Omar Khalid
Plastic is derived from natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. The process of making plastic from these raw materials is complex and multi-staged, requiring expertise and modern technology. The first step involves the extraction of raw materials, which are then processed and refined. The refining process transforms crude oil into different petroleum products, which are then converted into hydrocarbon chains through distillation. These chains are then broken down into simpler molecules through cracking, which can be done through steam cracking or catalytic cracking. The resulting monomers are then linked together through polymerisation to form long polymer chains, which can then be moulded into various shapes.
| Characteristics | Values |
|---|---|
| Raw materials | Natural, organic materials such as cellulose, coal, natural gas, salt, and crude oil. |
| Plastic production process | 1. Distillation of crude oil into fractions or gases and light petroleum products. 2. Conversion of fractions into hydrocarbon chains or gases into monomer materials. 3. Polymerisation or polycondensation of hydrocarbon monomers into polymers. 4. Processing and shaping of polymers into various plastic products. |
| Polymerisation process | Small molecules called monomers are joined together to form longer chains and polymers under specific reaction conditions, which may include catalysts, heat, or pressure. |
| Plastic shaping techniques | Injection molding, extrusion molding, blow molding, rotational molding, and compression molding. |
| Plastic products | Pipes, bottles, bags, tubes, hoses, sheets, films, car parts, toys, phones, vehicles, and homes. |
| Plastic properties | Resistance, flexibility, transparency, colour, hardness, strength, and weight. |
| Environmental considerations | Plastics can be produced from waste, renewable materials, or CO2 to reduce negative environmental impacts and promote a circular economy. |
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What You'll Learn
Extraction of raw materials
The first step in the production of plastic is the extraction of raw materials. These raw materials are largely crude oil and natural gas, but also include coal, cellulose, salt, and other natural, organic materials. Crude oil, a complex mixture of thousands of compounds, is first converted into gases and light petroleum products through oxidation. These gases are then converted into monomers, which are the building blocks of polymers.
Monomers are small molecules with double bonds, allowing carbon atoms to react to form polymers. Examples of monomers include ethylene, propylene, and butene. Ethylene, for instance, is a gaseous hydrocarbon that, when subjected to heat, pressure, and a catalyst, joins together into long, repeating carbon chains. These chains form a polymer called polyethylene (PE), a plastic resin.
The raw materials used in plastic production are derived from petroleum and natural gas, with the primary raw material being resin, a term used to describe the base polymer. The specific raw materials chosen and the subsequent refining processes are critical in determining the final characteristics of the plastic produced, including its resistance, flexibility, transparency, and colour.
The extraction and use of raw materials for plastic production are evolving. In the future, plastics will be increasingly made from waste, renewable materials, and CO2, supporting the shift towards a circular economy. This circular economy aims to process, use, reuse, collect, and sort plastics for recycling, minimising waste and maximising resource utilisation.
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Refining processes
The refining process is a vital stage in the production of plastic raw materials. It involves the transformation of crude oil into different petroleum products, which are then converted to yield useful chemicals, including monomers. Crude oil, a complex mixture of thousands of compounds, is heated in a furnace and sent to a distillation unit, where it separates into lighter components called fractions. One of these fractions, naphtha, is crucial for plastic production. The distillation step converts long-chain hydrocarbons into simpler hydrocarbons, which can be further processed into various chemicals.
There are two main methods for cracking hydrocarbons: steam cracking and catalytic cracking. Steam cracking employs high temperatures and pressures to break hydrocarbon chains without a catalyst, while catalytic cracking uses a catalyst to enable the process to occur at lower temperatures and pressures. The resulting product, often naphtha, serves as the raw material for the petrochemical industry.
The next step in the refining process is polymerisation, where monomers such as ethylene and propylene are linked together to form long polymer chains. This process can be tailored to produce plastics with specific characteristics, such as high-temperature resistance, excellent mechanical strength, or transparency. The polymerisation process generates thick, viscous substances known as resins, which are the base polymers used to make plastic products.
One example of a monomer is ethylene, a gaseous hydrocarbon. When subjected to heat, pressure, and a catalyst, ethylene joins into long, repeating carbon chains, forming a plastic resin called polyethylene (PE). This PE-based plastic is processed into plastic pellets, which are melted and cast into moulds to create the desired plastic product.
