T E CH CH N O L OG OG Y O F SY N T H ET I C RES I N S AND EMULSION POLYMERS
T E CH CH N O L OG OG Y O F SY N T H ET I C RES I N S AND EMULSION POLYMERS Written By :
Dr. Himadri Panda, Ph.D.,F.I.C.,F.I.C.S. Industrial Consultant
Fellow of the Essential Association of India, Fellow of the Indian Pulp & Paper Technical Association of India, Fellow of the Indian National Science Congress, Fellow of the Oil & Colour Chemist's Association, U.K. Member of Chinese Academy of Forests, Former Chemist, I.T.R. Co. Ltd. Bareilly, (U.P.), Former Cheif Chemist Chem ist (Q.C. & R & D) Tarpina Pvt. Ltd., Ramnagar, Uttranchal
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ISBN : 978-81-89765-96 978-81-89765-96-5 -5 Printed in New Delhi (India)
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Printed and Published by Sudhir Gupta for "Engineers India Research Institute", 4449, Nai Sarak, Main Road, New Delhi-110 006 and Printed at Swastik Offset, Delhi
Preface Paint and colour are as old as man man himself. Over 35 000 years ago, in seeking refuge from the weather and marauding beasts, man lived in caves. With the aid of naturally occurring materials, such as clays and chalks, and using animal fats as binders, he decorated his cave walls with drawings of animals and his fellow man. The Egyptians in about 2500 BC were still using the same pigments except that a clear blue had been added to relieve the earth colours. This blue is thought to have been derived by finely powdering azurite, a semiprecious stone, while the animal fat medium had given way to gums, wax, size, and perhaps albumen. Painters still recorded in tombs and temples, the happenings of the th e day, day, the battles, the pharaoh’s pha raoh’s eye, the priestly rites. In the first millennium BC the Greeks come into sharp focus as they pursue the art of painting, not only in their own country, but abroad in Rome. The Greeks developed a new technique, that of mixing colours not with water but with hot wax. This made a thicker, creamier type of paint which allowed the artist to model his forms by blending light and dark shades of colour. By now considerable advances had been made with various new pigments and nearly every colour colou r was obtainable - green chalk came from Smyrna , orpiment and red re d lead from Pontus , whilst vermilion was obtainable from the Ephesians. A purple pigment was made by heating yellow earth to redness and then plunging it into vinegar. Another purple was also produced from the murex, a species of sea mussel, and for tint changing, madder root r oot was used. After the Roman world had been over –run by the Barbarians in the fifth fifth century AD, many art techniques were lost. But with the slow revival of commerce, properity and the peaceful arts in the twelfth and thirteenth centuries came a growing interest int erest in colourful decoration. de coration. The Church was the hub, which accounts for the magnificent religious paintings made over over this period. The Renaissance swept Europe like a fire. Men came out of their fortified towns and interchange of thought and culture was eagerly sought. Journeyman artist – painters traveled Europe with their own secret paint recipes. By the eighteenth century paint factories were operating oper ating in Europe and later in America. By the early nineteenth century, artisan painters were
working extensively, as people fully realized the big part that architectural paint plays in decorating and protecting property. Paint crept into common and daily use throughout most of the Western Western world. wor ld. House painting, hitherto a luxury longer recognized as a mark of social distinction. Paint, once a costly product of hand labour by master craftsmen who prepared and mixed their own raw materials from secret formulae handed down from generation to generation, was now reachin the mass proction stage. The twentieth century witnessed the birth of the paint industry as a specialized branch of the chemical industry and saw the transformation of paintmaking from an art to a science. The availability of raw materials increased from a few - such as linseed oil, turpentine, white lead, mineral earth and inorganic ino rganic colours - to a vast range of complex organic chemicals, the use of which required technical specialists. The first production of paint in India is claimed to date from about the 1910s but it was