of self sustaining nuclear reaction is set up . This type of reaction is known as nuclear chain reaction.
 The secondary neutrons released may escape to the air and will result in the breaking of the chain and the amount of energy released will be less.
 For the chain reaction to continue, sufficient amount of U-235 must be present to capture the neutrons.
 The minimum amount of fissionable material requited to continue the nuclear chain reaction is called Critical mass. The critical mass of U-235 is between 1 to 100Kg.
 If the mass of the fissionable material is more than the critical mass, it is called super critical mass. And if it is lesser, it is called  sub critical mass.
 The super and sub critical mass may hinder the propagation of the chain reaction.
NUCLEAR CHAIN REACTION EXAMPLE OF NUCLEAR CHAIN REACTION
When U-235 is bombarded by thermal neutrons, it undergoes fission and releases three neutrons. These 3 neutrons strike another U-235 nucleus causing 3x3=9 neutrons. These nine further give rise to 27 reactions. This process is known as nuclear fission chain reaction.
 The energy released by the nuclear fission is called nuclear fission energy or nuclear energy. cause of the release of energy. The enormous amount of energy released during the nuclear fission isdue to the loss in some mass, when the reaction takes place. During nuclear fission, the sum of masses of the products formed is slightly less than thesum of masses of target species and bombarding neutron. The loss in mass get converted into energy according to Einstein equation. where c= velocity; m = loss in mass and E= energy
Total masses of reactants = 235.12 + 1.009 = 236.129 amu
Total masses of products = 140.91 +91.91 +3x1.009 + 235.847 amu
Loss in mass = 0.282 amu
The loss of 0.282 amu of U-235 liberates = 0.282x931.47 = 262.676meV
NUCLEAR ENERGY
NUCLEAR REACTOR OR PILE
 The arrangement or equipment used to carry out fission reaction under controlled conditions is called nuclear reactor.
 The energy released by the fission reaction in the nuclear reactor can be used to produce steam which can turn turbines and produce electricity.
COMPONENTS OF A NUCLEAR REACTOR
1. Fuel rods
2. Moderator
3. Control rods
4. Coolant
5. Protective screen
6. Heat exchanger / pressure vessel
7. Turbine
FUEL RODS: The fissionable material used in the nuclear reactor is enriched U-235. It is used in the form of rods or strips. It produces heat energy and neutrons , thus iniating nuclear chain reaction.
MODERATOR: It slows down fast fission neutrons . Ex., ordinary water, Heavy water , graphite, beryllium. The kinetic energy of fast neutron is reduced to slow neutrons(0.25 eV)
CONTROL RODS: To control the rate of fission of U-235 , these rods absorb the excess neutrons . So the fission reaction proceeds at steady rate. Movable rods made of Cd or B are suspended between fuel rods. These rods are lowered and raised as of need. If the rods are deeply inserted inside the reactor, they will absorb more neutrons and the reaction become very slow. If the rods are pushed outwards, they will absorb less neutrons and the reaction will be very fast. It controls the nuclear chain reaction and avoids the damage to the reactor.
COOLANT: Substance which cools the fuel core by removing heat produced by fission. The coolant liquid is circulated in the reactor core. It enters the base and leaves at the top. The heat carried by outgoing liquid is used to produce steam. Ex., Water ( act as coolant and moderator) Heavy water , liquid metal ( Na or K) , Air, organic compounds like poly phenyls.
PROTECTIVE SCREEN/ SHIELD: The moderator , control rods and fuel element are enclosed in a chamber which has a thick concrete shield(10m thick). These walls stop the nuclear radiations from moving out of the reactor. The environment and the operating persons are protected from destruction in case of leakage of radiation.
HEAT EXCHANGER : It transfers the heat liberated from the reactor core to boil water and produce steam at about 400Kg/cm2.
PRESSURE VESSEL : It encloses the core and also provides the entrance and as exit passages for coolant. It withstand the pressure as high as 200 atm.
TURBINE : The steam generated in the heat exchanger is used to operate a steam turbine, which drives a generator to produce electricity. The exhaust steam is condensed and sent back to the heat exchanger.
NUCLEAR REACTOR
LIGHT WATER NUCLEAR POWER PLANT
 It is the one in which U-235 fuel rods are submerged in water. Here water acts as coolant and moderator.
WORKING
 The fission reaction is controlled by inserting or removing the control rods of B-10 automatically from the spaces in between the fuel rods. The heat emitted is absorbed by the coolant (light water) .The heated coolant then goes to the heat exchanger containing sea water, which is converted to steam. The steam drives the turbines , generating electricity.
BREEDER REACTOR
 Breeder reactor is the one which converts non-fissionable material (U-238, Th-232 ) into fissionable material (U-235, Pu-239).
