CAREER EPISODE NO.

Corrosion control in machines by chemical addition

(a) INTRODUCTION

The Chronology:
From the 1st July 2001 to 31st December 2001 I was appointed as a trainee in the
Research and Development sector and conducted projects for Diplast Plastics
Limited.

Duration at worksite: July 2001 - December 2001.

The Geographical Location of the Worksite:

Diplast Plastics Limited
52, Sector 28-A
Chandigarh 160002
Chandigarh INDIA

The Name of the Organisation:

Diplast Plastic Limited
C-36, Industrial Phase-2,
S.A.S. Nagar, Mohali (Pb.)
Punjab INDIA

The Title of the Position Occupied:

Trainee in Materials & Quality Control Department.

(b) BACKGROUND

CE1.1

During my training at Diplast Plastics Limited, I was given the role as a

trainee engineer and was given responsibilities such as physical tests of
final products, chemical tests of raw materials, regular inspection of
extruders

and

injection

moulding machines,

quality assurance,

troubleshooting and finally documentation of test values and submission

to my supervisor.
1

CE1.2

When I was inspecting machines, especially injection moulding

machines engaged in manufacturing junction boxes for electrical
insulation, it was observed that the injection moulding machines IM-1,
IM-2 were severely affected by corrosion. I also observed that extruders
KTS-90, KTS-120, KTS-300 engaged in the manufacturing of conduit
pipes and pressure pipes, were affected by corrosion.

CE1.3

From my background in corrosion of metals, I found out that corrosion is

a common problem in machines which operate at elevated temperatures
and exposed to external environment. Also, from my background in
polymer sciences I understood that the corrosion can occur at alarming
rates when Polyvinylchloride (PVC) products are manufactured at
elevated temperatures reason being that PVC degrades in presence of air
forming corrosive gases which are considered harmful to metals as well
as human beings. By searching on the internet and some literature I
found out that regular inhalation of these corrosive gases may lead to
serious respiratory problems in human beings. As a consequence, I
concluded that there was urgent need to inhibit the corrosion and HCl
formation as it was severely affecting the workforce as well as the
machines.

CE1.4

Dossiers specifying the problems were submitted to the managers

through my project supervisor and the following objectives were set for
me:

Apply the most effective solution and find out the reasons behind the preferred
solution.

Gain idea about the corrosion processes with respect to plastics.

To enhance the quality standard of manufacturing products.

Make workplace safe for workers.

Decide weather the preferred solution was feasible.

Preferred solution should be cost-effective.

Meeting with project supervisor every two weeks.

Compilation of dossiers and submission of brief report to the managers for

review purpose.
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(c) WORKPLACE ACTIVITY

CE1.5

In August 2000, during commencement of the training period, I observed

that extruders and injection moulding machines were affected by
corrosion and by close inspection I concluded that it is due to the
complex circumstances where HCl gas in addition to high temperatures
and humid conditions led to high corrosion rate.

I also observed that

HCl was affecting workers health, so there was a strong need to

eliminate this problem.

CE1.6

I began my work with different theories which may lead to the formation
of HCl gas. I went through various books and articles about plastics and
their interaction with atmosphere at elevated temperatures, but I focused
on Polyvinylchloride (PVC).

CE1.7

found

out

that

at

elevated

temperatures

(100-170 0

C),

Polyvinylchloride reacts with moisture and oxygen to form Hydrochloric

acid (HCl) in form of gas. Hydrochloric acid is also known for stripping
off iron and chrome deposits. Because of corrosive nature of HCl, I
found out that inhalation of this gas can lead to Tuberculosis in human
beings.

CE1.8

The glass transition temperature of PVC was found to be 87 0 C and

melting temperature of 12 0 C. Also, the processing temperature to mould
PVC into final product was observed to be 160 0 C-165 0 C. Although the
melting temperature of PVC was 212 0 C it was observed that sufficient
degradation occurs at processing temperatures if additives were not
added.

