• Tag cloud

    • Rafinat Yarullin, director general of OAO Tatnentekhiminvest-Holding
      Directions for innovations in the polymers manufacturing industry of the Republic of Tatarstan

      Tatarstan, the leading Russian region in petrochemicals, keeps surprising the industry with its numerous polymer projects – both in the polymer manufacturing and polymer conversion sectors.

      Together with new facilities for base polymer production and capacity expansions in the plastics conversion sector, the republic has been developing science projects. A growing number of innovations have been implemented in the republic. Gaps are numerous though, which opens immense prospects for the development of the plastic conversion industry.

      Mikhail Katsevman, director, Science and Development, of the Polyplastic group
      Thermoplastic polymers market in Russia.
      Analysis and forecasts

      The production and consumption of thermoplastics have been growing in line with Russia’s GNP. However, the amount and share of these materials in the total consumption are still considerably lower than those in developed countries.

      Our approach to the product range, quality management and pricing of polymer materials must be further revised. Localization of production facilities by international leaders of the consumer market will either eliminate these drawbacks quickly or reduce Russia’s output.

      Vsevolod Abramov, chairman of the Russian Plastics Converters Association
      Report on results of K 2010.
      The latest European technologies and equipment

      The 18th international plastic and rubber exhibition K is being held in D?sseldorf this November. It is a major event in the global industry. Technologies presented at K set development directions for the plastics industry for at least 10 years. Participation in the event is a must for all companies in the sector. The results of the exhibition will be discussed in the report of the chairman of the Russian Plastics Converters Association.

      Petr Malina, deputy director, Science, of ZAO Bioenergetik
      Plan of establishing a manufacture of newly designed polymer valves. Investment project

      запорная арматура

      ?The most significant number of ruptures and leakages occur near check valves during transportation of liquid products. For example, the oil spill in the Gulf of Mexico would be impossible if the hydraulic pressure on the check valve of the system had been several times lower.

      Setting a valve at an angle of 45° to the pipe instead of 90° and other engineering solutions could reduce the pressure, make hydraulic impact impossible and allow opening and closing valves without a hydraulic rotation booster. Such a solution allows the substitution metal with polymers in those valve designs that excluded such replacement thus far.

      Our new check valves possess such advantages as resistance to corrosive environment and low cost in comparison with metal analogs. They are protected by over 10 invention patents. The technical characteristics of the valve and its competitiveness against foreign analogs have been confirmed by tests conducted by NPP Mashtest (Korolev, Moscow region), Tyazhprom-Armature (Aleksin, Tula region), Hydromash Plant (Novokuznetsk, Kemerovo region) and Neftepromremont (Strezhevoi, Tomsk region).

      The Russian Congress of Plastic Converters scheduled for this November will present the feasibility study of this project to potential investors describing the amount of investments needed, market size, equipment capacity, project payback period. If implemented, the project will prolong the service life of check valves used at numerous residential and industrial objects, including chemical facilities. The goal of the project is to gradually replace the old valves of currently operating pipeline systems and install the new valves on newly built plastic pipelines.

      Aslanbek Balov, director general of Polykhimgroup On substitution of existing flame retardants with new-generation products

      Recent statistics show that the number of fires in the Russian Federation stays at about 250,000 events per year. Annually, 20,000 deaths and direct damages of 4 billion roubles are caused by fires in Russia. The production of fireproof materials is being actively developed in Russia. A legal framework making the use of fire retardants in compounds mandatory is being created in parallel. There are clear distinctions between processes and ingredients meant for electric, electronic, construction, aircraft, and automobile industries.

      Refusal to use halogen fire retardants that contaminate the environment becomes a major trend. The recently adopted REACH and WEEE standards restrict, and in certain cases forbid the use of halogen fire retardants. Actually, this means a redistribution of the European market for fire retardants.

      Russian manufacturers have to react to the new market situation in a timely manner and choose an optimum feedstock to enter this market with. Aslanbek Balov, CEO of Polykhimgroup reviews basic kinds of feedstock and technologies for manufacturing fireproof materials in his report prepared for the second session of the Russian Congress of Plastic Converters to be held at the Moscow government building in New Arbat.

      Bernd Fischer, executive director of Schnorr von Carolsfeld Engineering & Service GmbH Dedusting of granules at the stage of loading and feedstock processing

      Any impurities of feedstock can negatively affect the quality of finished articles and stability of the production process. Dust may cause black specks, blotches or soft spots in yarns or films. Dozers are clogged with strands.

