Maya Ellison
Plastic is everywhere, and it's polluting our planet. From its extraction as fracked gas and oil to its production, use, and disposal, plastic contaminates at every stage. In this paragraph, we will introduce the topic of how plastic is produced and the environmental concerns associated with its manufacturing process. Plastic is primarily made from fossil fuels such as coal, crude oil, and natural gas, which are extracted through mining and drilling operations like fracking. These fossil fuels are then refined and processed into chemical compounds, which serve as the building blocks of plastic. The journey from extraction to final product involves several steps, each with its own environmental and health impact, and it is important to understand these processes and their consequences.
| Characteristics | Values |
|---|---|
| Plastic type | Synthetic or biobased |
| Synthetic plastic source | Crude oil, natural gas or coal |
| Biobased plastic source | Renewable products such as carbohydrates, starch, vegetable fats and oils, bacteria and other biological substances |
| Plastic composition | High molecular weight organic polymers |
| Polymer composition | Carbon, hydrogen, oxygen, nitrogen, sulphur and chlorine |
| Plastic classification | Chemical process used in synthesis, physical properties, resistance and reactions to various substances and processes, qualities relevant to manufacturing or product design |
| Plastic production process | Compounding, extrusion or moulding |
| Plastic production refinement | Oil and gas refinement to obtain hydrocarbons |
| Plastic production cracking | Large hydrocarbon molecules broken down into smaller molecules |
| Plastic production polymerization | Smaller molecules reassembled into long chains to create resins |
| Plastic additives | Plasticizers, stabilizers, fillers, pigments, and flame retardants |
| Plastic production environmental impact | Major source of carbon emissions, pollution, and environmental concerns |
| Plastic advantages | Inexpensive, lightweight, durable, flexible, nontoxic, adaptable, sanitary |
| Plastic disadvantages | Slow decomposition rate, pollution, endangering public health, environmental issues, waste |
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What You'll Learn
- Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt and crude oil
- Crude oil is distilled into fractions, which are mixtures of hydrocarbon chains
- Polymerisation and polycondensation are the two main processes used to produce plastics
- Additives are added to enhance the plastic's properties, such as colour, strength, and flexibility
- Finishing involves any post-processing steps to achieve the desired appearance and performance
Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt and crude oil
Plastic is a broad term for a wide range of synthetic or semisynthetic materials that use polymers as their main ingredient. They are derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. Crude oil is a complex mixture of thousands of compounds and needs to be processed before it can be used to create plastic. The production of plastics begins with the distillation of crude oil in an oil refinery, separating the heavy crude oil into lighter components called fractions. Each fraction is a mixture of hydrocarbon chains, which are chemical compounds made up of carbon and hydrogen. One of these fractions, naphtha, is crucial for plastic production.
The raw materials used to produce plastics are mostly found in the natural world. They are classified as fossil fuels, which are made up of carbon, hydrogen, nitrogen, sulphur, oxygen, and other minerals. The generally accepted theory is that these hydrocarbons are formed from the remains of living organisms called plankton, which existed during the Jurassic era. Over time, these organisms were buried beneath heavy layers of sediment in the Earth's mantle, where they decomposed without oxygen and transformed into tiny pockets of oil and gas.
Plastics are created through a polymerisation or polycondensation process, which involves linking chains of molecules (monomers) together to create a large molecule (a polymer). This process requires specific catalysts. An example of a polymer is polystyrene, and copolymers are formed when different monomers are linked together, such as Nylon (polyamide).
Synthetic plastics make up the majority of plastic in use today, and they are derived from crude oil, natural gas, and coal. Biobased plastics, on the other hand, are made from renewable products such as carbohydrates, starch, vegetable fats and oils, bacteria, and other biological substances. The ease of manufacturing methods involved in processing crude oil has led to the dominance of synthetic plastics. However, the limited oil reserves and environmental concerns are driving a need for newer plastics from renewable resources.
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Crude oil is distilled into fractions, which are mixtures of hydrocarbon chains
Crude oil is a complex mixture of thousands of compounds and needs to be processed before it can be used to make plastic. The production of plastics begins with the distillation of crude oil in an oil refinery. This process is called fractional distillation. Fractional distillation separates the heavy crude oil into groups of lighter components, called fractions. Each fraction is a mixture of hydrocarbon chains (chemical compounds made up of carbon and hydrogen), which differ in terms of the size and structure of their molecules.
The hydrocarbon chains that constitute petroleum fuel products are a family of hydrocarbons called alkanes, or paraffins, depending on their size. Alkanes are hydrocarbon chains with the chemical formula Cn+H2n+2. Alkanes are stable but versatile, making them safe for use and storage as a range of fuel products. The size and length of each hydrocarbon molecule determine which fraction it will be separated into. The size of each molecule is directly related to how many carbon and hydrogen atoms the molecule contains. Most fractions contain mainly alkanes, which are compounds of carbon and hydrogen with only single bonds between them.
The shortest hydrocarbons have very low boiling points. They do not condense but leave the column in the gas state. The top of the fractionating column gives rise to gases and liquids that have short carbon chains in their composition. While these products are often used as fuels, many have industrial and chemical uses too. Butane and propane, along with other petroleum gases, are formed right at the top of the distillation tower, where it is coolest, at a very mild 25°C. These gases are the lightest products formed in crude oil distillation and are flammable gases.
One of the fractions, naphtha, is the crucial compound for the production of plastics. Two main processes are used to produce plastics – polymerisation and polycondensation – and they both require specific catalysts. In a polymerisation reactor, monomers such as ethylene and propylene are linked together to form long polymer chains.
