Mahendra BharaskarAPAR Industries Limited

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Company Profile

• Apar Industries Limited, founded by Late Mr. Dharmsinh D. Desaiin the year 1958

• One of the best established companies in India operating in the diverse fields of electrical, metallurgical and chemical engineering.

• A 3000 crore diversified company offering value added products and services in Power Transmission Conductors and Petroleum Specialties.

• 53 years of existence, highly competitive & market leader in these fields

• Firmly committed to being a responsible corporate citizen with an abiding belief in human engineering.

• Focuses on innovative products, establishing state of art manufacturing facility of cross linked cables and wires and other products with Electron Beam Technology at G.I .D.C, Umergaon. Gujarat.

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Introduction of Radation

Definition of Radiation ProcessingThe treatment of products and materials with radiation or ionizing energy to change their physical, chemical or biological characteristics, to increase their usefulness and value or to reduce their impact on the environment

Ionizing Energy SourcesElectrons from Particle Accelerators.X-Rays from Accelerated Electrons.Gamma Rays from Radioactive Nuclides.

In absorbing materials, electrons, X-rays and gamma rays transfer their energies by ejecting atomic electrons, which can then ionize other atoms. These radiations produce similar effects.

The choice of a radiation source depends on the practical aspects of the treatment process, such as absorbed dose, material thickness, processing rate, capital and operating costs

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Introduction of Radiation

Radiation processing was introduced 50 years ago. Many practical applications have been discovered. The most important commercial applications are:

• Modification of plastic and rubber materials.• Sterilization of medical devices and consumer items.• Pasteurization and preservation of foods.• Reduction of environmental pollution.

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Electron Beam Processing

Electron beam (EB) processing has been demonstrated on a large commercial scale to be a very effective means of improving end-use properties of various polymers. It is a well established and economical method of precisely modifying the bulk and surface properties of polymer materials. Although many of the EB applications are in wide use, the combination of high energy and high power of new electron accelerators now enable economical application to larger and thicker products.EB radiation is a form of ionizing radiation, generally characterized by its fixed penetration range and its high dose rate. These electrons are generated in equipment called accelerators, which produce a beam that is either pulsed or continuous.EB is a process in which the products are exposed to a concentrated, highly charged stream of electrons. As a product passes in front of the electron beam, it absorbs energy from the electrons. The energy that is absorbed per unit mass of product or material is referred to as the absorbed dose.

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• Polymeric materials with high molecular weights are good candidates for radiation processing.

• Inorganic compounds with low molecular weights are poor candidates for radiation processing.

• Dilute solutions are exceptions. Ionizing a small fraction of the solvent will affect most of the solute.

• High energy electron used under high temperature & nitrogen atmosphere• Possible uses for electron irradiation include sterilization, degradation and to cross-link polymers. X-linking polymeric products to improve mechanical, thermal, chemical and other properties • Material degradation often used in the recycling of materials, and Sterilization of medical and pharmaceutical goods.• Electron energies typically varies from keV to MeV range, depending on the depth of penetration • In polymers, an electron beam may be used for chain scission & cross linking. • The result is a change in the properties of the polymer which is intended to extend the range of applications for the material. • The effects of irradiation may also include changes in crystallinity as well as microstructure.

Electron Beam Processing

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E-Beam Accelerator

• An Electron Gun is housed in a thick vessel where electrons are accelerated in an acceleration tube

• The Electrons are directed to a scanning device magnetically

• Similarly, depending on the dosage required, suitable under-beam handling systems are designed

•The products are passed under the beam thru set of under-beam equipments

Fig(1)

PRODUCTSp WIRE & CABLES, PE FOAM

p HEAT SHRINKABLES, TYRES

p ADHESIVE TAPES, ELECTRONIC MEDIA

p TAPES, PAPER, PANELS, FOOD

EUROPE8

RUSSIA50-100

CHINA140

KOREA10

JAPAN

22

N. AMERICA > 200

4

350

GLOBAL DISTRIBUTION OF ACCELERATOR

INDIA

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INDIAN SCENARIO

1. 2 MeV EB MACHINE - AT BARC FOR R&D 2. 3 MeV EB MACHINES ADDED IN 2003

3. 2.5MeV added in 2007 AND IN 2011

4. 1.5 MeV & 3 MeV – New Project of Apar Industries Limited

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Applications of Radiation Processing