 In breeder reactor, of the three neutrons emitted in the fission of U-235, only one is used in propagating the fission of U-235.The other two are allowed to react with U-238. Thus two fissionableatoms Pu-239 are produced for each atom of U-235 consumed. The breeder reactor produces more fissionable material than it uses.
 The fissionable nucleides such as U-235 and Pu-239 are called fissile nucleides. The nonfissionable nucleides such as U-238 & Th-232 are called fertile nucleides. The most common breeding reaction is that of plutonium-239 from non-fissionable uranium-238. The term "fast breeder" refers to the types of configurations which can actually produce more fissionable fuel than they use, such as the LMFBR. This scenario is possible because the non-fissionable uranium-238 is 140 times more abundant than the fissionable U-235 and can be efficiently converted into Pu-239 by the neutrons from a fission chain reaction.
SOLAR ENERGY CONVERSION
It is the process of conversion of direct sunlight into more useful forms. It occurs by the following two mechanism.
(i) Thermal conversion (ii) Photo conversion
THERMAL CONVERSION
It involves absorption of thermal energy in the form of Ir radiation. Solar energy is an important source for low temperature heat which is useful for heating buildings, water and refrigeration.
Methods of thermal conversion
1. Solar heat collectors : It consists of natural materials like stones, bricks or materials like glass, which can absorb heat during day time and release it slowly at night. Used in cold places, where houses are kept in hot condition using heat collectors.
2. Solar water heater : It consists of an insulated box inside of which is painted with black paint. It is also provided with a glass lid to receive and store solar heat. The black painted copper coil allows the cold water in and heats it up and flows out into a storage tank.
PHOTO CONVERSION
It involves conversion of light energy directly in to electrical energy. Ex. Photo galvanic cell or solar cell
PHOTOGALVANIC CELL
It is the one which converts the solar energy directly into electrical energy.
PRINCIPLE : The basic principle is based on the photovoltaic effect. When solar rays fall on a two layer of semiconductor devices, a potential difference between two layer is produced. This potential difference causes flow of electrons and produces electricity.
CONSTRUCTION : Solar cells consists of a p- type semiconductor ( Si doped with B) and n-type semiconductor(Si doped with P ) .
WORKING : When solar rays fall on p-type semiconductor, the electrons from the valence band get promoted to the conduction band and cross the p-n junction into n-type semiconductor. Thereby potential difference is produced which causes flow of electrons and hence current is generated.
APPLICATIONS OF SOLAR CELLS :
1. Lighting purpose
2. Solar pumps can be run by solar battery
3. Used in calculators, electronic watches, radios and TV.
4. Used to drive vehicles
5. Used in space craft and satellites
WIND ENERGY
20035-004-0E17DE04[1]
o Energy recovered from the force of the wind is called wind energy. The wind energy is harnessed by making use of wind mills.
o WIND MILLS : The strike of blowing wind on the blades of the wind mill make it rotating continuously. The rotational motion of the blade drives a number of machines like waterpump, flour mills and electric generators.
o WIND FARMS : When a number of wind mills areinstalled and joined together in a definite pattern it forms a wind farm. The wind farm produce alarge amount of electricity. The minimum speed required for satisfactory working of a wind generator is 15Km/hr.
Advantage: (i) no pollution (ii) cheap (iii) renewable
FUEL CELL
 A fuel cell is a device that converts a fuel and air directly into electricity, heat and water by means of electrochemical reactions.
 In a fuel cell, the electricity can be generated as long as the fuel and oxygen are supplied into the cell.
 It consists of an electrolyte and two electrodes.
 In a fuel cell , a fuel is sent through the anode and the oxygen is supplied through the cathode. The electrolyte carries the charged particles from anode and to cathode and vice versa.
 A catalyst such as Pt, Pd, Mg or Ni is often used to initiate and speed up the reactions at the electrodes.
 A fuel cell will also have a fuel reformer which can use hydrogen fuel from any hydrocarbon fuel like natural gas, methanol or even gasoline.
 A single fuel cell can generate a tiny number of direct current but a large number of such fuel cells in the form “stack” can provide the power output from few watt to mega watts. The cell consists of two porous carbon electrodes impregnated with a finely  divided platinum or nickel as catalyst with an electrolyte of 25-40% KOH .
 The cell develops an emf of 1.23V.
 The efficiency of hydrogen-oxygen fuel cell is 70% .
 The operating temperature is 60-70C .
 The cell power output is 300 watts to 5 kilowatts
 The cell may be represented as  C, Pt or Ni / KOH / C, Pt or Ni
WORKING :