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Polymerisation and polycondensation are the two main processes used to produce plastics
Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt and, most commonly, crude oil. Crude oil is a complex mixture of thousands of compounds and needs to be processed before it can be used. The production of plastics begins with the distillation of crude oil in an oil refinery. This separates the heavy crude oil into groups of lighter components, called fractions. Each fraction is a mixture of hydrocarbon chains (chemical compounds made up of carbon and hydrogen), which differ in terms of the size and structure of their molecules. One of these fractions, naphtha, is the crucial compound for the production of plastics.
Two main processes are used to produce plastics – polymerisation and polycondensation – and they both require specific catalysts. In a polymerisation reactor, monomers such as ethylene and propylene are linked together to form long polymer chains. This process generates thick, viscous substances as resins, which are used to make plastic products. When ethylene, a gaseous hydrocarbon, is subjected to heat, pressure and a certain catalyst, it joins together into long, repeating carbon chains. These joined molecules (polymers) are a plastic resin known as polyethylene (PE). The production of PE-based plastic is processed in a factory to make plastic pellets. The pellets are poured into a reactor, melted into a thick liquid, and cast into a mould. The liquid then cools down to harden into a solid plastic and produce a finished product.
Polymerisation occurs when light olefin gases (gasoline) such as ethylene, propylene, and butylene are chemically bonded into chains, leading to higher molecular weight hydrocarbons (polymers). There are two different mechanisms for polymerisation: addition polymerisation and condensation polymerisation. In addition polymerisation, one monomer connects to the next one (dimer) and the dimer to the next one (trimer) and so on, when a catalyst is introduced, in a process known as chain growth polymers, adding one monomer unit at a time. Common examples of addition polymers are polyethylene, polystyrene and polyvinyl chloride.
Condensation polymerisation includes joining two or more different monomers, by the removal of small molecules such as water. This process is also known as step growth, as you may add an existing chain to another chain. Common examples of condensation polymers are polyester and nylon.
Compounding, or processing, involves melting blends of materials to make plastic formulations. These formulations are then pelletized and processed into unique plastic objects with accurate properties according to predetermined conditions set in the processing machine. Synthetic plastic is produced from petrochemicals, which are extracted from the Earth’s surface through drilling and extraction.
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Additives are added to enhance the plastic's properties, such as colour, strength, and flexibility
Plastic is a polymer, composed of various elements such as carbon, hydrogen, oxygen, nitrogen, sulphur, and chlorine. They are often mixed with additives to enhance their properties. Additives are chemical substances that can be added to plastics to enhance their colour, strength, and flexibility. They can also be used to prolong the life of the plastic.
Additives are added to plastics during the compounding stage of plastic production. Compounding involves melt-blending various blends of materials to make formulations for plastics. The blended mixture is then pelletised and transformed into a finished or semi-finished product through extrusion or moulding.
To enhance the strength of plastics, glass fibres and ceramics can be added as fillers. These fillers increase the structural strength of the plastic, similar to glass-fibre fillers. However, a downside of using glass fibres and ceramics is that they increase the brittleness of the plastic, making it more susceptible to cracking or chipping upon impact.
Mineral-reinforced additives and ceramic fillers are also used, albeit less frequently, to increase the temperature resistance of plastics. These fillers strengthen the plastic but also make it more brittle. Designers must consider the shape of the filler used, as this can impact the distribution within the plastic and the risk of warping.
Additives can also be used to enhance the colour of plastics. For example, a 3% salt-and-pepper colourant mix can be added to give a unique colour to the final product.
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Finishing involves any post-processing steps to achieve the desired appearance and performance
Plastic is a synthetic or semisynthetic material composed of polymers. Its plasticity allows it to be moulded, extruded, or pressed into solid objects of various shapes. The manufacturing process for plastic involves several steps, including compounding, extrusion or moulding, and finishing.
Finishing is a critical step in the plastic production process, encompassing any post-processing operations performed on plastic parts after initial manufacturing. These operations enhance the appearance and performance of the plastic products, ensuring they meet the desired specifications. Finishing techniques can vary depending on the specific requirements of the product and the manufacturing process employed.
One common finishing technique is painting, which can be done by moulding with coloured resins or applying paint after the initial moulding process. Pad printing, a form of offset printing, is another method to add graphics and lettering to plastic products. It uses ink to transfer designs to the plastic surface, accommodating single-colour or multi-colour applications.
Heat staking is another important post-processing technique, used to install metal inserts into plastic components. This process involves melting the plastic at specific temperatures and pressures to accommodate the metal insert, facilitating the use of screws during product assembly.
Post-processing may also involve flash removal, laser marking, or the handling of threaded inserts with ultrasonic welding. These techniques enhance the functionality and aesthetics of the plastic product.
Overall, the finishing process is essential to achieving the desired appearance and performance characteristics of plastic products. By employing various post-processing techniques, manufacturers can ensure that plastic parts are ready for their intended end use.
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Frequently asked questions
Plastics are made from petrochemicals, which are derived from fossil fuels like coal, oil and natural gas.
The process of plastic production involves extraction, refinement, cracking, polymerization, processing and manufacturing.
The first step in plastic production is the extraction of fossil fuels like coal, oil and natural gas from the earth through mining and drilling operations.
During refinement, the extracted fossil fuels are processed in a refinery to obtain specific chemicals called hydrocarbons, which are needed to make plastic.
Plastic pellets, also known as nurdles, are tiny plastic particles formed by melting and cooling the resins created during the polymerization process. These pellets are then shipped to manufacturing facilities where they're melted and moulded into various plastic products.
