I&EC REPORTS & COMMENTS Polyisoprene moves into synthetic rubber picture Development defined Bacteria in corrosion control Petroleum improves it stature
POLYISOPREWE LATEX Polyisoprene (PI), a man-made duplicate of natural rubber, is making fast inroads in the latex market. The latex form is more or less a sleeper, because the elastomer in dry form has not penetrated rubber markets as expected. However, the latex has emerged as strong competition for natural latex and as a definite threat to other synthetic latexes. Shell Chemical is the only producer of PI latex. Others who are likely to enter the business include Goodyear, now a maker of dry PI. Shell began to make PI in 1959 at Torrance, Calif., by converting a styrene-butadiene plant there. In 1961, Shell switched the PI operations to the latex product when the demand for the dry form became stagnant. Now Shell is changing its plant at its Marietta, Ohio, PI plant. The plant was built to make 36,000 long tons of PI. Now the firm will add facilities to make 18,000 long tons of PI latex. Goodyear is adding to its PI plant at Beaumont, Texas. Present capacity is 28,000 long tons per year and this will be raised to 45,000 long tons per year; none of this capacity is slated for the latex form as yet. PI composition with a cis content as high as 92y0, differs from natural rubber’s cis content of 98 to 99gi’, with its quota of proteinaceous materials. This difference in cis content of PI is compensated for by uniformity from batch to batch and by lack of yellow color because the usual carotene-like materials are not present. Following a pattern observed in a number of concerns with world-wide holdings, Shell is reported to have
Units of the Shell Chemical Company polyisoprene latex plant at Marietta, Ohio
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deuterated benzene, chloroform, acetone
A new process developed by ClBA enables these compounds to be offered at greatly reduced prices. These products meet or surpass the high quality standards of NMR spectroscopy. They are also of interest as a chemical intermediate or general research tool. For technical bulletin and price list write: Dept. DC ClBA CHEMICAL & DYE CO. Fair Lawn, New Jersey
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I&EC REPORTS
filed for patents both in this country and abroad. A Belgian patent granted to Shell International ( 2 / 6 3 ) is believed to cover the emulsification system used for converting the PI/solvent cement into P I latex. T h e cement, with a P I content from 10 to 13y0 solids in a solvent, probably pentene, is emulsified with equal volumes of a 0.5% solution of potassium rosinate. T h e resulting emulsion, stripped of its solvent, loses some of its water and is reemulsified to an average concentration of 22o/G solid PI. T h e resulting slurry is concentrated to 60y6 solids, common to foam latexes. This PI latex, comparing favorably with natural and other synthetic latexes, can be used in the manufacture of foam rubber, adhesives, and dipped goods such as surgeons’ gloves. Though long a contender in the foam market, natural rubber‘s performance left much to be desired; the odor of oxidized rubber and the trace amounts of proteins were chief among the shortcomings. Polyurethane foams then moved into the area left vacant by natural rubber foams. Customer acceptance, though initially high, soon dropped because of certain structural failures on the part of urethane foams and some cheapening of materials for a price advantage. PI foam, now a force in the foam end-use market, is structurally similar to natural rubber foam. Many factors including price have assisted P I foam‘s entrance and subsequent growth in this market. Use of the “cigarette burn” test indicates that PI foam does not support combustion as long a s some of its competitors. Its tear strength is greater than that of natural rubber and it has better ‘‘snap-back’7 features. T h e absence of stearic acid, an antiadhesive, allows PI latex to be used in water-based adhesives. Surgeons’ gloves manufactured from PI latex reportedly can be
Circle NE. 18 an Readers’ Service Card
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I N D U S T R I A L A N D ENGINEER1
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worn longer than those made from natural latex and allow for greater sensitivity and dexterity on the part of surgeons and surgical personnel. Although some synthetic rubber manufacturers indicated that they had no interest in manufacturing P I or PI latex, others have made pilot quantities of both forms and are keeping a wary eye on the market. As the PI market continues to grow, it is to be expected that many fence sitters will enter the market when conditions warrant. L. CRITIDES
A DEFINITION OF DEVELOPMENT
’‘ T h e technical ejort expended between the search f o r new knowledge and the manufacture of products” We have come to use the word research to be inclusive of the two terms research and development. More often we use them together in a collective sense. Unfortunately, to my view, this collective use of R&D has become so widespread that the actual meanings of the two words and the separate activities which they describe are overlooked. This collective connotation is not restricted to the lay public, who constantly see the words used together, but is also prevalent among many business and professional people who have not had the opportunity to appreciate that each word describes a separate phase of activity. Moreover, it is difficult to understand this tendency, because the definitions of the two words are clear and exact. . . . Many discussions on R&D present a flow process for progress of a new product from laboratory conception through to a salable end item. These discussions accurately define the locations for and the importance of check points in the progress of de(Continued on page 76)