At anode,
At cathode,
The net reaction is
HYDROGEN – OXYGEN FUEL CELL
 It is an electrochemical cell or many electrochemical cells connected in series, to be used as a source of direct current to at a constant voltage.
 Batteries are the store houses of electrical energy on demand.
 Batteries are classified as
1. Primary battery – It is the device in which the cell reaction is non reversible and it cannot be recharged. Ex. Leclanche cell, alkaline cell, button cell ( silver and mercury cell )_
2. Secondary battery – These cells are rechargeable and reusable. Its electrode reaction can proceed in either direction. During charging, electrical work is done on the cell to provide the free energy needed to force the reaction in the non-spontaneous reaction. Example – Lead acid cell , Nickel cadmium cell
3. Fuel cell – It is similar to a battery and produce electricity using chemicals. They do not run down like batteries. Ex. Hydrogen-oxygen cell, methanol fuel cell.
BATTERIES
 Alkaline battery is a more modern version of dry cell. It is introduced in 1949.
 It consists of KOH electrolyte and Zn powder act as anode. The carbon rod and manganese dioxide act as cathode.
 The cell may be represented as
At anode
At cathode
The overall net reaction is
The alkaline cell gives a voltage of 1 volt to 1.5 volt.
ADVANTAGES :
1. It can deliver higher current without severe voltage drop.
2. The shelf life of alkaline battery is 5-8 times more than leclanche cell.
3. Zn does not dissolve in alkaline medium readily.
USES : It is used in shavers, radios, tape recorders and electronic photographic flash units.
ALKALINE BATTERIES
SECONDARY BATTERIES
LEAD ACID STORAGE BATTERY OR ACCUMULATOR
It was invented by Gaston Plante in 1859. It acts both as voltaic cell and electrolytic cell. On supplying electrical energy, this acts as a voltaic cell . On recharging, the cell acts as an electrolytic cell.
CONSTRUCTION
1. The cell consists of a polypropylene container containing six lead-acid electrochemical cells connected in series.
2. The voltage of cell is always multiple of 2 V, it can be increased by dividing each cell with microporous polyethylene dividers.
3. All the cathode and anode plates within a single cell are linked together, the anode of one cell being linked with the anode of the next cell and the cathodes are also linked like wise.
4. The anodes are made of lead. Cathodes are made of solid lead (IV) oxide or Lead dioxide, mounted on a lead base.
5. Both poles of the battery are also made of lead.
6. The electrolyte is 80% solution of sulphuric acid saturated with Lead sulphate.
7. The cell is represented by
The electrode reactions are
Discharging : During discharge the lead plates (anode) act as voltaic cell, and the cell reaction are
At anode – At the negative pole (anode) oxidation of lead takes place 
Then the lead ions combine with sulphate ions to produce lead sulphate
Net reaction
At cathode – The electrons released at anode flow to the cathode, where reduction reaction takes place
 
