A Z OF POLYETHYLENE - Ferret · 2015-12-03 · A – Z OF POLYETHYLENE THE RAW MATERIAL Naphta is...

A – Z OF POLYETHYLENE

WHAT IS POLYETHYLENE?

More PE is produced in the world than any other

polymer and everyone comes into contact with it daily.

Right from the start, PE was seen as real addition to the

world of materials. Nowadays, the strength of PE lies in

its subtle solidity, its obvious usefulness, and its

almost unlimited application potential.

PE characteristics can be adapted to very soft and

supple, as well as very tough, hard and solid.

The qualities of polyethylene

• strong

• safe

• versatile


THE RAW MATERIAL

Naphta is received by refining crude oil, by heating Naphta

you get Ethylene.

In a polymerization process of Ethylene, Hydrogen as well

as Catalysts Polyethylene is made. The Polyethylene raw

material is either a granule or powder form.

Depending on the polymerization process and catalysts PE

with different properties and characteristics can be

produced.

PE grades are:

Low-Density PE [LD-PE]

Linear-Low-Density PE [LLD-PE]

High-Density PE [HD-PE]

High-Molecular-Weight PE [HMW-PE]

Ultra-High-Molecular-Weight PE [UHMW-PE]


PROPERTIES OF POLYETHYLENE:

Properties of PE are influenced by Density, Flow

Properties (Melt Viscosity), Molecular Structure as well as

Additives:

Key properties for many applications are:

strength

stiffness

wear resistance

sliding properties

chemical and corrosion resistance

minimal water absorption

good processability / machinability


PROCESSING POLYETHYLENE: EXAMPLES

Blow Molding Blown Film Extrusion Injection Molding


PROCESSING POLYETHYLENE: Compression Molding of

HMW-PE and UHMW-PE (sheet product)

Due to the very high melt viscosity, especially UHMW-PE requires very

high pressure to be transformed from raw material (powder) to

consolidated form (sheet)


SPECIALTY POLYETHYLENE: UHMW-PE (Ultra-High-Molecular-Weight PE)

(CH2-CH2)n – carbon-hydrogen combination

The properties of UHMW-PE depend on the length of the molecular chains

[molecular weight], molecular structure [crystallinity] as well as additives.

Molecular weight of Polyethylene:

HD-PE approx. 250,000 g/mol

HMW-PE approx. 500,000 g/mol

UHMW-PE > 4,000,000 to 10,0000 g/mol

Raw material: powder, d50 = 120 – 150 µm

THE STORY OF UHMW-PE (Ultra-High-Molecular-Weight PE)

For the first time UHMW-PE was presented at K 1955 [international plastics and

rubber trade fair] by Ruhrchemie/Hoechst AG under the brand RCH® 1000.

The first company in the world compression molding UHMW-PE from powder to

sheet product was Wefapress Beck & Co. GmbH in Vreden/Germany.

Still today, UHMW-PE represents a very modern engineering plastic with lots of

innovative potential by constantly improved properties and new applications.

A – Z OF UHMW-POLYETHYLENE

THE PROPERTIES OF UHMW-PE (Ultra-High-Molecular-Weight PE)

very high wear resistance

excellent sliding properties

outstanding impact strength

very good chemical resistance

easy to machine (turning, milling, shaping/profiling)


recyclable

good price-performance ratio


THE PROPERTIES OF UHMW-PE (Ultra-High-Molecular-Weight PE)


Standardization within DIN 16972 (draft: EN ISO 15527)

semi-finished products: compression molded sheets made of

“high density polyethylene"

Range: UHMW-PE (TG 1+2), HMW-PE (TG 3), HD-PE (TG 4)

Impact strength

Form stability at warm temperatures

Wear resistance

Load capacity at higher speeds

Resistance to stress cracks

Important properties of polyethylene generally improve

corresponding to increasing molecular weight:

THE PROPERTIES OF: UHMW-PE (Ultra-High-Molecular-Weight PE)


100.000

500.000

3 Mio.

4,5 Mio.

6,5 Mio.