the First World War, through its inevitable shortages and restrictions on imports, which really prompted the establishment of local manufacturing. Today the Indian paint industry industr y comprises some s ome 200 plants, the majority of which are located in Mumbai, Delhi and Kolkata, Kolkata, adjacent to the main centres of population and industry. The industry has an annual turnover of bout Rs 500 crore and employs approximately 10,000 people, of which about 20 per cent have some form of technical qualification. The industry plays an important role in the Indian economy, for every industry uses paints and coatings in one form or another. About half the industry’s production takes the form form of the more familiar familiar architectural and decorative paints used to protect and beautify our homes, offices, industrial buildings and the like. In the architectural and decorative paint market over the past few years, whilst the production of solvent thinned paints has decreased, there has been a marked increase in the production of water based and latex paints. The other half of the industry’s output is is supplied as industrial coatings, which are formulated to meet special conditions encountered in numerous industrial and special speci al end-uses. These include the protection and finishing fini shing of motor vehicles of all types, agricultural equipment , ships and aircraft, a wide variety of manufactured consumer durable products (including refrigerators, washing machines, furniture), technical equipment, toys and containers of numerous types. Specialized coatings provide specifically designed properties for electrical installations, lining of food and beverage
containers, fire retardency, chemical resistance and a multitude of other properties. The development of the surface coating industry, particularly over the last thirty or so years, has been no less rapid than that in engineering, science and electronics which have been more obvious and spectacular. The technological advances have been such that paint manufacturing, which was regarded as an arts and crafts industry has now virtually becomes a technical branch of the chemical industry. Whilst paint manufacturers still rely on many natural sources of raw materials, materia ls, there has been a continuing shift in the direction of purely synthetic materials, which offer important benefits including consistency in quality and supply. supply. During recent years we have experienced a steady increase increas e in the range of new and improved raw materials. These newer products have enabled paint manufacturers to improve the performance properties of their paints and coatings and so satisfy the more stringent requirements requi rements of our modern industr ial society. society. Furthermore,it is clear that more extensive demands will be made for improved working conditions, to provide safe and healthy environments within factory locations. In improving occupational health and safety standards, in the long run, emphasis is likely to be placed on the reduction of hazards hazard s by requiring changes in workplace design and practice, rather than by the use of personal protection equipment such as maks or respirators. Mandatory product safety management programs will require manufacturers to provide employees and customers with comprehensive information to enable them to handle products in a safe manner, take appropriate precautions, precau tions, and be aware of actions to be followed in the event of a spillage, accident or unanticipated incident involving a given product. In order to deal with and overcome the various complex, technical problems which will be encountered, the industry’s scientific and technological innovative skills will be continually challenged. In responding to these challenges the industry will be involved in inventing, improving and refining products and processes at a t a rate faster than tha n ever before. However, However, we can be confident that to satisfy the emerging demands of society, our industry will respond in a positive manner and we will see the development of energy – efficient products that are environmentally acceptable and safe. This book, is intended for students in paint courses, technologists, scientists and research scholars associated with surface coating industries and for new employees in the oil, resin, pigment and paint industries.
