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Post-condensation

Polyesters (PET, PBT) and nylons (PA 6, 66, 46) are produced by melt condensation processes. During such process the molecular weight (MW) of the resin increases steadily, as the viscosity of the melt does. In practice, the polycondensation reaction, and hence the resulting MW, is limited to a certain viscosity range. Polymers prepared in this way are suitable for many applications. However, for heavy duty applications higher MW products are necessary, which can be achieved by post-condensation or chain extension.

The most common post-condensation process so far is solid state post-condensation (SSP) in batch tumble driers. Other post-condensation technologies comprise continuous SSP or melt finishers. The most important applications areas for high MW products are:

  • PET and PA industrial yarns/fibres, monofilaments and strapping
  • PET and PA recycling
  • PET custom containers/carbonated soft drink bottles and films  
  • PA, PET and PBT engineering plastics for E&E and automotive
Solid state Post-condensation

In SSP the resin is heated to about 20°C below its melting point, during which the polycondensation process continues, but at a lower rate than in the melt. Side reactions continue as well, but at a lower rate than the polycondensation reactions. High MW polycondensates are currently produced by SSP with satisfactory results. Yet, this method has some disadvantages:

  • SSP equipment is expensive (investment and operating costs)
  • SSP is an extra process step after melt polycondensation
  • The logistics are complicated
  • SSP is time consuming (10-50 hours)
  • SSP requires a high energy consumption and vacuum equipment
  • Fines are produced that differ in MW compared with the bulk of the material.
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