Which FREON" fluorocarbon could improve your - process? A WIDE RANGE OF BOILING POINTS, but other properties remarkably
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similar from one to the other-that's the interesting feature of the FREON I I family! Here's the unique combination of properties which apply to all I FREON compounds regardless of boiling point: I 1. High thermal stability 6. Very low toxicity 1 2. High chemical stability 7. Outstanding dielectric properties I 3. Selective solvency 8. Low surface tension I 4. Immiscibility with water 9. Low viscosity 5. Nonflammability 10. High density I So whatever the operating temperature of your process, there's a FREON I I compound which you should evaluate. Have you an idea where any of I this unique family of chemicals could be used? We'll help you develop it I products are used today as refrigerants, aerosol if you do! Clue: FREON I propellents, foam blowing agents, solvents, fire extinguishing agents, diI electrics, heat-transfer media, polymer intermediates and aerospace products. First step-send the coupon for complete technical information I fluorocarbon with the boiling point you want. about the FREON
MAIL COUPON FOR TECHNICAL BOOKLET Du Pont Company FREONProducts Division N-2420IC-5R Wilmington 98, Delaware
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Du Pont. first in fluorocarbons since 1931
FREON@
fluorocarbons BETTER THINGS FOR BETTER LIVING
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... THROUGH CHEMISTRY .C'
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Any particular uses in mind?
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AIRCOCHEMICAL CHEMICALS AND POLYMERS FOR THE PROCESS INDUSTRIES Airco Chemical is a major producer of chemicals from acetylene-vinyl monomers, organic chemicals, polyvinyl alcohol and polyvinyl acetate resins. Airco’s diverse experience in the application of acetylene chemicals is unmatched. Each product has been designed to meet a particular industry need and is backed by years of industry experience, dependable delivery and reliable technical service.
ARCO Papqr Coatlng-Airco’s new polyvinyl acetate emulsions offer exceptional pick PRODUCTS strength and mechanical stability for the FOR THE color coating of paper and paperboard and
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PAPER
open opportunities for hetter coatings at
INDUSTRY
lower For high quality color coatings, Airco FLEXBOND. 330 is a new vinyl-acrylic copolymer binder that makes possible coatinns that are comnetitive in everv wav wiih the accepted hl-acrylic systems, yit offersbig savings in binder costs. Airco’s new Vmr@ 880 is a highly efficient pigment binder with exceptional mechanical stability. high pick-strength and excellent printing qualities. Coatings
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strongly recommended. These Airco VmoLs form m s t a l clear solutions and colorless films which are mease and oil resistant, provide excellent lacquer and ink old out. Airco VINOLShave an adhesive rtrength of three to four times that of prons and starches. Thus, less binder is eded. with a resulting in - improvement . optical.quality and an important weight reduction of the finished Mated paper. Siring-Airw VINOL-BORAX sizing reduces the penetration of solvents, oils and greases into paper and board, resulting in better ink and lacquer holdout at very low costs. Airco superhydrolyzed VINOLp r ~ p a l yapd and used with the properquantity of ax results in smoother surfaces and unched printability, plus improved mileof size solutions and less frequent size preparation. Mill runs have repeatedly demonstrated a considerable improvement in properties at lower cost when run against
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AIRCO PRODUCTS FOR THE
Airco Emuislonr-Airco Chemical has long been a leader in the development of polyvinyl acetate copolymer emulsions for interior paints and high molecular weight PAINT copolymers for exterior paints. Airco emulsions are tough but flexible, with exi~~~~~~~ cellent washability and tint retention. As an ideal vehicle for both interior and exterior paints, Airco’s FLEX BOND^ 315 combines great pigment binding power with high water resistance to give exterior paints outstanding durability, tint retention and cleanliness. Interior paints with FLEXBONnm 315 as a base have superior touch-up qualities, color development and sheen uniformity. As a one vehicle primer-topat system for exterior paints for either wood or masonry, Airco’s FLEXBOND@ 840 wntributes film toughness, flexibility and durability and allows the use of higher pigment levels. FLFXBOND~ 840 resists extremes in temperature change and moisture conditions.. .does not fade. Among the vinyl-maleate emulsions for exterior-interior use, Airw’s FLEXBOND* 800 gives a truly bright white with a minimum of chalking to exterior paints. It has proved its superior durability with a trouble-free record of exterior performance for over nine years. For interior 800 has outstanding paints FLEXBOND* leveling and hiding characteristics. Surlace-Active Agent. For Latex PalntsAirco’s family of SURFYNOLS~ offers a variety of high-quality surfactants, dispersants and defoamers for paint formulations. As a defoamer, Airco’s SURFPNOL~ 104E is particularly recommended for emulsion paint systems. As a nonionic pigment dispersant and a low foamer, Airco’s SURFPNOL~ T.G. is a top performer in both polyvinyl acetate and styrene butadiene based paints. Paint Monomers-For the paint manufacturer who produces his own paint emulsions, Airco provides such high purity monomers as vinyl acetate, dibutyl maleate, dibutyl fumarate and a complete line of acrylics.
