the invention provides for study properties of polypropylene (injection grade) / polypropylene (extrusion grade) blend filled with calcium carbonates. In four formulations of PP(Injection grade)/PP(Extrusion grade)) viz. 95/5, 90/10, 85/15 and 80/20 in ratio of weight percentage were prepared for injection molding machine. This PP(Injection grade)/PP(Extrusion grade) (80/20) blend was selected and investigated at different three fractions of calcium carbonate. The mechanical properties such as tensile strength and elongation test were investigated. The rheological properties such as melt flow index (MFI) and melt density were evaluated. The results indicated that incorporate calcium carbonate increase the (MFI), melt density and elongation decreased while increase the tensile strength. It was obtained that increase calcium carbonate content into PP(Injection grade)/PP(Extrusion grade) blends will increase the density. Taking into consideration, it was concluded that, the optimum composition provided the good mechanical, rheological properties and density is PP(Injection grade)/PP(Extrusion grade)/Calcium carbonate (80/20/22.5) wt%

B. Ali, Sheikheldeen

H. Ali, Akram

H. Elabaid, Mawa

Hassanien, Muhab Salah Aldien Shalby

M. Ahmed, Arman

Y. Elgady, Ibrahim

English

SUST Journal Systems (Sudan Univ. of Science and Technology)

SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020  11  Enhancement of the Injection Grade Polypropylene using Extrusion Grade Polypropylene and Calcium Carbonate  Muhab S. Hassanien1, Mawa H. Elabaid1, Arman M. Ahmed1, Ibrahim Y. Elgady1, Akram.H. Ali2, Sheikheldeen B. Ali3   1Polymer Engineering Department, Sudan University of Science and Technology (SUST), Sudan,  2Textiles Engineering Department, Sudan University of Science and Technology (SUST), Sudan, 3Leather Engineering Department, Sudan University of Science and Technology (SUST), Sudan, muhabshalby@gmail.com     Receieved: 05/03/2020 Accepted: 12/05/2020  Abstract - This work studied composite properties of polypropylene injection grade using polypropylene extrusion grade and calcium carbonates. Four formulations of PPinjection and PPextrusion viz. 95/5, 90/10, 85/15 and 80/20 in ratio of weight percentage were prepared for injection molding machine. This PPinjection/PPextrusion 80/20 blend is selected and investigated at different three fractions of calcium carbonate. The mechanical properties such as tensile strength and elongation were investigated. The rheological properties such as melt flow index and melt density were evaluated. The work obtained blending PPinjection with PPextrusion in most cases decreased the tensile strength, elongation, melt density and melt flow index. The results indicated that incorporate calcium carbonate to blend increased the tensile strength, melt flow index and melt density while elongation decreased.   Keywords—Polypropylene, Blend, Calcium Carbonate, Mechanical, Rheological     صتتسملا –    ةةصئ صةةسارد تمت ثحبلا اذه يف نيلبوربلا يلوبلا   نقحلا صم ئ هجزم مت يذلاب صم ئ نيلبورب يلوبل قثبلا وك يهو  قثبلاو  نقحلا ا زم نم ت تلئ خبرب أمل مت تصف ةام  د مك  ويةسل كلا ت نوبر95/5 ، 90/10 ، 85/15  و80/20  ر ةي ئب مت يةلأ مة ب تصة و م صةبةةةةسنكلاصةتلخ 80/20 نم  ا زملا  مث نمو نم صة و م  ةةةةسن صةثسث صةف ةةةةضإ ت ةنوبرك ويسل كلا  ب يسنإ أم  م أثم صيج ولو رلا   صخلا ت هر ب ئب مت صل ت سلإا و مشلا صمو قم أثم صيكين كيملا   صخلا ت هلت  ةةةةا ب  ةهمييقتو  ةهر ةب ئب مت روهةةةةصملا صةف ةثكو روهةةةةصملا  يلوبلا خم نقحلا صةم ةئ نيلبورب يلوبلا  زم  ب رههب أةم لالبوربتروهةصملا ب يةسنإ أم  مو روهةصملا صف ثك اصل ت ةسلإا امةشلا  وو   ةصقن ىلإ ىدب قثبلا صم ئ ني  ا   نلاىلل تلد   بروهةصملا ب يةسنإ أم  م نم أك  د  ا ىلإ ىدب ا زملا ىلإ  ويةسل كلا ت نوبرك صف ةضب،   و روهةصملا صف ثكمةشلا  وو   منيب يف   صقن ا   نلا ترههبصل ت سلإا ت   INTRODUCTION  Interest in polypropylene (PP) and polyethylene (PE) is specifically due to the fact that; both these polymers are widely used as important engineering materials in the automotive, electrical appliances and packaging industries due to their excellent properties such as rigidity and stiffness, oil resistance and their thermal stability [1]. Apart from these good properties that polypropylene has, its applications as often limited due to its low impact strength and Young’s modulus, particularly at low and high temperature loading conditions. These polypropylene drawbacks can be considerably improved by blending polypropylene with other polymers [2]. Polypropylenes offer a good balance of properties and cost unachieved by most other thermoplastics polymer. Polypropylene has good mechanical, electrical and chemical properties and good resistance to tearing [3]. Long fiber and continuous fiber reinforcement technology with Polypropylene produce molding material with higher tensile strength and semi-finished materials such as sheet and tape which are beginnings to find applications, mainly in structural parts. This shows that the Properties of Polypropylene can be improved by adding a fibers or other reinforcement material. If additional stiffness or strengthen agent is needed, reinforcement can be added to Polypropylene.   A very important property that has led to many applications for Polypropylene is its superior resistance to cracking from mechanical stress [4]. The mechanical properties of Polypropylene depend on several factors and are strongly influenced by the molecular weight. The molecular weight of PP is normally estimated from the simple measurement of viscosity. Melt flow rate is more commonly used to measure the viscosity. General observations suggest that an SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020  12  increase in molecular weight, keeping all other structural parameters similar, leads to a reduction in tensile strength, stiffness, hardness, brittle point [5,6].  