CCB 4423

Polymer Process Engineering

(SPECIALISATION ELECTIVE)

AP Dr Zakaria Man

Lecture 1 : Tuesday 12.00 noon -1.00 pm Room 20-00-05

Lecture 2 : Wednesday 9.00 12.00 am Room 21-02-07
Tutorial : Wednesday 11.00 am 12.00 pm Room 21-02-07

CHEMICAL ENGINEERING PROGRAMME OUTCOMES (PO)

1. Apply knowledge of mathematics, science and engineering fundamentals and an engineering

specialisation to the solution of complex chemical engineering problems.
2 .Identify, formulate, research literature and analyse complex chemical engineering problems
reaching substantiated conclusions using first principles of mathematics, natural sciences and
engineering sciences
3. Design solutions for complex chemical engineering problems and design systems, components
or processes that meet specified needs with appropriate consideration for public health and
safety, cultural, societal, and environmental considerations.
4 Investigate complex chemical engineering problems using research based knowledge and
research methods including design of experiments, analysis and interpretation of data and
synthesis of information to provide valid conclusions.
5. Use modern engineering and IT tools to evaluate complex chemical engineering activities.
6. Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to professional engineering practice.
7. Understand the impact of professional engineering solutions in societal and environmental
contexts and demonstrate knowledge of and need for sustainable development.
8. Apply ethical principles and commit to professional ethics and responsibilities and norms of
chemical engineering practice
9. Communicate effectively on complex chemical engineering activities with the engineering
community and society.
10. Function effectively as an individual, and as a member or leader in diverse teams and in multi
disciplinary settings.

11. Recognise the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of
technological change.
12. Demonstrate knowledge and understanding of engineering and
management principles and apply these to ones own work, as a
member and leader in a team, to manage projects and in
multidisciplinary environments.

COURSE OUTCOME
At the end of this course, students should be able to:

1. Describe the polymerization mechanism and

polymer structure- property relationship.
2. Describe viscoelastic behavior & rheology
properties and relate to products performance.
3. Select suitable thermoplastic material and
fabrication technique for specific application.
4. Explain the phase separation behavior of
polymer blends and apply the knowledge in
polymer recycling and properties modification.
5. Formulate composite material with optimum
properties for specific applications.
Polymerisation reactions are included to give an overview of
how these apply to a wide range of processes, products and applications

1. Describe the polymerization mechanism and polymer structureproperty relationship (MW, Tm, Tg, density, reaction kinetics)
2. Describe viscoelastic behavior & rheology properties and relate to
products performance (Creep, Stress relaxation, Viscosity)
3. Select suitable thermoplastic material and fabrication technique
for specific application. (Membrane, injection moulding)
4. Explain the phase separation behavior of polymer blends and
apply the knowledge in polymer recycling and properties
modification.(Thermodynamic of mixing)
5. Formulate composite material with optimum properties for
specific applications.
6. (fiber/particulate and polymer matrix)

Synopsis
Students will be exposed to introductory concepts and
definition of polymeric materials, basic principles of polymer
molecular weight, structure of polymer solids, cross-linked
polymers and rubber elasticity, viscoelasticity,
mechanical/physical properties, rheology,
composites, processing technology,
environment and product recycling.

Week

Topic and Area

Assesment

Introductory Concepts and Definition

Some Definitions, Polymerisation and Functionality

Overview of Polymeric Materials
Why are Synthetic Polymers Useful?
Molecular Architecture,
Classification, Thermoplastics, Thermosets and Elastomer,
Polymer Nomenclature

Polymerisation
NG/LPG/naphta to monomers,
Polymerisation and catalyst systems
Addition and Condensation
Control of MW and product quality, grade control
Basic Principles of Polymer Molecular Weight
Importance of MW control
Number average, Mn, Weight average, Mw

Polyethylene Polymerisation (Case Study)

Rector control and Grade change in gas phase PE reactor,
Handling of polymer powder and pellets ( + additives)

Project
& Lab Work

Week

Topic and Area

Structure, Mechanical Properties and Application
- Crystalline and Amorphous Polymer
- Thermal Transition, Tm & Glass Transition Temp, Tg
- Effect of Polymer Structure on Tg
Mechanical/Physical Properties
Tensile, Impact, permeability
Selection of polymer in Membrane fabrication for gas
separation

Mechanical/Physical Properties
Linear Fracture Mechanics, Elastic-plastic Fracture, Brittle
Fracture, Toughening

Viscoelasticity
Creep, Stress relaxation, Viscoelastic
Model, Dynamic properties,

Revision, Project Identification & Evaluation, Critical

analysis on problem statement and Issues

Assesment

Quiz
1/Assignment

Quiz
2/Assignment

Test 1

Week

Topic and Area

Rheology
Overview
Newtonian and Non-Newtonian Fluids
Effect of MW, Temperature, and
Pressure on Viscosity

Polymer processing/fabrication
Using injection, extrusion etc.
-Product defects, selection of screw etc.

10

11

Assesment

Quiz
3/Assignment

Alloys and Blend

Compatibility , Thermodynamic of mixing,
Miscibility and Phase separation

Thermoset Part 1
The Sol-Gel Transition
Cross-links, Gels and Gelation,
reaction kinetics

Submission
of Project
Report
(Friday 4 pm)

Week

12

Topic and Area

Assesment

Thermoset-Part ii
Polymer network, Mechanical and physical properties,
Processing and fabrication.
Example of Application:
- Surface coating for corrosion protection

13

Polymer Composites
Filler and Fiber reinforcement
Product performance and economic evaluation

14

New Development /Application

Fire retardant, Intumescent Polymer, Nanocomposite
Material.
Biopolymer

Test 2

COURSE EVALUATION

Assesments

Marks

Tests

20 %

Lab / Project/Quiz

30 %

Final Exam

50 %

Total

100 %

Reference;
Refere
nce

McCrum, N. G.. Principles of Polymer

Engineering,
2nd Ed, Oxford
University Press, Oxford 1997
Kumar, Anil, Fundamental of Polymer
Engineering,
2nd Ed, Marcel Dekker,
New York, 2003.
Sperling, L. H. Introduction to Physical
Polymer Science, 4th Ed, John Wiley, New
Jersey, 2006

Main Reference

Optional
Reference