CE1.9

There were numerous solutions to the problem of corrosion but I found

out that the real problem which was to inhibit corrosive gas was more or
less related to most of the solutions.

CE1.10

After extensive research on internet I concluded that the objectives of my

3

project were similar to the requirements which are usually given in

systems engineering discipline, the only difference being that the
problem in this project was not as complicated as the problems which
require system engineering approach.

CE1.11

From common sense I was convinced that the best solution was to use
chemical compound to solve this problem due to two main reasons: it
addressed the safety issues of workforce and, apart from this, the
solution, once realised will be permanent, and novel in nature. However,
I needed solid grounds to prove that the solution provided by me was the
most cost effective, permanent, feasible and safe solution.

CE1.12

I utilised systems engineering approach by using trade-off analysis to

find out the best possible solution to this problem. I utilized
brainstorming exercise and then found out three candidate solutions
which may possibly solve the problem. Three candidate solutions
considered were; electroplating the surfaces of machines, cathodic
protection, and chemical addition in order to alter chemical
characteristics of bi products respectively. These solutions were
compared and then analysed with respect to seven attributes found from
the requirements expressed in the objectives assigned to me in this
project.

CE1.13

I considered seven attributes which were cost-effectiveness, safety,

efficiency, reliability, flexibility, permanency and feasibility. After tradeoff analysis, results exhibited that chemical incorporation was the most
suitable solution to the problem.

CE1.14

By consultation with my project supervisor, professor from my college,

for an understanding of corrosion processes, I developed a chemical
reaction which explained how iron is affected by Hydrochloric acid. In
another reaction I explained how chlorine forms Hydrochloric acid.
2Fe + 6HCl + 3O2
2Fe (OH) 3 + 3Cl2
heating
Reaction with HCl forming rust in iron

2H2O + 2Cl2
4HCl + O2
heating
Reaction with moisture forming Hydrochloric acid

CE1.15

By comprehensive search on the internet, journals, and books and

consultation with my professor, I found out that Lead silicate when
added to PVC during mixing operation in small amounts, can
successfully inhibit the HCl gas during manufacturing operation. Also,
because all the factors such as safety , cost effectiveness, and feasibility
were considered while searching for best solution using systems
engineering approach which involved trade-off analysis, it was clear that
the preferred solution meets all the requirements specified in the
objectives.

CE1.16

I found out that Lead stearate is readily available and because the
amounts which has to be added during mixing is very small that is 0.5 kg
in a batch of 30kg, I concluded that it is a cost-effective solution and it
stabilised the reaction when added meeting the requirements of safety
issues in workforce. On other hand, electroplating or cathodic protection
may have stopped corrosion but it didnt address the health and safety
issues of workers and the environment.

CE1.17

In my final report I explained in details the chemical reaction of chlorine

gas with Lead stearate which leads to Leadtetrachloride and other byproducts.

Because

chlorine

was

in

the

combined

state

as

Leadtetrachloride, therefore hydrochloric gas is not formed and it was

later observed that the quality of the finished products were enhanced
because of the reason that addition of Lead stearate controlled degassing
which generally occurs during PVC product manufacturing.

(c) SUMMARY

CE1.18

My contributions in this project and competencies as a Materials

engineer are demonstrated through applying my engineering knowledge
to identify the problem and the solution by systems engineering
approach, and organising the information accordingly.
5

CE1.19

Getting trained in this prestigious company provided me with confidence

to undertake technical problems in a systematic manner. Working with
engineers and supervisors provided me with understanding of workplace
ethics and working with the technical staff enhanced my analytical skills.
By guidance and supervision from the technical staff, my professor from
college, and the engineers in Diplast I was able to deliver my best in this
project.

CE1.20

I was really satisfied with my self at end of my training period. I received

a certificate of appreciation from Diplast Limited. In addition to the
training completion certificate, I am also looking forward to accepting
similar challenges in the field of material sciences and engineering in the
future.