Posted: 21 July 2023
What are Advanced Polymers?
Advanced Polymers, also known as
engineering polymers or high-performance polymers, are a class of synthetic
polymers that exhibit exceptional mechanical, thermal, chemical, and electrical
properties. These polymers are specifically engineered to possess superior
performance characteristics compared to conventional or commodity polymers.
They find application in a wide range of industries, including aerospace,
automotive, electronics, medical, and manufacturing.
Some key characteristics of
advanced polymers include:
- High strength and stiffness
- Thermal stability
- Chemical resistance
- Low friction and wear
- Electrical and thermal insulation
- Lightweight
- Dimensional Stability
- Design flexibility
- Biocompatibility
Examples of advanced polymers
include polyetheretherketone (PEEK), polyimides, polyphenylene sulphide (PPS),
liquid crystal polymers (LCP), polytetrafluoroethylene (PTFE), and
polyetherimide (PEI), among others. These polymers offer unique combinations of
properties that make them ideal for demanding applications where high
performance, durability, and reliability are required.
Process Cooling and Advanced Polymers
Process cooling equipment plays
a crucial role in advanced polymers research and production by controlling and
maintaining the temperature of various processes. Some examples of how process
cooling is utilised in the context of advanced polymers are below:
Polymerisation
- In the production of
advanced polymers, polymerisation reactions often generate heat as the monomers
react and form polymer chains. Process cooling equipment is used to remove this
heat and maintain the desired reaction temperature. Precise temperature control
during polymerisation is essential to achieve the desired molecular structure,
molecular weight, and polymer properties.
Melt Processing
- Advanced polymers can be
processed through techniques such as extrusion, injection moulding, or blow
moulding, which involve melting the polymer and shaping it into the desired
form. During melt processing, cooling is required to solidify the molten
polymer quickly and accurately. Process cooling equipment helps in cooling the
polymer melt, preventing excessive heat build-up, and maintaining the required
cooling rate for proper solidification.
Annealing and Quenching
- Annealing is a heat
treatment process used to relieve internal stresses in the polymer and improve
its mechanical properties. Process cooling equipment is employed to control the
cooling rate during annealing, ensuring that the polymer cools gradually and
uniformly to avoid distortion or cracking. Quenching, on the other hand,
involves rapidly cooling the polymer to freeze its structure and lock in
desired properties. Process cooling equipment facilitates the rapid quenching
process, allowing for the desired material characteristics to be achieved.
Material Testing
- In advanced polymers
research, material testing involves subjecting samples to controlled
temperature conditions to evaluate their mechanical, thermal, or electrical
properties. Process cooling equipment is utilised to cool the testing
equipment, ensuring precise temperature control during experiments. This
enables researchers to study the behaviour of polymers under specific
temperature conditions and make informed decisions regarding their application
or processing.
Environmental Control
- Process cooling equipment
helps to maintain controlled environmental conditions in advanced polymers
research and production facilities. It helps to regulate the temperature and
humidity levels in the workspace, ensuring stable conditions for consistent
material properties and avoiding moisture-related issues or unwanted variations
due to temperature fluctuations.
Equipment Cooling
- Advanced polymers
processing often involved specialised equipment such as extruders, moulds, or
reactors, that generate heat during operation. Process cooling equipment is
used to cool these equipment components, preventing overheating, and
maintaining their optimal performance and longevity.
Recirculating Chillers
Recirculating chillers are
widely used in advanced polymers applications. These compact and self-contained
units circulate a heat transfer fluid to remove heat from the process and
maintain precise temperature control. Recirculating chillers offer several
benefits in advanced polymers research and production, including:
Precise temperature control:
- Recirculating chillers
provide precise temperature control, allowing researchers and manufacturers to
maintain a specific temperature range required for various stages of advanced
polymers processing. This accuracy is crucial for achieving consistent results,
ensuring reproducibility, and optimising material properties. With precise
temperature control, the cooling process can be tailored to specific polymers,
enabling the production of materials with desired characteristics.
Efficient heat removal:
- Recirculating chillers can
cover a wide temperature range. This versatility makes them suitable for
various coating processes that require different temperature conditions.
Whether it’s room temperature coatings, high-temperature curing, or
low-temperature applications, recirculating chillers can be adjusted to meet
the specific temperature requirements of the process.
Efficient heat removal:
- Recirculating chillers
efficiently remove the heat generated during polymerisation, melt processing,
or other advanced polymers processes. They prevent overheating and help to
maintain a stable temperature environment, which is crucial for achieving the
desired material properties and avoiding defects. Efficient heat removal
improves process efficiency, enhances productivity, and minimises the risk of
thermal degradation or undesirable reactions.