Net reaction  
The overall cell reaction during discharging
When current is drawn , lead – acid battery becomes less efficient . So the battery has to be recharged.
RECHARGING
Charging is done by continuous application of potential from an outside power source. As long as the current is passed, Pb ions are reduced to lead metal while, at the lead dioxide electode, lead ions are oxidized . During charging, reverse reaction takes place
 LIMITATIONS
a. These batteries tend to slowly self discharge, so a car left idle for several weeks might be unable to start.
b. The sulphuric acid becomes viscous when the temperature is low, this inhibits the flow of ions between the plates and reducing the current. This makes it very difficult to start a car in cold weather.
 USES
a. The lead storage cells are mainly used in motor vehicle.
b. They also find applications in telephone exchanges , hospital , power stations, railway stations etc.,
 NICKEL CADMIUM BATTERIES
 LITHIUM BATTERY
OTHER TYPES OF SECONDARY LITHIUM BATTERIES

THE END

Polymers and Composites

Polymers & Composites

Polymers | Free Full-Text | Thermal Conductivity of Graphene ...
 

1. Polymers – Introduction
-a) Definition –monomer, polymer, degree of freedom, functionality, oligo polymer, High polymer, isotactic, atactic, syndiotactic, Homopolymers, Heteropolymers. 
b) Types of polymerization – Addition, condensation , co-polymerisation – comparison
c)Mechanism of Free radical polymerization – 3 step process
Step1-Initiation (Radical and Chain initiating species formation)
Step2 -Propagation (Living polymer formation)
Step3 -Termination (By coupling and disproportionation)

2. Plastics
a) Classification – i)based on thermal property – Thermo / Thermoset plastics            ii) Based on usage – Commodity and Engineering plastics
b) Prepration, properties and applications of  i) PVC      ii) Teflon   iii) Poly carbonate  iv) Poly Urethane    v)PET   vi) Nylon

3. Rubber
a) Raw rubber – Preparation - problems of raw rubber – Vulcanisation – Difference between raw and vulcanized rubber
b)Synthetic rubber – Preparation, properties, uses of i) SBR  ii) Butyl rubber

4. Composites
a) Definition – properties - Types  - Polymer matrix / Metal matrix / Ceramic matrix composties
b) Fibre Reinforced Plastics (FRP) – Types of FRP  - Applications of FRP



   TOPIC -1. POLYMERISATION:
1. Under the proper conditions of temperature, pressure and catalyst , the micro (Smaller) molecules are combining together to form a macro (big) molecule. This process is called Polymerisation.
E.g  n(CH2  = CH2à     --(CH2 - CH2 )—n

2. Micro molecules are called ‘Monomer’. Macro molecule is ‘Polymer’.
   Monomer is a micro molecule (small molecule) which combines with each other to form a polymer. Example: ethylene.
Condition for a monomer:

a.       Monomer should contain at least one double bond.
b.      It should contain minimum two same or different functional groups.

3. The number of monomers present in a polymer is ‘ Degree of polymerisation’ (n).
Degree of Polymerisation = Molecular Wt of polymer / Molecular Wt of monomer
                                  n= M/m
   If   n  = low , Mol.Wt  = 500 – 5000 Dalton units, it is Oligo polymer.
   If   n = High, Mol.Wt = 10,000 – 2,00,000 Dalton units , it is High polymer.

4. If the polymer chain contains same type of monomer, it is “Homo polymer”.
e.g PVC  structure  :  A – A – A- A- A-A -A
    If the polymer chain contains different type of monomer, it is “Hetero polymer” or
Copolymer.
e.g. Nylon  A-B- A-A-A-B-A

Types of Copolymers:
i)                     Alternating copolymer: M1-M2-M1-M2-M1-M2
ii)                  Random copolymer: M1-M2-M2-M1-M2-M1
iii)                 Block copolymer: M1-M1-M1-M2-M2-M2- M1-M1-M1-M2-M2-M2
iv)                Graft copolymer: M1-M1-M1-M1-M1-M1
   l
      M2
  l
      M2

5. Number of Reactive sites present in a monomer is called ‘Functionality’.
e.g  CH2  = CH2  , The double bond is acting as two reactive site, So, Ethylene functionality is 2.
CH2 – OH       In glycerol three –OH groups present. So, functionality = 3
CH – OH
CH2 – OH
Significances:
1.      If F = 2, they form linear chain structure.
2.      If F=3, they form branched structure.
3.      If F≥ 4, then they form complex 3D structure.

6. Orientation of monomers in a polymer chain is called “Tacticity”.  If the groups are in same orientation, it is isotactic.  If they are random it is “atactic”.  If they are arranged in alternative fashion, it is syndiotactic.




 A      A      A       A      A               A      B     B      A    B            A       B     A      B    A
│      │     │       │      │                │      │     │     │     │            │      │     │     │     │
 M  -M  -  M  -  M  -  M          -  M  - M -  M  -  M –M             M  -  M  - M – M - M        
 │    │      │      │      │                  │     │     │       │    │            │      │    │      │    │
   B     B      B      B       B                B      A     A      B    A             B      A     B     A     B

       (Iso tactic)                                    (Atactic)                                  (syndiotactic)

Cis polyisoprene                                  polypropylene                         Trans polyisoprene

TYPES OF POLYMERISATION
1. Addition  2. Condensation  3. Copolymerisation

No
Addition Polymerisation
Condensation Polymerisation
1
Eg. PVC
Eg. Nylon 6,6
2
Otherwise known as “Chain growth Polymerisation”.
Otherwise known as “Step wise Polymerisation”.
3
Monomers are adding together to form polymers.
Monomers are condensed to form polymer.
4
No elimination of other molecules occurs.
Elimination of smaller molecules occurs.
5
At least one multiple bond presence is essential condition.
Monomers must have two or more functional groups.
6
Homo polymers are formed.
Hetero polymers are formed.
7
Thermoplastics are formed.
Thermo set plastics are formed.
8
Molecular weight of the polymer is the integral multiple of monomers.
Need not be so.
9
Monomers disappear slow and steadily.
Monomers disappear at the initial stage of the reaction.
10
Longer processing time is needed.
Longer time is essential.
e.g
Addition Polymerisation:
n(CH2  = CH2à  -( CH2 - CH2  -)n
    Ethylene         à  Polyethylene

Condensation Polymerisation
n  H2N  - (CH2)6 – NH2   +  n HOOC – (CH2)4 – COOH  à
Hexa methylene diamine        Adipic acid
[ - HN  - (CH2)6 – NH - OC – (CH2)4 – CO - ]n
                                                                                        Nylon 6,6

Co-Polymerisation
1. It is a special kind of polymerisation, otherwise known as “Joint polymerisation”.
The product is known as ‘Co-polymers’.  It is used to alter the hardness, strength, rigidity of the monomers.

