Enhancement of the Injection Grade Polypropylene using Extrusion Grade Polypropylene and Calcium Carbonate
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SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020
Enhancement of the Injection Grade Polypropylene using Extrusion
Grade Polypropylene and Calcium Carbonate
Muhab S. Hassanien1, Mawa H. Elabaid1, Arman M. Ahmed1, Ibrahim Y. Elgady1, Akram.H. Ali2,
Sheikheldeen B. Ali3
1
Polymer Engineering Department, Sudan University of Science and Technology (SUST), Sudan,
2
Textiles Engineering Department, Sudan University of Science and Technology (SUST), Sudan,
3
Leather Engineering Department, Sudan University of Science and Technology (SUST), Sudan,
muhabshalby@gmail.com
Receieved: 05/03/2020
Accepted: 12/05/2020
Abstract - This work studied composite properties of polypropylene injection grade using
polypropylene extrusion grade and calcium carbonates. Four formulations of PPinjection and PPextrusion
viz. 95/5, 90/10, 85/15 and 80/20 in ratio of weight percentage were prepared for injection molding
machine. This PPinjection/PPextrusion 80/20 blend is selected and investigated at different three fractions of
calcium carbonate. The mechanical properties such as tensile strength and elongation were
investigated. The rheological properties such as melt flow index and melt density were evaluated. The
work obtained blending PPinjection with PPextrusion in most cases decreased the tensile strength,
elongation, melt density and melt flow index. The results indicated that incorporate calcium carbonate
to blend increased the tensile strength, melt flow index and melt density while elongation decreased.
Keywords—Polypropylene, Blend, Calcium Carbonate, Mechanical, Rheological
المستخلص – فٌ هزا الثحث ذمد دساسح خصائص الثولٌ الثرشبتيَه خامرح الحنره الرزً ذرم مضخر ترالثولٌ ترشبتيَه خامرح
ب19/59 , 10/50 , 9/59 ٌ ذم عمل أستع خيطاخ مه مضٍح الحنه بالثثرق بهر.الثثق بكشتوواخ الكالسَوم كمادج مضافح
مرره المررضٍح بمرره ررم إضررافح ة ررح وسررة ميوٍررح مرره كشتوورراخ20/50 تلررذ رلرري ذررم أخرَرراس الخيطررح. كىسررثح ميوٍررح20/50
الخصررائص الشٍولوٍدَررح مثررل ملامررل. الخصررائص المَكاوَكَررح مثررل منابمررح الاررذ ب اخسرررطالح ذررم أخرثاسهررا.الكالسررَوم لهررا
ٌ اللمل أظهش أن مضج الثولٌ تشبتيَه خامح الحنه مع الثول.ًإوسَاب المصهوس بكثافح المصهوس ذم أخرثاسها بذنََمها أٍضا
الىررائح دلرد عيري أن. كثافح المصهوس بملامل إوسَاب المصرهوس, اخسرطالح,تشبتيَه خامح الثثق أدى إلي ونصان قوج الاذ
كثافرح المصرهوس ب قروج الارذ تَىمرا, أضافح كشتوواخ الكالسَوم إلي المضٍح أدى إلي صٍادج كل مه ملامل إوسَاب المصرهوس
.أظهشخ الىرائح ونصان فٌ اخسرطالح
INTRODUCTION tearing [3]. Long fiber and continuous fiber
Interest in polypropylene (PP) and polyethylene reinforcement technology with Polypropylene
(PE) is specifically due to the fact that; both produce molding material with higher tensile
these polymers are widely used as important strength and semi-finished materials such as
engineering materials in the automotive, sheet and tape which are beginnings to find
electrical appliances and packaging industries applications, mainly in structural parts. This
due to their excellent properties such as rigidity shows that the Properties of Polypropylene can
and stiffness, oil resistance and their thermal be improved by adding a fibers or other
stability [1]. Apart from these good properties that reinforcement material. If additional stiffness or
polypropylene has, its applications as often strengthen agent is needed, reinforcement can be
limited due to its low impact strength and added to Polypropylene.
Young’s modulus, particularly at low and high A very important property that has led to many
temperature loading conditions. These applications for Polypropylene is its superior
polypropylene drawbacks can be considerably resistance to cracking from mechanical stress [4].
improved by blending polypropylene with other The mechanical properties of Polypropylene
polymers [2]. Polypropylenes offer a good depend on several factors and are strongly
balance of properties and cost unachieved by influenced by the molecular weight. The
most other thermoplastics polymer. molecular weight of PP is normally estimated
Polypropylene has good mechanical, electrical from the simple measurement of viscosity. Melt
and chemical properties and good resistance to flow rate is more commonly used to measure the
11SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020
viscosity. General observations suggest that an Calcium carbonate (CaCO3) used on
increase in molecular weight, keeping all other experimental of present work as additives
structural parameters similar, leads to a reduction (fillers) in granules form (white granules).
in tensile strength, stiffness, hardness, brittle A. Experimental Work
point [5,6]. In the experimental study, blends of PP114/PP113
The use of inorganic fillers has been a common were prepared according to the required
practice in the plastics industry to improve the compounds formulated as: 95/5, 90/10, 85/15
mechanical properties of thermoplastics, such as and 80/20 to make up a total of 100 g (wt. /wt.