ASK THE MAN FROM AIRCO. Airco salesmen are backed by Airco Technical Service, a team of widely experienced men who specialize in the application of polymer chemistry to the process industries. The entire Airco organization, research and development, production and management. stand behind the sales and service departments to guarantee your satisfaction. For more specific information write or call Air Reduction Chemical & Carbide Co., A Division of Air Reduction Co.. Inc.. 150 East 42nd Si., New York, N. Y. 10017. Area code 212, Murray Hill 2-6700.
AIRCO PRODUCTS FOR THE ADHESIVES INDUSTRY
As bases in adhesive formulations, Air VmoL polyvinyl alcohol and FLEXBONI copolymer and VINAC. homopolym-. PVAc resins and emulsions have outstanding advantages. For plastics, foils. etc., to paper,bonds, the FL-NO. BOUP of resinsit-meoded; for paper to paperboards. the VINAC. group is superior. Aim has a wide line developed to fit the needs of adhesive formulators. Aim VmoL superhydrolyzed and fully hydrolyzed polyvinyl alcohols adhere par. ticularly well to paper and paperboard, thus. are ideally suited for use in adhesive formulations for many uses in the paper indnstry. VrNoL-based adhesives have many advantages over natural productsstarches, gums, dextrines, animal glues and casein. VINOLSare stronger and more water resistant, have greater flexibility and a wider rang ofcompatibility. For solid Bbrc kminators, Aim’s new low cost,high-tack V ~ Loffer S a material that will replace any competitive mstaial and do the job hettcr ‘at lower a t . High-tack VmoLs set faster, are stronger and have charsacristies. producbetter @ning tion speeds can be i n c w d .and tbe bond is better With far less resin. For tube winda, too-Aho hi@-tack VmoLs combine top performance with low Eoat. For laminators who have probkm with hard to stick materials, Airco’s new FLEXaorpO.150 can be the answer. It is an unusual vinyl m a t e copolymer emulsion base fer pressure-sensitive adhesives that results in a product that will laminate to practically any material. Probleqs eucountered witb such materials as Mylar, &an, polystyrene and many others have been solved with this versatile emulaion. Alma Monomer8 For The Adhe&Indusby-For these adhesive manufacturers who do their own polymerization, Aireo offers h i purity vinyl acetate and d i i t y l maleate monomers.
AlRCO 10DUCTS FOR THE =lLE
Wmrp Sirillg-Airco superhydrolym VmoL 165 and VmoL 12s and fully hy drolyeed VmoL 350 and VmoL 325 im
crease tensile strength and abrasion re siof yarns during warp sizing.Yarn sizcd with VmoL show very little shddiq and have hi& weavian efficiencv. Tim perform mii at lower humidity ihan tla conventionally used starch. V m a resina can he removed with a simple hot water scour. They have a very low B.O.D. ( b h chemical oxygen demand) and. thus, htlp reduce stream pollution. Textile Finishing-Aim VmoL offers th finisher one of the most unique water sol uble resins available. Wash and wear characteristics of resin treated cottons and rayons are noticeably improved with the addition of VmoL; colors are brighter and stay brighter through many washings. Non-woven Binden-VINoL resins are excellent as binders for non-woven cotton and rayon fabrics and felts. They have excellent solvent and grease resistance. Superhydrolyzed VINOLShave high water resistance, add stiffness,impart high tensile strength and strength of lamination (peel strength). They are excellent for use in drapery inter-linings, tablecloths, bed covers and industrial filters. TEXlZE Chemicals-Airco Chemical’s Textlie industry DkMbutor-In order to provide top notch actvice to its customers in the textile industry, Airco Chemical has recently appointed T & Chemicals Inc., as its distributor to the southern textile iudustry. Texize, with its intimate knowledge of textile production problems, its excel. lent technical service. market coverage, and delivery systems. is fully equipped to acquaint the industry with Aim capabilities in this important market.