Hexagon: Oe.g SBR synthesis                                  CH2  = CH
                                                                                             
 n CH2  = CH -   CH  = CH2   +        n                             à
  (  75% butadiene)                                (25% Styrene)

 --[  CH2   - CH =   CH  - CH2  -  CH2  -  CH -]n         
Hexagon: O 


                                                                                                             

                                                (Styrene – Butadiene RubberSBR)   



MECHANISM OF FREE RADICAL ADDITION POLYMERISATION :

3 steps  in Free radical mechanism: 1. Initiation     2. Propagation   3. Termination

Step I - Initiation  : 1a)   Initiator  à  Radical
         1b)   Radical  +  Monomer  à  Chain Initiating Species  (CIS)

Step II  - Propagation:  CIS  +  n (monomer)  à  Living polymer

Step III  - Termination:

3a) By Coupling  :  Radical  + Radical   à  Macromolecule  ( Dead polymer)
3b)  By disproportionation (by Hydrogen transformation):
       Radical  +  Radical   à  Unsaturated polymer  + Saturated polymer

EXPLANATION:

1. Initiation

a)  Initiator  à  Radical
1.The substance which undergoes homolytic cleavage to form radical is called ‘Initiator’.  (e.g) acetyl peroxide initiator
2.The substance with single electron is called ‘ radical’. (e.g) acetyl peroxide radical
e.g  Acetyl peroxide  à  Radicals   ( at 800C)  CH3COO  - CH3COO  à  2 CH3COO.
(or)R.
 b)  Radical  +  Monomer  à  Chain Initiating Species  (CIS)
                          H                                  H
                          │                                  │                 
       R.  +  CH2=C       à    R – CH2  - C.                            
                          │                                  │
                         Cl                                   Cl

2. Propagation:
CIS  +  n (monomer)  à  Living polymer
                          H                                 H                                  H                 H
                          │                                 │                                 │                  │
        R – CH2  - C    +   n  (  CH2  =  C      )   à   R (-CH2 – C -)n-CH2  - C.
                          │                                 │                                 │                  │
                         Cl                                 Cl                                 Cl                Cl

3. Termination
a) Coupling
Radical  + Radical   à  Macromolecule  ( Dead polymer)
CIS + CISà Dead polymer

                          H                               H                                H    H
                          │                              │                                 │    │
        R – CH2  - C    +    R- CH2 – C.       à    R – CH2 – C – C – CH2 – R
                          │                              │                                 │    │             
                         Cl                              Cl                                Cl   Cl  
                                                                                 (Dead polymer)

b) Disproportionation (by Hydrogen transformation)
CIS + CIS à  Unsaturated polymer  + Saturated polymer
                          H                               H                                H                 H
                          │                              │                                  │                 │
        R – CH2  - C     +    R- CH2 – C.       à    R – CH  = C    +     H– C – CH2 – R
                          │                              │                                  │                 │             
                         Cl                              Cl                                 Cl                Cl  
The products are known as dead polymers.

TOPIC – 2 - PLASTICS
Definition:  Plastics are high polymers which can be moulded into any desired shape under proper conditions of temperature , pressure and catalyst.  (e.g) PVC , PET

Advantages of plastics:                                        Disadvantages of low quality plastics:
1. Insulator                                                      1.  very soft
2. Corrosion resistant                                      2.  Embrittlement
3. Easy mouldability                                       3. Agening ( Low durability)
4. Used as shock absorbers                             4. Cannot withstand high temperatures.
5. Has adhesive property                                5. Creep (shape Deformation  due to load)
6.  Less weight
7.  Chemical inertness
8.  Available in various colours


CLASSIFICATION OF PLASTICS:
a)Based on thermal properties  - i) Thermo plastics   ii)Thermo setting plastics
b)Based on utility  -  i) Commodity plastics  ii) Engineering plastics
                                      