The use of inorganic fillers has been a common practice in the plastics industry to improve the mechanical properties of thermoplastics, such as heat distortion temperature, hardness, toughness, stiffness and mold shrinkage. The effects of filler on the mechanical and other properties of the composites depend strongly on its shape, particle size, aggregate size, surface characteristics and degree of dispersion. Stiffness, Flexural strength, Ultimate modulus, heat deflection temperature and some other mechanical properties can be increase by filling suitable percentage of talc and modifier with PP for various new mechanical and electrical applications [5, 7]  Calcium carbonate has been one of the most commonly used inorganic fillers for thermoplastics, such as poly vinyl chloride (PVC) and polypropylene (PP) [8]. The incorporation of CaCO3 in PP is a common practice to improve the heat distortion temperature, dimensional stability, stiffness and hardness of the polymer. However, the addition of micron-sized-CaCO3 particles to PP has not shown significant improvement in the mechanical properties of the composites [7]. In the art, several attempts have been made to improve the mechanical and optical properties of polypropylene films by adding organic or inorganic filler materials and especially calcium carbonate [9].  Khartoum Petrochemical Company (KPC) Sudan produces two grades of polypropylene homo polymer under ASTM standard those are extrusion grade (PPKPC113) and injection grade (PPKPC114) [1]. `The present work aimed to study the properties of KPC polypropylene injection grade to overcome the processing and products problems.  MATERIALS AND METHODS Table 1 shows specifications of Polypropylene (PP113)–extrusion grade supplied by Khartoum Petrochemical Company, in powder with the following particulars. Table 2 shows the specifications of Polypropylene (PP114) extrusion grade product supplied by Khartoum Petrochemical Company (KPC, Sudan), in powder with the following particulars. Calcium carbonate (CaCO3) used on experimental of present work as additives (fillers) in granules form (white granules).  A. Experimental Work In the experimental study, blends of PP114/PP113 were prepared according to the required compounds formulated as: 95/5, 90/10, 85/15 and 80/20 to make up a total of 100 g (wt. /wt. %). The samples were prepared to an injection molding machine at (180–250°C). The processed samples were allowed to cool at room temperature for 48 hours. Then different tests were carried out such as tensile test and elongation. Also melt flow index and melt density of the blend. Shown in Table 3.   TABLE 1: SPECIFICATIONS OF POLYPROPYLENE PP 113 Trade Name KPC Polypropylene (PP 113) Density 0.900 g·cm−3 Melting Point 230 °C Melt Flow Index (MFI) 3g/10min (230°C, 2.16 kg) Tensile Stress at Yield 27.5MPa Flexural Modulus 1000MPa Izod Impact Resistance 25 J/m Heat Deflection Temp 74°C  TABLE 2: SPECIFICATIONS OF POLYPROPYLENE PP 114 Trade name KPC Polypropylene (PP 113) Density 0.910 g·cm−3 Melting Point 230 °C Melt Flow Index (MFI) 8 g/10min (230°C,2.16kg) Tensile Stress at Yield 27.5MPa Flexural Modulus 950MPa Izod Impact Resistance 20 J/m Heat Deflection Temp 71°C  TABLE 3: FORMULATIONS OF PP114/PP113 BLENDS Blend No Materials PP114 (wt. %) PP113 (wt. %) 1 95 5 2 90 10 3 85 15 4 80 20  In the experimental study; three different calcium carbonate concentrations were added to PP114/PP113 (80/20) by weight to produce composites make up a total of 1kg as in Table 4. The samples were prepared to an injection molding machine at (180 – 220°C). Then the tensile strength and elongation were carried out. The melt flow index and melt density determined.  SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020  13  TABLE 4: FORMULATIONS OF PP114/PP113/ CaCO3  Blend No Materials PP114 (wt. %) PP113 (wt. %) CaCO3 (wt. %) 1 80 20 7.5 2 80 20 15 3 80 20 22.5  TESTING AND RESULTS A. FIRST BATCH :PP114/PP113 BLENDS 1. Mechanical test: Tensile strength test The Tensile strength of PP114/PP113 is shown in Figure 1. Tensile strength of (PP114) was 34.37 N/mm2. Addition of (PP113) (5, 10, 15 and 20wt %) to (PP114) was decreased the tensile strength of (PP114).    Figure 1: Tensile strength of PP114/PP113 blends  Elongation Test The elongation of PP114 was 7.52mm. Addition of PP113 (5, 10, 15 and 20wt %) decreased the elongation of PP114.as in Figure 2.    Figure 2: Elongation OF PP114/PP113 BLENDS  2. Rheological Test: Melt flow index (MFI) test: This test is used to investigate the flow properties of PP114. Figure 3 show the effect of PP113 contents on the MFI of PP114. The MFI of PP114 was 8.2 g/10 min. The addition of PP113 (5, 10, 15 and 20 wt. %) to PP114 decreased the MFI.   