heat distortion temperature, hardness, toughness, %). The samples were prepared to an injection
stiffness and mold shrinkage. The effects of filler molding machine at (180–250°C). The processed
on the mechanical and other properties of the samples were allowed to cool at room
composites depend strongly on its shape, particle temperature for 48 hours. Then different tests
size, aggregate size, surface characteristics and were carried out such as tensile test and
degree of dispersion. Stiffness, Flexural strength, elongation. Also melt flow index and melt
Ultimate modulus, heat deflection temperature density of the blend. Shown in Table 3.
and some other mechanical properties can be
increase by filling suitable percentage of talc and TABLE 1: SPECIFICATIONS OF POLYPROPYLENE PP 113
modifier with PP for various new mechanical Trade Name KPC Polypropylene (PP 113)
Density 0.900 g·
and electrical applications [5, 7]
Melting Point 230 °C
Calcium carbonate has been one of the most
Melt Flow Index
commonly used inorganic fillers for 3g/10min (230°C, 2.16 kg)
(MFI)
thermoplastics, such as poly vinyl chloride Tensile Stress at Yield 27.5MPa
(PVC) and polypropylene (PP) [8]. The Flexural Modulus 1000MPa
incorporation of CaCO3 in PP is a common Izod Impact
practice to improve the heat distortion 25 J/m
Resistance
temperature, dimensional stability, stiffness and Heat Deflection Temp 74°C
hardness of the polymer. However, the addition
of micron-sized-CaCO3 particles to PP has not TABLE 2: SPECIFICATIONS OF POLYPROPYLENE PP 114
shown significant improvement in the KPC Polypropylene (PP
Trade name
mechanical properties of the composites [7]. In 113)
Density 0.910 g·
the art, several attempts have been made to
Melting Point 230 °C
improve the mechanical and optical properties of Melt Flow Index (MFI) 8 g/10min (230°C,2.16kg)
polypropylene films by adding organic or Tensile Stress at Yield 27.5MPa
inorganic filler materials and especially calcium Flexural Modulus 950MPa
carbonate [9]. Izod Impact Resistance 20 J/m
Khartoum Petrochemical Company (KPC) Sudan Heat Deflection Temp 71°C
produces two grades of polypropylene homo
polymer under ASTM standard those are TABLE 3: FORMULATIONS OF PP114/PP113 BLENDS
extrusion grade (PPKPC113) and injection grade Blend Materials
No PP114 (wt. %) PP113 (wt. %)
(PPKPC114) [1]. `The present work aimed to study
1 95 5
the properties of KPC polypropylene injection
2 90 10
grade to overcome the processing and products 3 85 15
problems. 4 80 20
MATERIALS AND METHODS
Table 1 shows specifications of Polypropylene In the experimental study; three different calcium
(PP113)–extrusion grade supplied by Khartoum
carbonate concentrations were added to
Petrochemical Company, in powder with the PP114/PP113 (80/20) by weight to produce
following particulars. composites make up a total of 1kg as in Table 4.
Table 2 shows the specifications of The samples were prepared to an injection
Polypropylene (PP114) extrusion grade product molding machine at (180 – 220°C). Then the
supplied by Khartoum Petrochemical Company tensile strength and elongation were carried out.
(KPC, Sudan), in powder with the following The melt flow index and melt density
particulars. determined.
12SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020
TABLE 4: FORMULATIONS OF PP114/PP113/ CaCO3
Blend Materials
No PP114 (wt. %) PP113 (wt. %) CaCO3 (wt. %)
1 80 20 7.5
2 80 20 15
3 80 20 22.5
TESTING AND RESULTS
A. FIRST BATCH :PP114/PP113 BLENDS
1. Mechanical test:
Tensile strength test
The Tensile strength of PP114/PP113 is shown in
Figure 1. Tensile strength of (PP114) was 34.37
N/ . Addition of (PP113) (5, 10, 15 and 20wt Figure 3: MFI of PP114/PP113 BLENDS
%) to (PP114) was decreased the tensile strength
of (PP114). Melt density Test
The melt density tests of PP114/PP113 blends are
shown in Table 8 and Figure 4. The melt density
of PP114 was 1.124 g/cm3. The result showed
addition of PP113 (5, 10, 15 and 20wt %) to
(PP114) decreased melt density of PP114.
Figure 1: Tensile strength of PP114/PP113 blends
Elongation Test
The elongation of PP114 was 7.52mm. Addition
of PP113 (5, 10, 15 and 20wt %) decreased the
elongation of PP114.as in Figure 2.
Figure 4: Melt density tests of PP114/PP113 blends
3.PP114/PP113 Blends Tests Summary:
The summary of PP114/PP113 blend is shown in
Table 5.
