OM
POLYESTER
Polyester is defined by the International Standards Organisation (ISO) as 'a polymer comprising
synthetic linear macromolecules having in the chain at least 85% (by mass) of an ester of a diol and
terephthalic acid.
POLYMER PRODUCTION
Poly(ethylene terephthalate) is a step growth (condensation) polymer and is produced industrially
by one of the following two routes:
1. DMT route: raw materials are dimethyl terephthalate (DMT) and monoethylene glycol
(MEG);
temperatures starting from 150°C and slowly increasing to 210°C
the ethylene glycol to DMT ratio of 1.7 – 2
The reaction is reversible and is driven to completion by distilling off the by
product methanol.
The addition of catalyst, most often metallic salts of a weak or volatile acid,
such as Pb, Zn, Mn, Ca or Cd acetate, is preferred.
2. PTA route: raw materials are terephthalic acid (TPA) and monoethylene glycol (MEG).
the reaction temperature and pressure to 240-260 °C and 4 x 105 Pa.
an EG/TPA ratio of 1.1 to 1.3
The reaction is self-catalyzed by the carboxylic acid groups.
additional catalysts such as stronger acids and esters of titanic acid are also
used
TPA route has several economical advantages over DMT route, which are given below:
The yield by weight of polymer obtained from the monomer is higher in PTA route, because, DMT is a diester
with two methanol molecules which needs to be removed during ester interchange reaction.
EG/PTA ratio is much lower in PTA route than EG/DMT ratio used in DMT route, therefore lower amount of
EG needs to be removed during the polycondensation step (i.e. 2nd step) to achieve same molecular weight.
The cost of PTA is lower than that of DMT
Methanol obtained from ester interchange reaction, needs to be collected, purified by distillation and sold as a
byproduct, which makes DMT route more expensive.
Therefore, the PTA- based production saves 8% of total capital investment and 15 % of feedstock cost.
Side Reactions in melt PET polymerization
(i) Formation of Diethylene Glycol (DEG) and Dioxane
DEG (Diethylene glycol) is the most important side product in PET synthesis. DEG and dioxane can be regarded as
condensation products of EG formed according to the following stoichiometric as shown in reactions .
Reaction for the formation of DEG and DIOXANE
PET made by direct esterification of TPA generally contains more DEG than PET made by
transesterification of DMT. Alkaline compounds of alkali metals, alkaline earth metals,
amines or ammonium compounds of the fourth group are effective catalysts for reducing
DEG formation. Dioxane, which is formed from DEG, has a high vapour pressure (i.e. is
quite volatile) and is removed from the process as column top product. However, DEG is less
volatile (boiling point 215°C) and, since it is a diol, it gets incorporated into the PET chain as
comonomer. This alters the crystallization behaviour of PET. The quantity of DEG in PET
molecules influences many important properties of the polymer; e.g., density, thermal,
oxidative and hydrolytic degradation, light-stability, and thermal transitions. Incorporation of
DEG is known to increase the dyeability, though the dye take-up of PET is not uniform. DEG
content in the polymer decreases the melting point and thermal stability of the polymer. The
melting point of the polymer is depressed by approximately 2.5-5°C for each 1% of DEG
incorporated in the polymer chain. It is therefore important to control DEG formation in PET
manufacture.
(ii) Thermal degradation of Repeat units
Thermal degradation of PET polymer chains is a major problem at temperatures above the melting point and occurs
during the melt polycondensation because of high temperature and residence time required for obtaining high
molecular weight. The major consequences of these on the PET quality are: drop in intrinsic viscosity, formation of
carboxyl end groups and acetaldehyde, and yellowing of polymer.
BATCH PROCESS
CONTINUOUS PROCESS
APPLICATIONS
cotton blends.
filling fibre for quilts, pillows and sleeping bags which can be laundered.
microfibre having ultrasoft handle.
Sutures.
carpet application.
surgical implants.
reinforcing fibre for car tyres.
earth stabilization in the construction of roads, embankments and dams.