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uI V O L 5 6 NO. 5
MAY 1964
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WHICH ELECTRON MICROSCOPE GUARANTEES 15A RESOLUTION BUT COSTS ONLY $16,4953
THE NEW JEM-T6S ONLY FROM FISHER. The JEM-TGS, available in the United States and Canada exclusively from Fisher Scientific, is a compact, general purpose electron microscope for metal Iu rgical, crystal lographicaI, biological and medical research. Easy-to-operate, simple to maintain. Large specimen chamber accepts various attachments such as those for specimen heating and cooling. Resolving Power., . . . .15A guaranteed; 10-12A attainable Direct Magnification . . .Continuous from 500X to 50,OOOX Accelerating Voltage, . .60KV Price.. . . , , . , . , , , , . . .$16,495 duty free; $18,918 duty paid ~~~~
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Get complete facts in free JEM-T6S bulletin. Write Fisher Scientific Company, 130 Fisher Building, Pittsburgh, Pennsylvania 15219. T.375
FISHER SCIENTIFIC
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M a n u f a c t u r e r - O i r l r i b u t o r of L P b O r a t o r y Appl~anter b R e a g e n t C h e m i c a l s
U S A -ATLANTA BOSTON CHICAGO FORT WORTH HOUSTON NEWYORK PHILADELPHIA PITTSBURGH ST. LOUIS U N I O N , N . 1. WASHINGTON CANADA EDMONTON MONTREAL e TORONTO
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,.elopment, but generally make no listinction between research and ievelopment. That is, there is no ibrupt separation of the research ’unction from the various development steps. I t is assumed that :here is a natural flow from research to development, and the existence sf a barrier which must be overcome in order for this natural movement to occur has not been emphasized. The barrier, of course, represents the important and highly creative step 3f foreseeing an application for the research result which initiates the development. By my definition, development starts, and the research work ends, as soon as an experiment has accurately defined that something new has been established. If laboratory work proceeds to produce more of the material or to increase the yields obtained, or to utilize lower temperatures or pressures or cheaper raw materials, it is obvious that a decision has been made that the new knowledge has some value or use. The barrier has been crossed, and the development phase has been initiated. . . . Development under my definition is the primary investigative area of our great technological effort. I t represents the area in which 90% of the funds are spent. I do not separate development on the basis of where the work is done-that is, in a laboratory or in a plant-or whether it involves prototype models, engineering design, or chemical reactions. However, it is always work which has passed the barrier, and is performed because there is some reason for the exploration and a reasonable chance of success. . . . The development part of the budget can comprise a large number of different projects concerned with new products, new processes, and modifications in existing products, processes, and facilities. I t can involve quality control, new raw materials, new applications, and customer problems. Perhaps you may
feel that this is too broad a listing of development activities because your company’s development efforts are distributed between central R&D, sales, engineering, or other departments. However, each group involved in these various functions of a modern industrial organization is involved in development. G. A . WEBB, D I R E C T O R OF ADMINIST R A T I O N , M E L L O N I N S T I T U T E , TO T H E .4MERICAN I N S T I T U T E OF C H E M I C A L E N G I N E E R S , MEMPHIS, T E N N .
PETROLEUM MORE IMPORTANT AS A SOURCE OF CHEMICALS
20% growth in a decade places n e z demands on chemical technology Petroleum is now the source for approximately 65y0of the value of all basic and intermediate chemicals and polymers manufactured in the United States, compared with 45y0 in 1950. I n his speech on April 13 before the American Section of the SociCtt de Chimie Industrielle, Mr. M. J. Rathbone, chairman of the board for ESSO,speculated that further improvement of the lives of both the already technically advanced and the underdeveloped countries will result from the ingenious application of chemistry to the enormous stores of oil and gas within the earth’s crust. Of particular importance today is the growing of protein-rich food from oil by biosynthesis. Estimates indicate that 1Yo of the world’s daily supply of crude oil would eliminate the entire protein deficiency for the world. Another important use for crude oil would be in providing the raw materials for nitrogen fixation. In the less developed countries there are already about two dozen ammonia (Continued on page 79)
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INDUSTRIAL AND E N G I N E E R I N G CHEMISTRY
Circle No. 1 on Readers’ Service
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1 REACTIVE CHEMICAL LEVULlNlC ACID: promising applications for this highly reactive chemical Current research points to an extremely wide range of commercial applications for often-overlooked levulinic acid (LA).The chemical reactivity of levulinic acid derives from the carboxylic acid group, the g a m a keto configuration, the carbonyl structure and the seven hydrogen atoms activated by beiig alpha to a carbonyl group. Chemically it acts as both a fatty acid and a ketone. Levulinic acid is a promising starting material for: plasticizers, solvents, resins, polymers, pharmaceutical and biological chemicals, and food flavoring agents.