A work of this kind is made possible only reviewing and compiling the brilliant ideas and ingenious experimental techniques which have been published in scientific literature. However, However, despite the best of human efforts there will be inevitable errors erro rs of omission and commission. It is my earnest desire that these be brought to our attention so that future revisions may be more satisfactory. The random thoughts in this book are intended for those who do not live by bread alone. Life becomes barren barre n when the pursuit of material things is its sole object. To live successfully it is necessary to maintain equilibrium among materials, mental and spiritual activities. Also, there is the need to give and to receive the stimulus of noble thoughts expressed by illustrious predecessors or by those with whom we associate. This is a good opportunity to thank the various industrialists for supplying technical datas and the publisher for his broadness of vision. Dr. Himadri Panda
Ph.D.,F.I.C.,F.I.C.S. Industrial Consultant Fellow of the Essential Association of India, Fellow of the Indian Pulp & Paper Technical Association of India Fellow of the Indian National Science Congress, Fellow of the Oil & Colour Chemist's Association, U.K. Member of Chinese Academy of Forests, Former Chemist, I.T.R. Co. Ltd. Bareilly, (U.P.) Former Cheif Chemist (Q.C. & R & D) Tarpina Pvt. Ltd., Ramnagar, Uttranchal
CONTENTS AND SUBJECT INDEX C ha pter
Pa ge No . C ha pter 1
The Ch Chemist strry of of Res Resiin Formation and Resin Properties - IIn n t ro d u ct i o n - Fun damen tals of Po lymer formation - Fu n ct io ns of R ea ct ive Gro u ps - C ro s s- l i n k e d P o l y m e r s - Fo rm ati on of Polyme rs - Po l yc o nd e n s at i o n - In t erf a ci al Po lyc on de n sa ti on - Seque nce of Re action - Co po lym er Fo rma t io n - Rat e of Po lymerizatio n - Addit ion Polymerizat ion in Practice - Ch a in Tra n sf e r R e a ct io n s - St er eo p se cif i c Po Po l yme ri zat i on - Polyad dit ion R eact ion s - Typ es o f Po l yme rs - Po l y e st e rs - Format ion of Alkyd s - Satu ra ted an d Unsaturated Polyesters - Po l ya m id e s - Phen olic Re sins - Am A mino Resin s - Ep oxi d e R e sin s - Vinyl Pol ymers - Polyvinyl Al coho l - Silicone s - Pra ctica l App licat ion s
1-24
1 1 2 4 5 5 6 6 8 8 9 9 10 11 12 12 12 13 13 14 17 19 20 21 22 24
2
The Chemical Engineering of Oil and Resin Processing - Ge n era l Re qu ire me nt s f or for Processing Equipments
-
25-70
25
-
Pa g e N o .
M at erial s o f C on struct ion B ra nc h es an d C on n e ct io n s St irri ng Equipm ent Typ es of Agit at ors Sealing D ri ve Un it s F u m e D i s p o sa l a n d S c r u b b i n g D esin g Co nsid erat ion S ludg e H and ling Eq uipme nt C ond ensin g an d R efl uxing D esign a nd Layou t of Tube s W a t e r R ec e i ve r A ncillary Eq uipme nt A g it a t or s Heating R e f lu x C o nd e ns er T h erm om et er Th S t ea m A rra ng e me nt s V acuu m Pum ps Pre ssu re an and Fl Flow In Ind icatio n F um e Ext ra ct i on L a gg in g M i sce l la n e o us H eat ing and Coo ling C riteria f or Select ion o f Heating and Cooling system C al al cu cu la la titi on on o f Fi lm lm C oe oe ff ff ic ic ie ie nt nt s H e at Tra nsf e r C o ef fic ien t St eam Heat ing P re ssu rise d Ho t Wa t er H ea eat in ing at at Hi Higher Te Te mp mperatu re re D irect Firin g I m m er si on T ub e s Ke stne r C oil Ke Ty pi ca l Arr an ge me n t C oo ling The a dvant ages of this type of heating system are : H eat ing b y Ele ctricity I mm ersi on He at in g Heat He atin ing g thro throug ugh h The The Vess Vessel el Wa Wall ll I nd uctio n Hea ting ' Iso duct ive ' He He ati ng Sy Syst em
26 32 33 35 35 36 37 37 38 39 40 40 44 44 44 45 45 47 47 51 52 52 53 53 53 53 54 55 56 56 58 58 59 61 61 61 63 64 65 66 68
C ha pter
Pa ge No . C ha pter
- Heat ing of P ipew ork an d Ancillaries
68
3
Alkyd Resins -
71-101
The n atu re of Al kyd R esin 71 Raw Ma terials 72 Diba sic Acids 72 Po lyh yd ric A lco h ol s 73 Modif ier for Alkyd Re sins 74 Formu latio n o f Alkyd R esins 75 Fo rmu la D eve lo pme nt 78 Calc Ca lcul ulati ation on of Alk Alkyd yd For Formul mulati ation ons s 78 Ty pica l Fo rmu lat io ns 82 Manuf actu re of Alkyd Resin 85 Al c o h o l y s i s Al 85 Ca t al yst s 87 C o n t r o l o f A l c o h o l ys i s 87 Acid o lysi s 88 Fat t y Ac id Pr oc e ss 88 Es t er if i ca t i o n 89 A l ky d M a n u f a ct u r i n g P l a n t 90 Applicat ion s of of Al Alkyd Re Resins 96 Oil Fre e Alkyd s 10 1
4
Polyesters
102-115
- Sa tu ra t ed P ol ye st e rs 10 2 - Con densa tion an and Ad Ad dit ion 1 02 Polymerization - Main Co mpone nts of 1 03 Unsaturated Polyesters - Bri Brief ef Histor History y of Surf Surface ace Coat Coating ings103 s103 - C ha ha ra ra ct ct er er is is titi cs cs o f U ns ns at at ur ur at at ed ed 1 0 4 Polyesters - Two poi points nts sho should uld be noted noted her here e 105 - Fun ctions of initia tors, 10 6 Accelerators, Inhibitors - Ef f e c t o f s t r u c t u r e o f 1 07 Polyester Backbone on Properties of Cured products - Ef fe ct of Ch emical Structu re 1 08 08 on Melting points of Linear Polyesters - Ef fect of Structu re on 10 8
Pa g e N o .
