Transcript Slide 1

Mahendra Bharaskar
APAR Industries Limited
Tomorrow's Progress Today
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Company Profile
• Apar Industries Limited, founded by Late Mr. Dharmsinh D. Desai
in the year 1958
• One of the best established companies in India operating in the
diverse fields of electrical, metallurgical and chemical engineering.
• A 3000 crore diversified company offering value added products and
services in Power Transmission Conductors and Petroleum
Specialties.
• 53 years of existence, highly competitive & market leader in these
fields
• Firmly committed to being a responsible corporate citizen with an
abiding belief in human engineering.
• Focuses on innovative products, establishing state of art
manufacturing facility of cross linked cables and wires and other
products with Electron Beam Technology at G.I .D.C, Umergaon.
Gujarat.
Tomorrow's Progress Today
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Introduction of Radation
Definition of Radiation Processing
The treatment of products and materials with radiation or ionizing energy to
change their physical, chemical or biological characteristics, to increase their
usefulness and value or to reduce their impact on the environment
Ionizing Energy Sources
Electrons from Particle Accelerators.
X-Rays from Accelerated Electrons.
Gamma Rays from Radioactive Nuclides.
In absorbing materials, electrons, X-rays and gamma rays transfer their
energies by ejecting atomic electrons, which can then ionize other atoms.
These radiations produce similar effects.
The choice of a radiation source depends on the practical aspects of the
treatment process, such as absorbed dose, material thickness, processing
rate, capital and operating costs
Tomorrow's Progress Today
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Introduction of Radiation
Radiation processing was introduced 50 years ago. Many
practical applications have been discovered. The most important
commercial applications are:
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Modification of plastic and rubber materials.
Sterilization of medical devices and consumer items.
Pasteurization and preservation of foods.
Reduction of environmental pollution.
Tomorrow's Progress Today
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Electron Beam Processing
Electron beam (EB) processing has been demonstrated on a large
commercial scale to be a very effective means of improving end-use
properties of various polymers. It is a well established and economical
method of precisely modifying the bulk and surface properties of polymer
materials.
Although many of the EB applications are in wide use, the combination of
high energy and high power of new electron accelerators now enable
economical application to larger and thicker products.
EB radiation is a form of ionizing radiation, generally characterized by its fixed
penetration range and its high dose rate. These electrons are generated in
equipment called accelerators, which produce a beam that is either pulsed or
continuous.
EB is a process in which the products are exposed to a concentrated, highly
charged stream of electrons. As a product passes in front of the electron
beam, it absorbs energy from the electrons. The energy that is absorbed per
unit mass of product or material is referred to as the absorbed dose.
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Electron Beam Processing
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Polymeric materials with high molecular weights are good candidates for radiation
processing.
Inorganic compounds with low molecular weights are poor candidates for radiation
processing.
Dilute solutions are exceptions. Ionizing a small fraction of the solvent will affect
most of the solute.
High energy electron used under high temperature & nitrogen atmosphere
Possible uses for electron irradiation include sterilization, degradation and to crosslink polymers. X-linking polymeric products to improve mechanical, thermal,
chemical and other properties
Material degradation often used in the recycling of materials, and Sterilization of
medical and pharmaceutical goods.
Electron energies typically varies from keV to MeV range, depending on the depth
of penetration
In polymers, an electron beam may be used for chain scission & cross linking.
The result is a change in the properties of the polymer which is intended to extend
the range of applications for the material.
The effects of irradiation may also include changes in crystallinity as well as
microstructure.
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E-Beam Accelerator
• An Electron Gun is housed in a
thick vessel where electrons are
accelerated in an acceleration tube
• The Electrons are directed to a
scanning device magnetically
• Similarly, depending on the dosage
required, suitable under-beam
handling systems are designed
•The products are passed under the
beam thru set of under-beam
equipments
Fig(1)
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GLOBAL DISTRIBUTION OF ACCELERATOR
EUROPE
KOREA
10
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RUSSIA
50-100
CHINA
140
N. AMERICA > 200
JAPAN 350
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INDIA
2
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PRODUCTS
p WIRE & CABLES, PE FOAM
p HEAT SHRINKABLES, TYRES
p ADHESIVE TAPES, ELECTRONIC MEDIA
p TAPES, PAPER, PANELS, FOOD
INDIAN SCENARIO
1. 2 MeV EB MACHINE - AT BARC FOR R&D
2. 3 MeV EB MACHINES ADDED IN 2003
3. 2.5MeV added in 2007 AND IN 2011
4. 1.5 MeV & 3 MeV – New Project of Apar Industries Limited
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Applications of Radiation Processing
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Modifying Polymeric Materials
Curing Monomers and Oligomers
Grafting Monomers onto Polymers
Crosslinking Polymers
Degrading Polymers
Biological Applications
Sterilizing Medical Products
Disinfecting Consumer Products
Pasteurizing and Preserving Foods
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Environmental Applications
Reducing Acid Rain
Treating Waste Materials
Solid State Applications
Modifying Semiconductors
Coloring Gemstones
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Applications of Radiation Processing
Materials Suitable for Grafting
• A variety polymeric materials
– Polyethylene, Polypropylene
– Polyvinyl Chloride, Fluoropolymers
• Cellulose, Wool
Property Improvements by Grafting
• Addition of hydrophilic surfaces on hydrophobic
polymers to make perm selective membranes.