8 Mio.

+ _

Weldability

Formability

Wear resistance

Stability /

Solidity

Melt Viscosity

Molecular Weight [g/mol]



high

low

UHMW-

PE

PP POM PTFE PA6 PETP PEEK St 37

Impact Strength



UHMW-PE TG 1 | TG 2

2 4 6 8

molecular weight

in million g/mol 5

wear resistance

impact strength



wear value [relative]

800

700

600

500

400

300

200

100

0

PP POM PTFE PA6

Test method:

Sand-Slurry-Test

Type of wear:

hydroabrasive erosion

UHMW-

PE

HD-

PE


Medium ST 1000®

UHMW-PE PP POM PTFE PA

Water

Acids

Alkalis

Salts

Halogens

Oxidizing compounds

Oils | Fat

Alcohols

Esters

Organic acids

+

+

+

+

Aromatics

-

- +

+

+

+

[+]

+

+

+

+

-

- +

+

[+]

[+]

-

+

-

+

+

-

- +

+

[+]

[+]

[+]

+

+

+

+

+

+

+

+

+

+

+

-

- +

+

-

- +

[+]

+

[+]

[+]

+ resistant | [+] limited resistance | - not resistant

CHEMICAL RESISTANCE


UHMW-PE Program


Material

designation

Resin Molecular

weight

Color Key Properties

ST 1000® UHMW-PE

[GUR/UTEC]

5 – 9.2

Mio. g/mol

natural,

green, black,

colored

very high wear resistance, excellent

sliding properties, high impact strength

ST 1000® BOR

Neutrolen

UHMW-PE

[GUR/UTEC]

5.0 Mio.

g/mol

natural PE-UHMW with boron based additive for

shielding and absorption of high energy

neutrons

ST 4000® ATEX UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

black ATEX compliant plus increased wear

Resistance

ST 6000® AST UHMW-PE

[GUR/UTEC]

5 Mio.

g/mol

black AST = anti-static properties

ST 6000® Protect UHMW-PE

[GUR/UTEC]

5 – 9.2

Mio. g/mol

black increased wear resistance in combination

with rubber for protection and shock

absorption

ST 6000® ELS

UHMW-PE

[GUR/UTEC]

5 Mio.

g/mol

black

ELS = electrically conductive

ST 6000® GB UHMW-PE

[GUR/UTEC]

7.0 Mio.

g/mol

blue-grey Optimum combination of wear resistance

and impact strength

UHMW-PE Program


Material

designation

Resin Molecular

weight


ST 7000® EHT UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

brilliant-white PE-UHMW for increased

temperature range, oxidation

inhibiting formulation, compliant

with FDA and EU regulations for

food contact

ST 7000® AF

UHMW-PE

[GUR/UTEC]

5 Mio.

g/mol

black-anthracite Flame retardant PE-UHMW:

UL94 V-0

ST 7000® AMB UHMW-PE

[GUR/UTEC]

5 Mio.

g/mol

natural, colored Anti-microbial PE-UHMW

UHMW-PE Program


Material

designation

Resin Molecular

weight


ST 9000® MoS2 UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

anthracite PE-UHMW with MoS2 as solid

lubricant for higher loads and

speeds

ST 9100® Oil UHMW-PE

[GUR/UTEC]

5 - 9.2 Mio.

g/mol

black, blue, purple,

light-green

PE-UHMW with incorporated,

permanent lubrication to

improve sliding properties,

lubricant is food approved

US 9200®

UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

grey

PE-UHMW with incorporated

solid/dry lubrication

UHMW-PE (REG) and PE-HMW Program


Material

designation

Resin Molecular

weight


A4® UHMW-PE

[GUR/UTEC]

~ 5 Mio.

g/mol

green,

black

UHMW-PE with recycled content

A4® REG UHMW-PE

[GUR/UTEC]

~ 3 – 5 Mio.

g/mol

black UHMW-PE and HMW-PE with recycled

content

A4® FQ UHMW-PE

[GUR/UTEC]

~ 5 Mio.

g/mol

black Recycled UHMW-PE for dock fendering

A4® FQ AST UHMW-PE

[GUR/UTEC]

~ 5 Mio.

g/mol

black Recycled UHMW-PE for dock fendering,

anti-static

ST 500® (V)HMW-PE

[Poliex,

Lupolen]

0.5 / 0.8 Mio.

g/mol

natural,

green,

black

PE-HMW

ST 500® AST (V)HMW-PE

[Poliex,

Lupolen]

0.5 / 0.8 Mio.

g/mol

black PE-HMW with anti-static properties

Materials for the Paper Industry


Material

designation

Resin Molecular

weight


PS 1000® UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

black UHMW-PE + graphite + carbon black

PS 1004®

UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

black UHMW-PE + graphite (for improved sliding

properties) + micro silica (for improved

wear resistance) + carbon black

PS 4190® UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

black UHMW-PE + MoS2 (for improved sliding

properties) + micro silica (for improved

wear resistance) + carbon black

CeraDur® UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

yellow-

green /

black /

custom

colors

UHMW-PE + micro silica (for improved

wear resistance)

CeraDur® XL

UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

grey Modified UHMW-PE (cross-linked + micro

silica) for improved wear resistance

CeramX® UHMW-PE

[GUR/UTEC]

9.2 Mio.

g/mol

beige Hybrid material combining ceramic and

UHMW-PE properties

ST 1000® [PE-UHMW]