Properties of Cured Products - C ommo nly used po lyols and their advantages are : - T h e e f f e ct o f u n sa t u r a t e d monomers on properties of cured products - P ol ol ye ye st st er er c oa oa titi ng ng c om om po po si si titi on on - R adia tio n C ure - Me tho ds of App licatio n
10 9 11 0
111 11 3 11 4
5
Amino Resins -
116-129
Format ion of Amino R esins 11 7 Me thylo l forma tion 11 7 Alk yl a t io n Al 11 8 U re a Fo rm al d eh y de R e si ns 11 8 M eth ylol Fo rmati on 11 8 Et herif ica tion re actio n 11 9 M el el am am in in e Fo Fo rm rm al al de de hy hy de de R es es in in 1 2 0 Me lamine Me Me thyl Fo Fo rma tion 12 0 Alky Al kylat latio ion n of Melam Melamine ine Met Methyl hylol ols s 121 Ot her Amino Resin s 122 Gl y c o l u r i l Gl 12 3 Pro duct ion Amino Resin s 12 3 Prop ertie s o f Amino Resin s 12 3 U ses of Amino R esins 12 4 S e l f - P o l ym e r i z a t i o n 12 4 C o-rea ction wit h alkyd 12 5 and polyester resins Co-r Co -rea eact ctio ion n with with Acry Acryli lic c Resi Resins ns 126 E p o x y r e si n s 12 6 A cid Ca t aly sed La cq ue rs 12 6 Wat er Based Co ating s 12 7 A pp pp en en di di x 1 S ol ol ve ve nt nt To le le ra ra nc nc e 1 2 9 Append App endix ix 2 NonNon-Vo Vola latil tile e Conten Contentt 129
6
Poly Po lyur uret etha hane ne Re Resi sins ns -
130 13 0-1 -15 51
C h emi st ry R aw Mat erials I s o c ya n a t e s To lyl en e Di Dii so cyan a te (T (T D I ) 4 ,4' Dip henylm eth ane Diisocyanate (MDI) - H y d r o xy l C o m p o n e n t
13 1 13 3 13 3 13 4 13 5 13 6
C ha pter
Pa ge No . C ha pter
- H a za r d s o f I s o c ya n a t e s - Cl Clas assi sifi fica cati tion on of Po Poly lyur uret etha hane nes s - Ureth ane Oils and Urethane Alkyds - Mo i st u r e -c u r e d u r e t h a n e s - Bl o ck e d Is Is o cy na t e e Sy Sy st e m s - Tw o - c o m p o n e n t c a t a l y s t Cured Polyurethanes - Tw o-C om po ne nt Po lyo l Type Polyurethanes
13 7 138 13 9 14 0 1 45 45 1 45 1 46 46
7
Epoxy Resins
152-166
- Ep o xy Re Re si n s Ma Ma n u f a ct u re and Characterization - Cu Curi ring ng Age Agents nts for Ep Epoxy oxy Re Resi sins ns - Prin ciples in Formulat ing with Epoxy Resins - Solvent less a nd H igh Solid s Coatings - Ta r Ep oxy C oa ti ng s - Fl oo rin g C om po un ds - Fi bre gl ass La min at e s - Solvent Based Pa int - High Solid s Coa tin gs - So Solv lvent entles less s Tar Tar Epox Epoxy y Coati Coatings ngs - Solvent less C oat ing fo r Airless Spray Equipment - Si n gl e -P ac k Ep o xy Maintenance Paints - Ep o xy E st e rs - Single Pack Th ermopl astic Epoxy Systems - Epoxy I ndu strial Ba king Finishes