TABLE 5:PP114/PP113 BLENDS TESTS SUMMARY
Melt Tensile
Blend MFI Elongation
density Strength
No (g/10min) (mm)
(g/cm3) (N/
PP114 8.2 1.124 34.37 7.52
1 7.07 0.904 31.66 7.348
2 6.87 0.876 32.68 7.202
3 6.14 0.757 32.18 7.152
4 5.65 0.630 32.48 6.952
Figure 2: Elongation OF PP114/PP113 BLENDS
2. Rheological Test: Results showed addition of polypropylene
Melt flow index (MFI) test: (PP113) to polypropylene (PP114) in most cases
This test is used to investigate the flow properties decreased the tensile strength and elongation of
of PP114. Figure 3 show the effect of PP113 polypropylene (PP114). These results indicate that
contents on the MFI of PP114. The MFI of PP114 the decrease in tensile strength with the increase
was 8.2 g/10 min. The addition of PP113 (5, 10, of (PP113) is related to the bonding strength
15 and 20 wt. %) to PP114 decreased the MFI. between PP114/PP113 compared to the
13SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020
intermolecular bonding of PP114. From these was 5.65g/10min. The result showed addition of
results, it is assumed that the decreased tensile calcium carbonate increased (MFI).
strength related to the decreased brittleness and
stiffness of the blend, due to the addition of
(PP113). The PPinjection/PPextrusion 80/20 blend is
selected which provided balance the good
performance. Also the results obtained decrease
melt density and melt flow index of PP114.
B. SECOND BATCH :PP114/PP113 CaCO3
COMPOUNDS
1. Mechanical test:
Tensile strength test
The tensile strength of PP114/PP113 blend was
32.48N/ . The result showed addition of
(7.5, 15 and 22.5 wt. %) calcium carbonate
Figure 7: MFI of PP114/PP113/ CaCO3
increased tensile strength as in figure 5:
Melt density test
Melt density test of PP114/PP113 and compound
are shown in Figure (8). The melt density of
PP114/PP113 blend was 0.630 g/cm3. The result
showed addition of (7.5, 15 and 22.5 wt. %)
calcium carbonate increased melt density.
Figure 5: Tensile strength PP114/PP113 / CaCO3
Elongation Test
The elongation of PP114/PP113blend was
6.952mm.
Figure 8: Melt density of PP114/PP113/CaCO3
3. PP114/PP113/Caco3 Tests Summary:
The Table (6) shows the mechanical and
rheological test of PP114/PP113/CaCo3 compound.
The result showed addition of (7.5, 15 and 22.5
wt. %) calcium carbonate increased melt flow
index and melt density of PP114/PP113. This result
may be directly related to the undeform ability of
the filler and its lack of contribution to the flow.
The result showed addition of calcium carbonate
increased tensile strength with the increase of
calcium carbonate is related to the improved
FIGURE 6: ELONGATION OF PP114/PP113 /CaCO3 bonding strength between PP114/PP113 compared
to the intermolecular bonding of PP114. From
2. Rheological test
these results, it is assumed that the increased
Melt flow index (MFI) test
tensile strength related to the increased
The melt flow index test is used to investigate the
brittleness and stiffness of the blend, due to the
flow properties of PP114/PP113 and compound are
addition of calcium carbonate. While the work
shown in Figure (7). MFI of PP114/PP113 blend
assumed that the decrease in elongation with the
increase of calcium carbonate is related to the
14SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020
improved bonding strength between PP114/PP113 Mechanical Properties of Polypropylene",
compared to the intermolecular bonding of PP114. International Journal of Research in Engineering
and Technology (IJRET), Volume: 2 Issue: 4
TABLE 6: PP114/PP113/ CaCO3TESTS SUMMARY 411 – 415.
Melt Tensile
Compound MFI
density strength
Elongation [7] Neelam Singh, Santanu Dutta, (2013)
No (g/10min) (mm)
(g/cm3) (N/ "Reinforcement of Polypropylene Composite
PP114/PP113 system via Fillers and Compatibilizers", Open
5.65 0.630 32.48 6.95
(80/20) Journal of Organic Polymer Materials, Volume
1 7.27 1.141 33.02 7.37 3.
2 8.63 1.037 34.51 6.93 [8] Chan Chi-ming, Wu Jingshen, Li Jiang
3 9.25 1.029 34.87 6.75 Xion, Cheung Ying-kit,
(2003)"Polypropylene/calcium carbonate
CONCLUSION nanocomposites", United States Patent, A
Blending PPinjection with PPextrusion in most cases SumoBrain Company (FPO), Application
decreased the tensile strength, elongation, melt 20030060547.
density and melt flow index. The work obtained [9] Brunner, Hirsiger, Blanchard, Roux, (2019)
blending PPinjection with PPextrusion in most cases "Calcium Carbonate As Cavitation Agent For
decreased the tensile strength, elongation, melt Biaxially Oriented Polypropylene Films",
density and melt flow index. Also indicated that United States Patent, A SumoBrain Company
incorporate calcium carbonate increases the melt (FPO), Application 20190218352.
flow index, melt density and the tensile strength [10] Abu Ghalia, Mustafa A, (2011)
while elongation decreased. The results showed "Mechanical, rheological, and thermal properties
enhancement on the mechanical and rheological of calcium carbonate filled polypropylene /
properties of PPinjection. linear low density polyethylene
composites",Applied Polymr Science 121(4),
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