General property profile:

outstanding abrasion resistance

superior impact strength

non-sticking and self-lubricating properties

excellent mechanical properties (even in cryogenic conditions)

very good chemical resistance


food approved as per FDA and EU regulations (ST 1000® virgin grade +

selected colors and premium grades)

easy to machine (turning, milling, shaping/profiling)

environmentally friendly and recyclable

good price-performance ratio

ST 1000® [PE-UHMW]


Agency approvals (ST 1000 virgin grade + selected colors and premium grades):

Food contact:

Food and Drug Administration (FDA) - 21 CFR 177.1520

United States Department of Agriculture (USDA): Plastics approved for contact in meat and poultry

applications

National Sanitary Foundation (NSF) - Drinking Water and Food Processing Equipment, standards 42, 61,51

3A Sanitary Standards

2004/1935 (Framework Regulation -> replaces EU directive 89/109/EC):

2002/72/EC. European Directive for plastic materials, positive list of monomers and additives

Germany: BfR (=German Federal Institute for Risk Assessment = formerly known as BgVV and BGA)

Drinking water approvals:

UK: WRAS listing

Germany: Microbiological testing according to DVGW-standard W 270, KTW testing of major products at

standard plates

France: ACS testing

Netherlands: KIWA – Testing

Electronic and Electrical Applications

WEEE: EU-Directive 2002/96/EC (WEEE = Waste on Electrical and Electronic Equipment)

RoHS : EU-Directive 2002/95/EC

EU-Directive 2003/11/EC

ST 1000® [UHMW-PE]


Industries in which ST 1000® is used:

Packaging and filling industry

(Unit Material Handling)

Power transmission & Conveyor Industry

Food processing

Chemical industry

Paper industry

Port construction and offshore

platforms

Bulk material handling

Premium Materials [UHMW-PE]


ST 4000® ATEX

[modified UHMW-PE, 9.2 Mio. g/mol]

color: black

Features and benefits:

ATEX compliant (reference YEX 550794, TÜV Germany)

electrically conductive

increased wear resistance

high impact strength

Application examples:

chemical industry

general engineering

power stations

explosion protected equipment

aircraft industry

laboratory construction



ST 7000® EHT


color: brilliant-white


higher temperature resistance (110° C

depending on load)

oxidation inhibiting formulation

approved for food contact according to

FDA, 3A and EU regulations

low coefficient of friction

very high wear resistance

very good chemical and corrosion

resistance

nice and clean optical appearance

Application fields:

beverage industry [hot filling of beverages]

conveying and packaging industry

candy, food processing and baking industry

pharmaceutical industry

seals and valves

galvano technology | plating

bulk materials handling of food and fertilizers

[even at higher temperatures]

forming of window frames

drying plants and shrinkage tunnels

Examples of applications:

rail guides and wear strips

timing screws

segments, star wheels and corner tracks

seals

guide rails, wear strips and plates in spiral

conveyors and drying plants

linings for bulk materials handling in food and

fertilizer industry



ST 6000® Protect

[modified UHMW-PE, 5 Mio. g/mol]

color: black


combination of ST 1000® with rubber back

very high shock and energy absorption

high wear resistance

allows adhesive bonding via rubber back


Transportation

Lining

Mining



ST 9100® Oil


colors: black, blue, purple, light-green,


very low friction

incorporated permanent lubrication (allowing higher dry-

running speeds)

minimum drag and noise in conveyor lines

noise reduction

extends chain life (plastic and metal flat top chains)

color stable

FDA and EU approved ingredients (except for black)

black: anti-static properties


corner tracks

guide rails and profiles

flat and V-belt guides at high speeds

sliding components in elevators



ST 9100® Oil Plus


color: grey


higher oil loading to increase lubricating effect

suitable for very high speed belt and chain guides

ideal for expensive “high speed and maintenance-free” roller

chains (e.g. cigarette packaging lines)

increased wear resistance

very good noise reduction

extends life span of expansive chains and belts

FDA and EU approved ingredients

Application examples: high speed belt guides (e.g. in airport baggage handling systems)

chain guides in high speed application (e.g. maintenance-free roller

chains)

conveyor components for lifts / elevators

note: not to be used in very dusty environments



US 9200®


color: grey


formulation with dry lubricants

significantly reduced coefficient of friction

promotes material flow

maintains high wear resistance

permanently self-lubricating

noise suppressant


corner tracks

guide rails and profiles

flat and V-belt guides at high speeds



CeraDur®


color: yellow-green, red, custom colors


enhanced wear resistance (addition of micro silica)

to be used in higher wear and load applications

less deformation

Application examples: corner tracks for metal flat-to chains (especially in glass bottle lines)

chain guides for heavy goods

neck guides in air conveyor

components in the pulp and paper industry: forming boards,

foils and low vacuum foils, deflector strips and suction

blades, suction box covers, sealing strips



ST 1000® BOR Neutrolen

[modified UHMW-PE, 5 Mio. g/mol]

color: natural


with Boron trioxide (B2O3) additive

moderation of high-energy radiation (neutrons)

ability to absorb lower-energy thermal neutrons

low weight, i.e. considerably lighter than e.g. concrete, lead,

tungsten

improved deformation and heat resistance over low-

molecular PE types (e.g. PE 500 and PE 300)