1 54 156 1 58 16 0 1 61 16 1 16 2 16 2 1 63 163 1 63 16 4 16 4 16 4 16 5
Resin Coatings for Electrodeposition - Epoxy Aqueo us Po wde r Suspension (APS)
167-172
- Epo xy/ P oly am id e Em E mu lsi on s - Epoxy Bakin g Ena mels - Wa t e r D i s p e r s i b l e E p o x y
16 7 16 8 17 0
1 71
9
Silicone Resins -
-
8
Water Dispersible Epoxy Resins
Pa g e N o .
-
173-188
Dire ct Proce ss Gr i g n a rd P r o c e s s Pre parat ion o f Silan ols Po l y me r iz a t i o n Silicone resin s Pure Silicon e Re sins R : Si Rat io Me t h yl -a n d ph p he n y l-c o nt e n t Visco sity Pro pertie s of pu pure Si Silicone Surface Coating Resins Resista nce t o Weat hering : Blend ing Re sins Silicone I nte rme diat es : Silicone— Organic Copolymers Pre parat ion a nd Formul atio n of Silicone Resin Based Coatings Cu re C at a lyst Dri ers P i g m e n t s a n d D ye s Thin ne rs A p p l i ca t i o n G u i d e s Surf ace Pre pa ra t ion Primin g Applyin g t he C oat ing s Cu ring Uses To xi ci t y Ot her Silicon e R esin Application Ele ct rica l Va ris he s R el e a se R e si n s Ma son ry Wa te r R ep ell an t s Ot her Silico nes fo r Surface Coatings
1 74 1 75 1 75 1 75 1 76 1 76 1 76 1 77 1 77 1 77 1 78 1 78 1 79 1 80 80
1 81 1 81 1 82 1 83 1 84 1 84 1 84 1 85 1 85 1 86 1 86 1 86 1 86 1 86 1 86
C ha pter
Pa ge No . C ha pter 10
Acrylic Solution Resins -
189-206
Ba c k b o n e M o n o m e r s Synth esis Addit ion Polymerizat ion Co p o l ym er iz a t io n Th e r m o p l a s t i c A cr y l ic s Solut ion Polymerizat ion Pro pertie s a nd End U ses Th e rm o s e t t i n g A cr yl i c s Se l e c t i o n o f M o n o m e r Classif icat ion an a nd pr p rope rt ies Ac ry la m i d e C o p o l ym e rs Aci d C op o ly me rs Hyd rox y C op ol yme rs Cu ring Re ac tio ns Aqueo us Solut ion Acrylics Non -Aqu eou s Dispersions (NAD)
19 0 19 0 1 91 1 93 1 95 1 97 19 8 19 9 19 9 2 00 00 2 00 2 01 2 02 2 03 20 4 20 5
-
-
11
Rubber Resins
207-231
-
I n t ro d u ct i o n Na tu ral Ru bb er Sy n t h e t i c R u b b e r s P ro c e d u r e Rub ber R esins a nd L at exes Chlo rinat ed R ub ber Re sins L if t i n g Pa r l o n Cy cli ze d R u b be r R e sin s Hig h St yre ne -But adi ene Rubber Resins - Chrlo rina te d Bip he nyls - Chl orina te d Pa raf fin s - Synt he ti c Rub be r Re sins Latexes
20 7 20 8 2 10 21 1 21 2 21 2 21 5 21 6 21 9 22 0 22 1 22 3 22 6
12
Emul ulsi sio on Po Pollym ymer ers s - Key- C ompo nen ts in Emulsion Polymerization
232-284 23 2
-
Pa g e N o .