Differences between Thermoplastics and thermosetting plastics
No
THERMOPLASTICS
THERMOSETTING PLASTIC
1
Eg. PVC , Polyethylene
Polyester, Bakelite
2
Plastics which are melted at high temperature, solidified at low temperature They can be remelted and remoulded into any desired shapes for any number of times.
They cannot be remoulded after their first usage.
3
Scarp can be used again.
Scarp can not be used again.
4
Formed by addition polymerisation
Formed by condensation polymerisation
5
They have linear structure
M – M – M – M – M – M
They have complex 3D structure.
         -  M  - M -  M  -  M –M            
│      │     │       │      │  
M  -M  -  M  -  M  -  M         
│      │     │     │     │       
M  -  M  - M – M – M
 │      │     │     │     │
6
The bond strength is low
The bond strength is high
7
Molecular weight is low
Molecular weight is high
8
Soluble in organic solvents.
Insoluble in organic solvents.
9
Prepared by Injection moulding
Prepared by compression moulding.








Differences between Commodity and Engineering plastics
No
COMMODITY PLASTICS
ENGINEERING PLASTIC
1
Eg. Low grade PVC ,polystyrene, Polyethylene
PVC, Teflon , Polycarbonate, poly urethane, Nylon, PET
2
Used for domestic and general purposes.
Used for special  and engineering purposes
3
Easily affected by chemicals
Not affected by  most of the chemicals.
4
Thermal property is very poor.
Thermal property is verygood.
5
They are not 100 % insulators.
They are  having high insulating properties.
6
They cannot withstand abrasion.
They can withstand abrasion.
7
Mechanical strength is low.
Mechanical strength is high.
8
Comparatively cheap.
Comparatively costly.

PROPERTIES AND USES OF ENGINEERING PLASTICS
No
Name
Properties
Uses
1
PVC
1.Colourless , odourless powder.
2. Affected by Organic chlorinated acids.
3. It is degraded by high temperature and radiations.
1.Pipes
2Electrical wire covering
3.Table cloth
4.Adhesives
2
TEFLON
1. Except Fluorine, it is chemically inert.
2.Withstands up to 3500C
3. Electrical insulators.
1. In chemical carrying pipes
2.Gaskets in cookers
3. Electrical switchboards.
3
POLY
CARBONATE
1. Withstand very high temperatures.
2. They are having high transparency.
1. In sterilizable bottles.
2. Film industry – Camera, Photography films
3. Transparent bottles
4
POLY URETHANE
Used at Subzero (-ve) temperatures.
1.Oceanography
2.In defense
3.High altitude mountains
5
PET
1.High stretch resistance
2. High wrinkle resistance
3. Unbreakable
4. Acid proof
1. PET jars, bottles
2.Helmets
3.Terylene fabrics
4.Textile , wool industry
6
POLY AMIDES
1.Flexibililty
2.Elasticity
3.Elongatable property
1. Tooth brush bristles
2.Automobile gears
3.Textile industry
4. Nylon ropes

PREPARATION OF SOME IMPORTANT ENGINEERING PLASTICS

1. PVC – POLY VINYL CHLORIDE

Step 1 – Acetylene is treated with Hydrochloric acid at 60-800C in presence of some metallic chloride catalyst. It forms Vinyl chloride.

CH≡CH    +    HCl    MCl /  60-800C       CH2 = CH                                                                                       
                                                                                │
                                                                                 Cl
(Acetylene)                                                     (Vinyl chloride)

Step 2 – Vinyl chloride, in presence of Hydrogen peroxide undergoes polymerisation to form Poly vinyl Chloride.
 


n CH2 = CH                     H2O2                               CH2          CH                                                                           
           │                                                                                  │
           Cl              Polymerisation                                          Cl      n

Vinyl Chloride                                                                                   PVC

2. TEFLON (Poly Tetra Flouro Ethylene –PTFE)

 Step – 1 When Chloro Diflouro methane is heated, it forms Tetra flouro ethylene is formed.
2CHClF2         heating               CF= CF2
(Chloro difluro methane)         (Tetra flouro ethylene)

Step 2 - Tetra flouro ethylene   , in presence of Benzoyl peroxide (Be2O2) , polymerized to form PTFE.
 


n (CF2 = CF2 )         Be2O2            CF- CF2   n
                           polymerisation
(Tetra flouro ethylene)                        (Teflon – PTFE)

3. POLY CARBONATE ( Lexan / Merlan)
Hexagon: O
 


                   _O                                                                              CH3
Hexagon: OHexagon: O                                                                             l
  n                              C = O   +  n OH -          __C __        --OH  à
Hexagon: O                  _ O                                                                                 l
                                                                            CH3

                                                      O               CH3
                                                     ║                  l
                                          -- (O—C—C6H4—C-- C6H4—O)n--    +2n   C6H5OH
                                                                          l
          CH3


4.POLY URETHANE  ( Perlon – u)