Figure 3: MFI of PP114/PP113 BLENDS  Melt density Test The melt density tests of PP114/PP113 blends are shown in Table 8 and Figure 4. The melt density of PP114 was 1.124 g/cm3. The result showed addition of PP113 (5, 10, 15 and 20wt %) to (PP114) decreased melt density of PP114.    Figure 4: Melt density tests of PP114/PP113 blends  3. PP114/PP113 Blends Tests Summary: The summary of PP114/PP113 blend is shown in Table 5.  TABLE 5: PP114/PP113 BLENDS TESTS SUMMARY Blend No MFI (g/10min) Melt density (g/cm3) Tensile  Strength (N/𝐦𝐦𝟐) Elongation (mm) PP114 8.2 1.124 34.37 7.52 1 7.07 0.904 31.66 7.348 2 6.87 0.876 32.68 7.202 3 6.14 0.757 32.18 7.152 4 5.65 0.630 32.48 6.952  Results showed addition of polypropylene (PP113) to polypropylene (PP114) in most cases decreased the tensile strength and elongation of polypropylene (PP114). These results indicate that the decrease in tensile strength with the increase of (PP113) is related to the bonding strength between PP114/PP113 compared to the intermolecular bonding of PP114. From these SUST Journal of Engineering and Computer Sciences (JECS), Vol. 21, No. 3, 2020  14  results, it is assumed that the decreased tensile strength related to the decreased brittleness and stiffness of the blend, due to the addition of (PP113).  The PPinjection/PPextrusion 80/20 blend is selected which provided balance the good performance. Also the results obtained decrease melt density and melt flow index of PP114.  B. SECOND BATCH :PP114/PP113 CaCO3 COMPOUNDS 1. Mechanical Test: Tensile Strength Test The tensile strength of PP114/PP113 blend was 32.48N/mm2. The result showed addition of (7.5, 15 and 22.5 wt. %) calcium carbonate increased tensile strength as in figure 5:   Figure 5: Tensile strength PP114/PP113 / CaCO3  Elongation Test The elongation of PP114/PP113blend was 6.952mm.    FIGURE 6: ELONGATION OF PP114/PP113 /CaCO3  2. Rheological test Melt Flow Index (MFI) Test The melt flow index test is used to investigate the flow properties of PP114/PP113 and compound are shown in Figure (7). MFI of PP114/PP113 blend was 5.65g/10min. The result showed addition of calcium carbonate increased (MFI).    Figure 7: MFI of PP114/PP113/ CaCO3  Melt Density Test Melt density test of PP114/PP113 and compound are shown in Figure (8). The melt density of PP114/PP113 blend was 0.630 g/cm3. The result showed addition of (7.5, 15 and 22.5 wt. %) calcium carbonate increased melt density.    Figure 8: Melt density of PP114/PP113/CaCO3  3. PP114/PP113/Caco3 Tests Summary: Table 6 shows the mechanical and rheological test of PP114/PP113/CaCo3 compound. The result showed addition of (7.5, 15 and 22.5 wt. %) calcium carbonate increased melt flow index and melt density of PP114/PP113. This result may be directly related to the undeform ability of the filler and its lack of contribution to the flow. The result showed addition of calcium carbonate increased tensile strength with the increase of calcium carbonate is related to the improved bonding strength between PP114/PP113 compared to the intermolecular bonding of PP114.  From these results, it is assumed that the increased tensile strength related to the increased brittleness and stiffness of the blend, due to the addition of calcium carbonate. While the work assumed that the decrease in elongation with the increase of calcium carbonate is related to the improved bonding strength between PP114/PP113 compared to the intermolecular bonding of PP114.   15  TABLE 6: PP114/PP113/ CaCO3TESTS SUMMARY Compound      No MFI (g/10min) Melt density (g/cm3) Tensile strength (N/𝐦𝐦𝟐) Elongation (mm) PP114/PP113 (80/20) 5.65 0.630 32.48 6.95 1 7.27 1.141 33.02 7.37 2 8.63 1.037 34.51 6.93 3 9.25 1.029 34.87 6.75  CONCLUSION  Blending PPinjection with PPextrusion in most cases decreased the tensile strength, elongation, melt density and melt flow index. The work obtained blending PPinjection with PPextrusion in most cases decreased the tensile strength, elongation, melt density and melt flow index. Also indicated that incorporate calcium carbonate increases the melt flow index, melt density and the tensile strength while elongation decreased. The results showed enhancement on the mechanical and rheological properties of PPinjection.   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Enhancement of the Injection Grade Polypropylene using Extrusion Grade Polypropylene and Calcium Carbonate

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Enhancement of the Injection Grade Polypropylene using Extrusion Grade Polypropylene and Calcium Carbonate

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