S urf a ct an t s I n it ia t o rs W a te r Po lymerizat ion i n Emulsion Systems Ba sed on Styrene I nflu ence o f Mon omer Composition on properties and performance H a rd en i ng M on o me rs Vin yl Acet ate S t yre n e M et h yl Me t ha cry la te Fle xibilizin g Mon ome rs Est ers o f Acrylic Acid s Est ers of Maleic or Fumaric Acids V i nyl Este rs O le f i n s -B u t a d ie n e Ol ef i ns- Et hyl en e S p ec if i c M o no m e rs Effe Ef fect ct of of Mono Monome merr Com Compo posi siti tion on on Film Properties E f f e c t o f W a t e r P h a se and Particle Size Pa rticle Size Ma nuf actu re and Test ing P r o ce s s V a ri a b l e s Em ulsion Te sting Ap plicat ion of Emulsio n Polymers A d h e si v e I n d u s t ry The Printin g Ink Ind ustry The Text ile In dust ry Th e Le at he r I nd ust ry The Floor Polish In dustry Th e P ap er I nd ust ry Th e Ag ric ul t ure I n du st ry
23 3 23 3 23 4 23 5 23 7 23 8
23 8 23 8 23 8 23 9 23 9 23 9 24 0 24 0 24 0 24 1 24 1 242 24 5 24 9 25 1 25 4 25 9 26 4 28 0 28 1 28 2 28 2 28 3 28 3 28 4
13
Water Reducible Resins -
Wat er So luble Polymers M a l e i n i ze d d r y i n g o i l s A lkyd Re in s Al A cry lic -mo d if ie d w at e r-
285-329 28 5 28 6 28 7 29 0
C ha pter
Pa ge No . C ha pter
Soluble Alkyds - D is a d v a n t a g e s a re - Po Po l y e s t e r s - Silico ne -m od ifie d Al kyds and Polyesters - Ep o x y R e si n s - An Anh yd rid es - Def unct ioal izing t he Epoxide Ring - Ca t io n ic P o lym er s - Th e rm o p la s t ic Po Po l y m e r s - Th er mo s e t t in g P o ly me r s - Amino Resin s - Ur e a Fo r ma l d e h yd e - Mel am in e Fo Fo rma ld eh yd es - Sub stit ut e d Gua na mine Formaldehyde - Self-cross-linkin g - Ot he he r Wa te te r so lu lu bl bl e P ol ol ym ym er er s - V i s co s i t y Ch C h a r a c t e ri st i c s - Amines - Viscosi ty - D ry i n g - St a b i li t y - Foa m Con trol - Colou r R ete nti on - To xi ci t y - Variatio n of Amine Levels - Viscosi ty - Dr yi n g P ro p e rt ie s
2 90 291 29 1 29 1 29 2 2 93 29 3 3 00 30 0 30 2 30 2 30 2 30 3 30 3 304 30 4 30 6 30 6 30 6 30 8 30 9 31 0 31 0 3 10 31 0 31 1
-
Pa g e N o .
Stabilit y Gloss C o s o l ve n t s Co Co uplin g Ef ficie ncy Visco sit y Variat ion of Cosolve nt water ratio Stabilit y D ry i n g p ro p e r t ie s Foam Co ntrol Drier for air dry and Force dry systems Cross Linking o f Wate r Soluble coatings Add itives f or C oat ings Pi g me n t s F o r m u l a t i o n o f Wa t e r Soluble Coatings Tro uble Sh oot ing w ith Water- Soluble Polymers
312 3 12 313 315 316 316 316 316 317 317 319 321 322 322 326
14
Water Soluble Polymers -
330-345
C l a ss i f ic a t i o n P ro ro pe pe rt rt ie ie s o f C el el lu lu lo lo se se E th th er er s A pp licat ion Ap Uses
330 3 35 35 337 341