      Pelletron Corporation, founded in 1986 in USA, offers to producers and converters of polymers effective solutions for the conversion of dedusting virgin and recycled polymers, automotive industry, medicine, food processing, etc. DeDusters are ranging in capacity from 50 to 100,000 kg per hour. Processors can install them directly on injection moulding machines, extruders, or dryers, while manufacturers could use them prior to bagging their material or loading railcars.

      Marina Chumakova, Silicone Sales Department of Wacker Chemie Rus
      Innovative liquid silicone resins for injection molding

      Wacker CHEMIE, the largest player in the global silicone market, offers to rubber and plastic processors a new product, liquid silicone rubber. Injection moulding of liquid silicone rubber makes it possible to manufacture large amounts (millions of pieces) of products of extremely high quality for various applications. Made without wastes or burrs, they are resistant to aggressive environment, nonflammable, oil sweating, conductive, low- frictional.

      Dariusz Lukaszewski, regional director of Milliken Chemical Opportunities for the production of innovative polypropylene grades in Russia

      The global market offers over 800 various grades of polypropylene made through innovative hyper nucleation and clarification technologies developed by Milliken. At present, the company is interested in offering its technologies to Russian converters.

      Dariusz Lukaszewski’s report at the 4th Congress of Plastic Converters will dwell on the following issues:
      – Demand for new PP grades in Russia.
      – Production of innovative import-replacing PP grades in Russia.
      – Consumption of new PP grades in Russia, including market needs and restrictions.

      Eugeny Bukharev, director general of NPP Mayak-93 Establishing of a manufacture of new-generation metal-polymer pipes

      No industry can develop without modern pipeline systems. The quality of pipes influences the quality and duration of life.

      The availability of newly developed composite materials creates ample opportunities for manufacturing pipes with new consumer properties, namely:
      – high thermal and fire resistance;
      – resistance to aggressive environment;
      – abrasive resistance, etc.

      NPP Mayak-93М improves polymer extrusion and polymer melt homogenization technologies to include ultrasonic methods. As a result, new specimens of equipment and experimental samples of new products have been developed.

      Sergei Tarskikh, director general of the Statico group. Specifics of the Russian waste separation. Technical solutions

      About 60% of municipal solid wastes are recycled in Europe. In Russia, this share is negligibly small. One of the strategic mistakes made by Russian legislators is the attribution of MSW utilisation requirements to the nature protection legislation, while these requirements must be dealt with in the industrial policy. To create waste recycling industry it is needed to solve four tasks:
      1. Removing the issues concerning wastes from the competence of the Ministry of Natural Resources.
      2. Establishing of a body regulating activities in the wastes processing sector without the right to fine for violations of environmental standards.
      3. Management of the quality of feedstock in the wastes processing industry. Arranging of a system of waste streams centralised management on a regional basis.
      4. Toughening of municipalities and population’s liabilities. Reduction of the landfilled MSW share, differential payment for sorted residual wastes, reasonable tariffs.

      Mikhail Zaikov, ZAO Bioenergetik.
      Experience of waste business development. Economics of mini thermal power-stations.

      By various estimates, polymers make 10–30% of total municipal solid wastes in Russia. Their presence makes it impossible to recycle millions of tons of garbage accumulated at authorised and unauthorised landfills across the Russian Federation.

      What danger polymers in garbage create? Are all polymers hazardous? What gas purification technologies used for thermal MSW utilisation are the most effective? Can accumulated landfills be eliminated in Russia without building large industrial plants nearby? What scheme of garbage and polymer waste delivery/sorting is the cheapest and the most friendly to the environment?

      Michael Zaikov, director of ZAO Bioenergetik, who has been involved in waste processing in the Moscow region for 20 years, will try to answer those and other questions in his report at a roundtable dedicated to MSW.

      Eugeny Antipov, professor, deputy director of the Topchiev Institute of Petrochemical Synthesis.

      Cable wastes and modifying additives. Review of new recycling technologies

      A team of Russian scientists have developed a cable waste recycling technology which will allow sorting tonnes of wastes of the cable industry and used cables into valuable nonferrous metals and initial polymers. A business plan concerning commercial equipment manufacture and a system of cable wastes conversion will be presented to partners and investors at the Congress of Plastics Converters.