  O                                 O   
  ║                                 ║       
nC = N – (CH2)6 – N = C        +         n   HO – (CH2)4 – OH     à
(Hexa methylene di iso cyanate)        (Butane diol)

                                                              O                                       O
                                                              ║                                       ║
                                                            (-C – NH – (CH2)6 – NH – C – O – (CH2)4 – O- )n
                                                                                    (poly urethane)








5. POLY ETHYLENE TERYPTHALATE (PET)

Hexagon: O
 


 n HO – (CH2)2  - OH    + n HOOC -        - COOH   à

Ethylene glycol                    Terephthalic acid
Hexagon: O
 


                                (-O – (CH2)2 – O – C - - C - --C--)n     +  (2n-1) H2O
                                                                 ║              ║
                                                                 O             O   (PET)

6.  POLYAMIDES ( NYLON -6,6)                                                            
Condensation Polymerisation

n  H2N  - (CH2)6 – NH2   +  n HOOC – (CH2)4 – COOH  à

Hexa methylene diamine        Adipic acid

[ - HN  - (CH2)6 – NH - OC – (CH2)4 – CO - ]n  + (2n-1)H2O
                                                                         Nylon 6,6


TOPIC – 3 -    RUBBERS

Rubber is a high polymer with basic qualities of elasticity and non-crystallinity. They are known as elastic + polymer = elastomers.

Types – i) Raw (natural) rubber ii) Synthetic rubber

Natural rubber preparation:

1. When we cut the bark of rubber tree, latex milk is coming out.  It is collected in containers.
2. Latex contain major portion of water (70%) and 30% rubber as isoprene C5H8 units.
3. To get colloidal rubber, as coagulant, we are adding acetic acid.
4. The colloidal rubber is dried in air or passing smoke.  The previous one is called ‘dried rubber’ and another one is ‘smoked rubber’.
5. Then it is made as sheets using rollers.

Vulcanisation:
To remove the defects of rubber, we are adding sulphur to rubber and heating at 100 – 1400C under high pressure.  This process is called Vulcanisation.
     The defect of rubber is mainly due to the non-cross linked isoprene structure of rubber.  But, the added sulphur attacks the double bond of isoprene units and converts the  non-cross linked structure into a cross linked structure. So, the defects of natural rubber are removed.
     If 3 -5 % sulphur is added, it is soft rubber. They are used in tyres.
     If more than 30% Sulphur is added, it is called ‘hard’ or ‘ebonite rubber’. They are used in acid battery cases.

                         Isoprene C5H8   à   Poly isoprene





            CH3                                                               CH3                               CH3
            │                                              │                                    │
CH2 = C – CH = CH2     à   –CH2 – C= CH–CH –CH2 –  C = CH – CH2


                                                –CH2 – C= CH–CH –CH2 –  C = CH – CH2
                                                             │                                    │
                                                              CH3                                              CH3
                                                   ( Rubber defects due to non-cross linked structure)



Adding sulphur during vulcanization alters the structure as follows:
                  CH3                               CH3
                │                                    │
   –CH2 – C– CH–CH –CH2 –  C – CH – CH2
                │     │                             │   │
                 S     S                             S    S
                │     │                             │   │
   –CH2 – C– CH–CH –CH2 –  C –  CH – CH2
                │                                    │
                CH3                                              CH3


Differences between raw and vulcanized rubber

No
Raw  rubber
Vulcanised rubber
1
Soft and sticky during summer
Not Soft and sticky during summer
2
Hard and brittle during winter
Not Hard and brittle during winter
3
Swells in oil
Does not Swell in oil
4
Absorbs high amount of water
Does not Absorb high amount of water
5
Affected by organic and inorganic acids
 Not Affected by organic and inorganic acids
6
Easily undergoes oxidation
Does not easily undergo oxidation
7
Poor life time
High  life time
8
Tensile strength is low (200 kg/cm2)
Tensile strength is high (2000 kg/cm2)
9
Used between 10 – 60 0C
Used between  - 40  to 100 0C
10
E.g) Raw rubber
E.g) SBR , Butyl rubber


SOME IMPORTANT SYNTHETIC RUBBER

1.SBR – Styrene Butadiene Rubber – Buna -S
Hexagon: O                                                                CH2  = CH
                                                                                             
 n CH2  = CH -   CH  = CH2   +        n                             à
  (  75% butadiene)                                (25% Styrene)

                               [  CH2   - CH =   CH  - CH2  -  CH2  --  CH -]n         
Hexagon: O 




                                                                                    (Styrene – Butadiene RubberSBR)    


properties:
1. For vulcanization, it needs little amount of sulphur but more amount of accelerators.
2. High tensile strength.
3. Not Soft and sticky during summer
4. Not Hard and brittle during winter
5. Not affected by organic and inorganic acids.