Moderation and shielding material in nuclear facilities (e.g. door

systems, handling systems)

Nuclear technology equipment (transportation and storage)

Protective and shielding equipment for medical and X-ray facilities

shielding material in nuclear submarines



Development Projects

“softer PE-UHMW” for surface protection of PET

bottles, other sensitive containers and labels


avoids / reduces scratches of PET bottles during transportation

and filling

protects surfaces of sensitive containers [printed aluminium],

labels and sleeves in the cosmetic and pharmaceutical industry

maintains high wear resistance

improved sliding properties

Application examples: guide rails and sliding components

scrolls and feedworms

change parts like star wheels, corner track segments

beverage industry (PET bottles)

cosmetic industry (alu containers, PET bottles, sensitive

labels/sleeves)



Development Projects

CeramX

[hybrid material combining PE-UHMW and ceramic properties]


combination of PE-UHMW and ceramic properties

highly improved wear resistance in high speed applications (e.g.

paper industry)

less deformation

improved heat resistance [105 °C]

excellent surface finish

Application examples: components in wet-end section of paper mills: foils, dewatering

elements

parts in bottling and filling lines (e.g. rollers)

Delivery Program: Sheet Product


ST 1000® [UHMW-PE, 5 - 9.2 Mio. g/mol]

ST 500®

[(V)HMW-PE, 0.5 / 0.8 Mio. g/mol]

sheet dimensions thickness tolerance

[mm] [mm] [mm]

1,010 x 2,020 10 - 200 +/- 0.2/0.3

1,010 x 3,030 10 - 200 +/- 0.2/0.3

1,010 x 4,020 10 - 200 +/- 0.2/0.3

1,010 x 6,140 10 - 200 +/- 0.2/0.3

1,220 x 2,020 10 - 200 +/- 0.2/0.3

1,220 x 2,440 10 - 200 +/- 0.2/0.3

1,260 x 3,030 10 - 200 +/- 0.2/0.3

1,260 x 10,200 10 - 200 +/- 0.2/0.3

2,020 x 4,020 10 - 200 +/- 0.2/0.3

2,020 x 6,050 10 - 200 +/- 0.2/0.3

Delivery Program: Blocs



ST 500®

[(V)HMW-PE, 0.5 / 0.8 Mio. g/mol]

Wefapress has the unique cabability to supply large blocs made from ST 1000®,

A4 and ST 500® grades.

Max. length Max. width Max. thickness

[mm] [mm] [mm]

1,300 1,200 650

1,220 500 490

Delivery Program: Rods (pressed and extruded)



ST 500® [(V)HMW-PE, 0.5 Mio. g/mol]

Pressed Diameter

[mm]

20

25

30

40

50

60

70

80

90

100

Extruded Diameter

[mm]

110

125

130

140

150

160

180

200

250

Due to dimensional stability and efficiency in machining Wefapress recommends

pressed rod over extruded rod. The pressed material is a bit more expensive,

however, this is easily compensated when machining the more stable &

homogenous material. Wefapress Premium Materials as well as colored products

are also available as pressed rod.

Color range



ST 500® [(V)HMW-PE, 0.5 Mio. g/mol]

Precision Engineering


CNC machining centers [up to 5 axis, up to 10,000

mm length]

Routers

CNC lathes [with milling axis]

multi-head spindle-molders

high precision panel saws

Keywaying equipment

annealing (to improve dimensional stability of

materials)

Precision Engineering


WefaCut: online calculation for cut-to-size

WebToCad – service for power transmission and

conveying products

Scrolls and feedworms: support, design &

machining

Alu-Clip product for aluminum profiles & linear

technology

Engineering support

One-Stop-Shopping: precision machining of other

engineering plastics [PA, POM, PET, PEEK, etc.]

A Z OF POLYETHYLENE - Ferret · 2015-12-03 · A – Z OF POLYETHYLENE THE RAW MATERIAL Naphta is...

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Transcript of A Z OF POLYETHYLENE - Ferret · 2015-12-03 · A – Z OF POLYETHYLENE THE RAW MATERIAL Naphta is...