Versatility in cooling capacity:
- Recirculating chillers are
available in various cooling capacities, allowing flexibility in choosing the
appropriate chiller for specific research or production needs. Whether it is a
small-scale experiment or a large-scale industrial operation, recirculating
chillers can be selected to match the heat load and cooling requirements of the
process. This versatility ensures optimal cooling performance and efficient
operation.
Compact and self-contained design:
- Recirculating
chillers feature a compact and self-contained design, making them easy to
integrate into research or production setups where space is limited. They
typically have a small footprint and can be placed near to the equipment or
process being cooled. The self-contained nature of recirculating chillers
simplified installation, eliminated the need for external refrigeration units,
and reduces the complexity of the cooling system.
Low maintenance:
- Recirculating chillers
require minimal maintenance, making them convenient to use in advanced polymers
research and production. They are designed for reliable and continuous
operation, with features such as automatic temperature control, built-in safety
mechanisms, and alarm systems. Routine maintenance tasks such as heat transfer
fluid refilling or filter cleaning are typically straightforward, ensuring
smooth and uninterrupted operation.
Reduced water usage:
- Recirculating chillers
offer an advantage of reduced water consumption compared to traditional
water-cooling systems. Instead of continuously using large volumes of water,
recirculating chillers utilise a closed-loop system where the heat transfer
fluid is recirculated and cooled for re-use. This reduces water consumption,
conserves resources, and minimises the environmental impact of cooling processes.
Noise reduction:
- Recirculating chillers are
designed to operate with low noise levels, ensuring a comfortable working
environment in research labs or production facilities. Noise reduction features
can be investigated to further minimise disturbances and create a quieter
workspace.
Safety:
- Recirculating chillers are
equipped with safety features to ensure the protection of personnel, equipment,
and processes. They typically include features like over-temperature
protection, low liquid level detection, and electrical safety measures. These
safety features help to prevent accidents, protect the integrity of advanced
polymers processes, and provide peace of mind during operation.
Heat Exchangers
Heat exchangers are devices that
facilitate heat transfer between two fluids. In advanced polymers research and
production, heat exchangers are used to remove excess heat generated during
processes. They offer many benefits, including::
Efficient heat transfer:
- Heat
exchangers are designed to maximise heat transfer between two fluids, enabling
efficient cooling or heating of advanced polymers processes. They facilitate
the exchange of thermal energy, allowing for precise temperature control and
uniform distribution of heat. Efficient heat transfer helps to maintain optimal
process conditions, prevents overheating, and ensures consistent material
properties.
Enhanced process efficiency:
- Heat
exchangers contribute to temperature control and stability during the coating
process. By regulating the flow of the heat transfer fluid, heat exchangers
help to maintain a consistent temperature within the coating equipment or
system. This temperature stability is critical for achieving uniform coating
properties, controlling the curing or drying process, and ensuring consistent
results from batch to batch.
Flexibility in temperature range:
- By efficiently removing or
adding heat, heat exchangers contribute to improved process efficiency in
advanced polymers production. They enable precise temperature control, reducing
the risk of thermal degradation or unwanted reactions. Optimised process
conditions achieved through heat exchangers lead to increased productivity, reduced
cycle times, and improved energy efficiency.
Cost savings:
- Heat exchangers can
contribute to cost savings in advanced polymers research and production. By
effectively transferring heat, they minimise energy consumption and reduce the
need for additional heating or cooling equipment. Heat exchangers also minimise
waste by maintaining precise temperature control, preventing the production of
defective or subpar polymer materials.
Scalability:
- Heat exchangers offer
scalability in advanced polymers processes. They can be scaled up or down to
accommodate different production volumes or research needs. Whether it’s a
small-scale laboratory experiment or a large-scale industrial operation, heat
exchangers can be selected or customised to meet the specific cooling or
heating demands of the process.
Safety:
- Heat exchangers are
designed with safety features to ensure the protection of personnel and
processes. They incorporate features such as pressure relief valves,
temperature sensors, and proper insulation to prevent accidents or equipment
failures. By maintaining safe operating conditions, heat exchangers contribute
to a secure working environment.
The specific process cooling
equipment used in advanced polymers research and production depends on factors
such as the scale of operation, cooling requirements, temperature range, and
desired level of control. Different cooling equipment can be combined or
customised to suit the specific needs of the application, ensuring efficient
cooling and optimal process conditions.