• Modifying Polymeric Materials• Curing Monomers and Oligomers• Grafting Monomers onto Polymers• Crosslinking Polymers• Degrading Polymers• Biological Applications• Sterilizing Medical Products• Disinfecting Consumer Products• Pasteurizing and Preserving Foods

• Environmental Applications• Reducing Acid Rain• Treating Waste Materials• Solid State Applications• Modifying Semiconductors• Coloring Gemstones

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Applications of Radiation Processing

Materials Suitable for Grafting• A variety polymeric materials

– Polyethylene, Polypropylene – Polyvinyl Chloride, Fluoropolymers

• Cellulose, Wool

Property Improvements by Grafting• Addition of hydrophilic surfaces on hydrophobic

polymers to make perm selective membranes.• Fuel cell and battery separator films.• Improvement of surface adhesion properties.• Biocompatible materials for medical applications.

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Applications of Radiation Processing

Typical Materials for Crosslinking• Polyethylene

– Polyvinylchloride– Polyvinylidenefluoride– Ethylene-propylene rubber– Ethylene vinylacetate

• Polyacrylates

Products Improved by Crosslinking• Plastic Products in Finished Form• Heat Shrinkable Tubing and Film• Electrical Wire and Cable Jackets• Tires for Automobiles and Trucks• Plastic Foam Padding for Automobiles• Bulk Plastic Materials

APPLICATION OF EB SYSTEM

Source : NHV

Flue Gas Treatment (2.3%)

Others (8.8%)

Sterilization (0.9%)

R&D (27.8%)

Wire & Cable (26.4%)

PE Foam (7.9%)

Automobile Tire (13.9%)

Curing & Conveting(7.4%)

Heat Shrink Tube (4.6%)

• Improved Heat Resistance• Improved Pressures(Stress Rupture)Resistance at elevated

temperatures.• Improved environmental stress crack resistance• Mechanical properties such as tensile strength• Scratch resistance• Reliable and efficient use of energy.• Performance at temperatures, often increase in the melting

temperature• Resistance to chemicals with lower solubility in organic solvent• Gas permeation reduction• Improved low temperature strength

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Improve Material Properties through X-linking

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Commercial Examples

Typical Polymer(s) Property Improved Due to E- Beam Processing

Foam PE Improved cell structure, mechanical properties and appearance

Gaskets, Seals PE, EVA,(TPE) Improved heat properties, chemical resistance and resistance to compression

Heat Shrinkable Tubes / Films PVC, PE, PVDF “Memory” Imparted, chemical resistance

Medical Devices PP Sterilization

Molded parts( Electronic Components)

PA Solder Iron Resistance

Molded parts(Automotive ) PA Improved heat deflection & operating temperature

PEX- Crosslinked flexible pipe PE Increased heat distortion temperature, operating temp & dimensional stability

Recycling of Ram Materials PTFE Micronized Powders used in Inks, Lubricants and Coatings

Rubber Various Cold Vulcanization

Wire & Cable Insulation PVC, PE High temperature properties, chemical resistance, tensile strength, “low smoke/zero halogen”(PE)

COMPARISON OF HDPE, PP(H) & X-LINKED HDPE

Sr.No.

Properties HDPE PP(H) X-LINKED HDPE

1. Continuous use 90 °C 90 °C 120 °C

2. Melting Temperature at 170 to 180 °C

Melts easily Melts Does not melt

3. Oil Resistance at 150 °C for 24 Hrs.

Not Good (Melts & Dissolves)

Not Good Very Good

4. High Temperature ageing resistance (150 °C / 7 days)

Brittle Brittle Good

5. Hot Set Test at 200 °C for 15 Minutes

Fail Fail Pass

6. ASTM Oil Swelling at 150 °C fir 24 Hrs.

Swelling very high > 40%

Swelling very high > 50%

Swelling very less < 10%

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Application of

Crosslinked Nylon 6

Automotive connectors, where higher temperature performance is required, are one application where crosslinkable nylon 6 compounds can exhibit cost-performance advantages over high-performance engineering thermoplastics.

Experimental setup for a simple test of nylon crosslinking (above). The 350 C soldering iron with a 1-kg load immediately penetrates the non-crosslinked nylon sample (below) but does not penetrate the crosslinked sample (bottom) after 30 sec.

Non Crosslink Crosslink By Electron Beam