Other suggested uses: food acidulent, preservative, flavoring agent and biocide.
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Write for our technical brochure reporting on the muny applications for fhis exceptionally reactive chemical. A sample, too, if you want it.
CROWN ZELLERBACH @
CHEMICAL PRODUCTS DIVISION
CAMAS 11. WASHINGTON
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FILTER IT?
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...Y O U CAN’T €VEN SEE IT?
Any suspended particle under 0.2 microns is small. I n f a c t , you won’t even see i t u n d e r a n optical microscope. Yet Dicalite finds it, t r a p s it and filters it to assure you of t h e ultimate in filtrate purity. You g e t t h i s infinitesimal s e p a r a t i o n w i t h one type and grade of Dicalite filteraid. I t meets a specific need. Your filtration requirements might be different.
To help you obtain optimum performance a n d economy in your. filtration process, Dicalite offers all five m a j o r filteraids. A complete r a n g e of grades assures you of the one best suited to produce maximum filtration efficiency in your particular production. Call your Dicalite sales engineer or agent. H e will be happy t o work with you t o make s u r e your filteraid is right f o r you.
Slides shown DlCALlTE DEPARTMENT
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are {a) a l g a e , ( b ) mycelium and spores of peniollium, { c ) escherfchia colt
GREAT LAKES CARBON CORPORATION Circle No. 21 on Readers’ Service Card
INDUSTRIAL AND ENGINEERING CHEMISTRY
630 Shatto Place, Los Angeles, Calif. 90005
New from W h e e l e r . advanced concepts in
I&EC REPORTS
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MACHINE DESIGN plants taking their feed from oil and natural gas. All these plants have been built within the past five years. With the advent of the low octane engine upon us, the need for conversion of lighter and heavier crude fractions to high-test fuel will alter and the slack should be more than taken up by the rapid development of petrochemicals both in the United States and abroad. While the oil companies now have chemical sales approaching three billion dollars annually in the United States, less than 10% of total chemical sales is thus accounted for and Mr. Rathbone clearly indicated that the oil companies will be moving into the chemical business on an increasingly substantial scale. The relative availability of petroleum and its convenience will, no doubt, reinforce the present favorable position of petrochemicals. At the same time the natural complexity of petrochemical manufacture will require a progressively more sophisticated technology to properly exploit petroleum’s potential.
QUALITY EMBOSSING MACHINES e e e PILOT CALENDERS OPEN OR CLOSED SIDE MODELS, WEB OR SHEET Custom o r standard machines with any number of rolls, 2 to 16, any type and hordness of filled r o l l . All machines feature: Embossed, super, machine or Schreiner finishing * Welded steel Self-aligning anti-friction bearings Individual construction Quick and easy roll pressure control to each side of machine changes Automatic roll separation Unwind and rewind Camplelely self-contained Safety equipped. F o r stands the complete story, contact:
wheeler roll company 1910 L A N E B L V D . , K A L A M A Z O O , M I C H I G A N Manufacturers of Pilot model paper machines, calenders, embossers, COaterS, Supercalender, rubber, steel and alloy rolls. c u s t o m machinery
Circle No. 42 on Readers’ Service Card
J. H. S. H A G G I N
METAL REDUCING BACTERIA Corrosion control in the metals industries mill include biogenic measures
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Research by U. S. Industrial Chemical Co. has isolated a group of small bacteria which utilize the oxidation of metals as their sole energy source for sustaining life. The bacteria are active in pitting and corroding stainless steel, iron, copper, zinc, chromium, brass, vanadium, and aluminum, and are highly resistant to sterilization, including autoclaving. The research, supported by NASA, is aimed at developing methods of controlling bacterial growth.
Here are spray nozzles that operate automatically under remote control , for spraying synchronized t o any “on.off’ cycle. Available as pneumatic or hydraulic atomizing nozzles in a variety of body designs and i n a wide choice of spray patterns and capacities. These modern nozzles offer dependable performance, eliminate waste of liquid sprayed. For complete information, just send for Bulletins 114 and 115.
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WRITE FOR BULLETIN 114 Automatic PNEUMATIC Atomizing Spray Nozzles BULLETIN 115 Automatic HYDRAULIC Atomizing Spray Nozzles
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SPRAYING SYSTEMS CO.,
3255 Randolph St., Bellwood, 111.
J. H. S. H A G G I N Circle
No. 38 on Readers’ Service Card VOL. 5 6
NO. 5
M A Y 1964
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