      Valery Blok, director of SPKB, Volgograd.
      Review of MSW recycling technologies in Russia and abroad

      All known technologies of waste recycling and processing have been entered the Russian market by 2010. Foreign experience shows that a rational organization of MSW processing offers a chance to use up to 90% of recycled polymers in the construction industry, for example as concrete aggregates. The incineration of 1,000 kg of MSWs yields energy equivalent to that produced by burning 250 kg of fuel oil. The real savings turn out to be even greater, since waste, unlike fuel oil, requires no expenses for its production.

      When developing a thermal recycling technology, it is important to control atmospheric emissions of nitrogen dioxide and furans. Based on profitability and environmental friendliness, the following municipal solid wastes storage and recycling methods can be cited as promising: preliminary sorting, landfilling, incineration, biothermal composting, low-temperature and high-temperature pyrolysis.

      Yuri Radyushkin, director for projects at ZAO Ecros-Engineering.
      Monitoring and control: how to capture pollution and save money

      Any manufacture emitting potentially hazardous substances needs a control system. Control systems, as well as production operations, have become subject to full automation.

      To provide reproducibility and precision of results, samples, until recently, have been prepared only manually. The process usually took several days and heavily depended on human factor. To resolve this problem, Fluid Management Systems (USA) developed an automated sample preparation system. Its advantages are obvious: in one stage, it automatically performs full preparation of a sample without the presence or assistance of a lab technician, thus providing a precise and reproducible analysis without the cross-pollution of extracts and at minimal harmful influence on personnel. In those locations that do not require permanent monitoring, mobile posts for area inspection can be organised.

      This system can be particularly useful for regional administrations of the Russian Federation to organise ecological control over industrial enterprises, or for companies that prepare samples and have to monitor emissions in accordance with the current legislation.

      Ekaterina Kraeva, director general of RCC Group.
      Yuri Frei, representative of OAO Tatneftekhiminvest-Holding in the EU.
      On possible adoption of EN-DIN standards in the Russian Federation and outlooks for the expansion of the domestic polymer products market

      About 90% of DIN standards developed by the German Institute of Standardization have been recognized by the international community. Those standards cover residential and industrial construction, road building, pipelines, packaging and transportation, principles of facility operation in Germany and across the EU.

      The Association of Plastic Converters, the organising committees of the Moscow International Chemical Summit and the 4th Russian Congress of Plastic Converters address the Russian government with a proposal to adopt DIN standards in long-distance and municipal road-building and pipeline laying. This measure could result in an essential increase of sales of high performance polymers and composites in the domestic market, thus giving a powerful impetus to plastic processing.

      Vera Myasoedova, professor, chief scientist, Institute of Chemical Physics of the RAS. Wood-polymer and other fibrillar nanocomposites for pressure molding and extrusion applications

      Pulp is the most widespread organic polymer on the Earth. Russia possesses 25% of the global reserves of lignocellulose feedstock in the form of forest and annual plants’ wood. Articles made of ecologically pure wood-polymer fibrillar composites are known to have a superior performance.

      The report will dwell on how chemical nature, composition and structural features of wood-polymer and other fibrillar composites containing different modifiers affect the material processability using compression and extrusion. Benefits of applying thermoplastic polymer binders based on renewable feedstock in such composites will also be analysed.

      Valery Kulichikhin, director of the polymer rheology laboratory of the Topchiev Institute of Petrochemical Synthesis. Thermoplastics-based nanocomposites: first steps to commercialization.

      Nanocomposites based on polymer matrix are being developed by many scientific centers, but their commercialization in the engineering polymers market, with few exceptions, failed despite their functional properties. On the one hand, it damaged reputation of the “nano” prefix, and on the other hand, compelled researchers to investigate why this happens to understand whether the introduction of true nanoparticles yields a nanocomposite.

      The report will discuss new ways of introducing nanoparticles of layered silicates and nanodiamonds into a polymeric matrix, which were developed by a group of scientists as part of an ISTC project and attracted the interest of LSP Access International LTD and Milena Trading Ltd.

      Victor Avdeev, head of the Chemical Technology and New Materials Division of MSU, director of the Institute of New Hydrocarbon Materials and Technologies.
      Polymer composites and products for engineering, fire protection, sealing and other industrial applications

      The application of polymer composites whose unique properties allow making customized structures is spreading in various industries, including aerospace, alternative energy, shipbuilding, manufacture of goods for sports and leisure, as well as construction, infrastructure, and chemical engineering.

      Carbon-carbon composite materials form a separate direction both in scientific researches and industrial applications. Their development expands applications of these materials and opens new markets for them, including high temperature seals, frictional materials, heat insulation, etc.

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