The final stage of the refining process involves processing the plastic into various shapes and sizes to meet the needs of different industries. This showcases the complexity and expertise of chemical engineering, which is crucial for enhancing the performance and quality of plastic products. The plastic can be moulded into shapes such as pipes, bottles, boxes, and films through techniques like injection moulding, extrusion, blow moulding, and rotational moulding.
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Polymerisation
For instance, in the polymerisation of ethylene into polyethylene (PE), initiators are added to start the chain reaction. Only after the formation of PE is it sent for processing by the addition of some chemicals (antioxidants and stabilisers). An extruder then converts the PE into strings, and grinders convert it into PE pellets. Factories then melt them into the final products.
Ethylene is a gaseous hydrocarbon. When it 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).
Condensation polymerisation involves joining two or more different monomers by removing small molecules such as water. This process also requires a catalyst for the reaction to occur between adjacent monomers. This is known as step growth, as you may add an existing chain to another chain. Common examples of condensation polymers are polyester and nylon.
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Plastic moulding
One of the most common types of plastic moulding is injection moulding. This process involves melting raw polymer resin granules into a liquid, which is then injected into a mould and shaped. Injection moulding is suitable for manufacturing large quantities of plastic parts, such as bottle caps, storage containers, and toys. It offers the flexibility to accommodate different designs and is suitable for various industries, including surgical and automotive.
Another type of plastic moulding is blow moulding, which is similar to glass blowing. In this process, a heated plastic mass, typically in the shape of a tube, is inflated with air until it fills the mould and conforms to its shape. Blow moulding is ideal for creating thin-walled containers, such as bottles, in large volumes. It is a cost-effective method for manufacturing one-piece, hollow objects.
Compression moulding is a highly efficient and cost-effective process that involves placing heated plastic inside a heated mould, which is then closed to compress the plastic into the desired shape. This process yields stronger and more durable parts, making it popular across industries. Compression moulding is versatile, allowing for variations in thickness, length, and intricacy of the final product.
Extrusion moulding is a unique process where the melted plastic material is extruded directly into the die, and the shape of the die, rather than the mould, determines the final product's shape. This process is well-suited for manufacturing long, hollow-formed applications like tubes, pipes, and straws, and can create various cross-sectional shapes.
Vacuum forming is another common plastic moulding technique that offers high-detailed outcomes for large-sized products. It is a fast process that requires lower equipment costs compared to injection moulding. Vacuum forming is used in various industries, including automotive, industrial components, and food packaging.
Lastly, rotational moulding, also known as roto-moulding, is a process where a powder or liquid resin is placed into a metal mould and rotated in an oven until the resin evenly coats the mould's surface. This process is commonly used to create large hollow plastic products, such as storage tanks, car parts, and playground slides. It allows for customisations, such as adding bends and signage, and has lower tooling costs compared to other moulding techniques.
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Plastic recycling
The plastic recycling process involves melting and reforming plastic into other items, which can cause polymer degradation at the molecular level. This process requires that waste be sorted by colour and polymer type before processing, which is often complicated and expensive. Errors can lead to inconsistent material properties, making it less appealing to industry. In feedstock recycling, waste plastic is converted into its starting chemicals, which can then be used to create fresh plastic. This method involves higher energy and capital costs.
Another method of plastic recycling involves burning plastic in energy recovery facilities in place of fossil fuels, or biochemically converting it into other useful chemicals for industry. Advanced recycling plants are designed to turn plastic waste, including material that cannot be processed through traditional mechanical recycling, into liquids and gases that can be used to make new plastics and other chemical products.
Despite the benefits of plastic recycling, it has faced economic and technical challenges since its early advocacy in the 1970s. The plastics industry has been criticised for lobbying for recycling programmes despite knowledge that most plastic could not be economically recycled, and that recycling would not effectively address the solid waste problem. Instead, the industry's promotion of recycling was mainly for its public relations value and to avoid regulations and ensure continued demand for plastic.
In the late 1980s, plastic recycling efforts intensified, with the establishment of organisations and associations such as the Council for Solid Waste Solutions and Plastic Recycling, Inc. (PRI) to promote plastic recycling to the public and expand waste collection programmes. However, the challenges of plastic recycling remain, and it is generally agreed that reduction and reuse are more favourable long-term solutions for sustainability.
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