Uses:
Tyres – Belts – Gaskets – Shoes – Tank linings

2. BUTYL RUBBER – (GR-I) rubber
                                                         CH3
                                                         │ 
n [ H2C = C (CH3)2 ]  +  n [CH2 = C – CH = CH2]   à
                                                                                                    CH3
                                                                                                    │ 
                                                      --[ H2C – C (CH3)2  -  CH2 –   C  = CH –CH2] --n

Properties:
1. Low permeability to air 2. High tensile strength. 3. Not Soft and sticky during summer 4. Not Hard and brittle during winter 5. Not affected by organic and inorganic acids.

Uses:
Inner tubes of automobile tyres - Belts – Gaskets – Shoes – Tank linings


TOPIC 4 – COMPOSITES AND FIBRE REINFORCED PLASTICS (FRP)
 COMPOSITES

# Composites are the special kind of material system consist of two distinct phases – matrix and dispersed phase.
# Matrix phase is the external continuous body constituent.
(e.g) Ceramics, Polymer, metals
# Dispersed Phase is the internal structural constituent.
(e.g) Fibre, Flakes, particulates

Need / Advantages / Properties of composites:
1. They are inert towards chemicals.
2. Corrosion resistance
3. Improved mechanical strength.
4. Improved creep resistance.
5. High insulation property.
6. Variable dielectric constant.
7. Withstand very high temperature.
8. High dimension stability.

Types of composites (Based on Matrix)
1. Polymer matrix composite(PMC)      
 2.Metal matrix composite (MMC)
 3. Ceramic matrix composite(CMC)








  POLYMER MATRIX COMPOSITE ( FIBRE REINFORCED PLASTICS –FRP)
Synthesis:
Step 1.
Polymer plastic resin is taken as matrix phase.
Example:

S.No
Resin
 To provide
1
Polyester
Good strength and mechanical property
2
Epoxy resin
Tensile and mechanical strength
3
Silicone resin
Excellent thermal and electrical property
4
Phenolic resin
High temperature resistance
5
Aromatic amide ( Aramid) resin
Reusable nature

Step 2.
Fibre is taken as Dispersed Phase.
Example:

S.No
Fibre
 To provide
1
Alumina
Dimension stability
2
Boron  
Stiffness
3
Glass
Corrosion resistance
4
Carbon
Bio compatibility
5
Graphite
Lubrication


Step 3.
 Matrix Phase + Dispersed Phase are suitably mixed, and cured under proper heat and pressure.  This results in FRP.

COMMON APPLICATIONS  OF  FRP:
1. Medical field    
2. Aero planes   
3. Air crafts     
4. Automobiles
5. Sports                 
6. Industries     
7. Submarines    
8. Pollution control

1. Medical field: -       For hip joints and fracture curing plate treatment, steel may have some side effects due to non-bio compatibility.  But Carbon FRP plates are highly bio compatible and they are used as plates.

2. Aeroplane: - In Aero planes vertical and horizontal wings, Boron FRP are used due to their very low mass / volume ratio.  It is 30% lighter than steel.

3. Air crafts: -  In aircraft wings, high resistant blocks, nose cones of missiles, Carbon or graphite FRP are used.

4. Automobiles -Due to high mechanical strength, they are used in automobile parts.

5. Sports -        Due to high water resistivity, graphite, silicone FRPs are used in sports mats and artificial sports lawns.

6. Industries -   As they are not affected by chemicals, they are used in chemical industries as reservoirs.

7. Submarines -           Due to high water resistivity and strength, Glass FRP and silicone FRP are used in submarines.

8. Pollution control -   As they are easily bio degradable, their pollution problem is minimum.

SPECIFIC EXAMPLE:
CARBON FRP:

No
TYPE
PROPERTY
USES
1
Carbon- Polyester FRP
1.Bio compatability
2.Improved mechanical property
1. Medicine
2. High load automobiles
2
Carbon – Epoxy resin FRP
 1.Good tensile and mechanical strength
Chemical industries
3
Carbon – Phenolic FRP
1.High temperature resistance
2.Friction resistance
1.Aircraft,
2. Aeroplanes
4
Carbon – Silicone FRP
1. Bio compatability
2. Excellent thermal and electrical nature
1. Sports lawns
2. Submarines
3. Medicine
5
Carbon – Aramid FRP
1. Bio compatability
2. Reusability
1. Pollution free plastics

In Similar way , we can have glass FRP, Alumina FRP, Boron FRP etc.,.