• Fuel cell and battery separator films.
• Improvement of surface adhesion properties.
• Biocompatible materials for medical applications.
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Applications of Radiation Processing
Typical Materials for Crosslinking
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Polyethylene
– Polyvinylchloride
– Polyvinylidenefluoride
– Ethylene-propylene rubber
– Ethylene vinylacetate
Polyacrylates
Products Improved by Crosslinking
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Plastic Products in Finished Form
Heat Shrinkable Tubing and Film
Electrical Wire and Cable Jackets
Tires for Automobiles and Trucks
Plastic Foam Padding for Automobiles
Bulk Plastic Materials
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APPLICATION OF EB SYSTEM
Sterilization (0.9%)
Automobile Tire (13.9%)
Flue Gas Treatment (2.3%)
Others (8.8%)
Curing & Conveting
(7.4%)
R&D (27.8%)
PE Foam (7.9%)
Heat Shrink Tube (4.6%)
Source : NHV
Wire & Cable (26.4%)
Improve Material Properties through X-linking
• Improved Heat Resistance
• Improved Pressures(Stress Rupture)Resistance at elevated
temperatures.
• Improved environmental stress crack resistance
• Mechanical properties such as tensile strength
• Scratch resistance
• Reliable and efficient use of energy.
• Performance at temperatures, often increase in the melting
temperature
• Resistance to chemicals with lower solubility in organic solvent
• Gas permeation reduction
• Improved low temperature strength
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Commercial Examples
Typical Polymer(s) Property Improved Due to E- Beam Processing
Foam
PE
Improved cell structure, mechanical
properties and appearance
Gaskets, Seals
PE, EVA,(TPE)
Improved heat properties, chemical
resistance and resistance to
compression
Heat Shrinkable Tubes / Films
PVC, PE, PVDF
“Memory” Imparted, chemical resistance
Medical Devices
PP
Sterilization
Molded parts( Electronic
Components)
PA
Solder Iron Resistance
Molded parts(Automotive )
PA
Improved heat deflection & operating
temperature
PEX- Crosslinked flexible pipe
PE
Increased heat distortion temperature,
operating temp & dimensional stability
Recycling of Ram Materials
PTFE
Micronized Powders used in Inks,
Lubricants and Coatings
Rubber
Various
Cold Vulcanization
Wire & Cable Insulation
PVC, PE
High temperature properties, chemical
resistance, tensile strength, “low
smoke/zero halogen”(PE)
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COMPARISON OF HDPE, PP(H) & X-LINKED HDPE
Sr.No Properties
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HDPE
PP(H)
X-LINKED
HDPE
1.
Continuous use
90 °C
90 °C
120 °C
2.
Melting Temperature at
170 to 180 °C
Melts easily
Melts
Does not melt
3.
Oil Resistance at 150 °C
for 24 Hrs.
Not Good
(Melts &
Dissolves)
Not Good
Very Good
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High Temperature
ageing resistance (150
°C / 7 days)
Brittle
Brittle
Good
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Hot Set Test at 200 °C
for 15 Minutes
Fail
Fail
Pass
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ASTM Oil Swelling at
150 °C fir 24 Hrs.
Swelling very
high > 40%
Swelling very
high > 50%
Swelling very
less < 10%
Tomorrow's Progress Today
Application
of
Crosslinked Nylon 6
Automotive connectors, where higher temperature performance is
required, are one application where crosslinkable nylon 6
compounds can exhibit cost-performance advantages over highperformance engineering thermoplastics.
Experimental setup for a simple test of nylon crosslinking (above). The 350 C
soldering iron with a 1-kg load immediately penetrates the non-crosslinked
nylon sample (below) but does not penetrate the crosslinked sample
(bottom) after 30 sec.
Non Crosslink
Crosslink By Electron Beam