Introduction to Stabilisers:

稳定器： PVC分子对热和光不稳定。加热PVC会导致聚合物链破裂，从而释放盐酸气体。HCL催化更多的降解，降解可能会爆炸，从而释放大量的腐蚀性HCl和其他有毒气体。暴露于紫外线辐射也可以分解聚合物链，但比热降解慢得多。 Heat Stabilisers: To process PVC, it has to be stabilised against the action of Heat required at processing temperatures. Most Stabilisers contain metal elements which react with HCl and inhibit further degradation. They are Metal Salts, Soaps or Complexes. Stabilisation of PVC is a vast subject, and they are the second most important ingredient in UPVC Formulations and after Plasticisers in a Flexible PVC formulation. Some of the most important families are:

类型	Form	PHR使用了	明晰	有毒的ity	气味	Cost/Kg
Leads	Powder	2 -4	不透明	有毒的	没有任何	~ Rs 120-150
Ba- Cd	Liquid	1.5 – 2.5	清除	非常有毒	轻微	~ Rs 200
BA -ZN	Liquid	2 - 3	清除	有毒的	轻微	〜190
Cd - Zn	Liquid	2 - 3	清除	有毒的	轻微	~ Rs 220
Ca - Zn	Liquid	3 -4	清除	无毒	Negl.	~ Rs 250
罐头	Liquid	0.5 -1	Crystal	T & Non	Strong	~ Rs 350
BA -ZN	Liquid	2 - 3	清除	有毒的	轻微	〜190

The correct choice of stabilisers for the target application is best done in consultation with the stabilizer supplier and technical service cells of PVC Resin suppliers, However, as a guideline the following table would be useful.

稳定器应用领域：

类型	Heat Stability	主要应用	不建议
Leads	Very Good, esp. long term.	Cables, Pipes & Fittings, Sleeves, Profiles. Cheapest.	清除Application. Can be toxic.
罐头	Best	Transparent tubings and sheeting, High quality Pipes, Medical	Causes sulphide staining with Leads. Costliest Stabiliser.
Cd - Zn	缓和	ROHS电缆，无毒。管道和挤压。	For high heat history.
Ba- Cd	Good	Leather Cloth, Calendared products, Footwear.	Non Toxic applications
Cd - Zn	缓和	泡沫皮布	For high heat history.
Metallic Stearates	低的	Co-stabilisers with lubricating action	Sole Stabiliser.

重金属环境污染问题的背景提供了新的热稳定剂家族。有机稳定剂和钙锌位于这一趋势的最前沿。

由于其成本相对较低和强大的稳定动作，铅稳定器历史上一直是最受欢迎的
•铅稳定器：共同的铅稳定剂是：
o TBLS- Tri Basic Lead Sulphate. A strong heat stabiliser as it has about 80% PbO, the active ingredient in absorbing and neutralising the HCl before it gets liberated on heating. It is non-lubricating and is opaque, cannot be used in Transparent/Transluscent applications
o DBLS- Dibasic Lead Stearate. A Lubricating stabiliser very useful for lubrication at the mixing and metering zone of the extruder. Translucent.
o ls-硬脂酸铅。最弱的铅稳定剂。强大的外润滑剂，尤其是在早期挤出阶段。半透明。
o还有其他铅稳定剂，例如二叠铅磷酸盐，当光稳定性很重要且二纤维铅苯甲酸酯时使用，用于高速挤压，但是本文中没有涵盖这些铅，因为它们具有利基市场。

硬脂酸钙和硬脂酸通常与铅稳定剂一起使用，主要用于平衡润滑。CS是一种弱稳定剂，但是一种出色的内部润滑剂，在枪管排放和模具头时在晚期润滑中非常有效。硬脂酸是一种强大的外部润滑剂，过度使用会导致螺丝滑移和凝胶不良。

Lead Content of Lead Stabilisers.

One disadvantage that Lead stabilisation systems have is that a good, balanced formulations require a combination of all the Lead stabilisers plus Calcium Stearate and a few more lubricants. Other systems like Tins and Mixed metals are normally one grade of Stabiliser and one or two lubricants. With Leads, careful weighing of six or seven ingredients may be required, which requires skilled operation.

Lubricating Lead Based One Pack Systems
The Stabiliser mix for the high-volume PVC Pressure Pipes which I have used extensively in the past till the one packs came on the scene, is given in my article on Volume Costs, referred to in Page 6.


您会注意到，由领先制造商提供的PVC管的常规等级的剂量建议起点约为2.2至2.4 PHR。这与上面的5-6个成分的剂量相匹配，并且是方便的一个包装系统的基础。

The initial one packs offered were premixed single component stabilisers. The desired quantity was weighed out into packets according to the amount of Resin charged per batch. This is in line with the practice followed inhouse, but separate weighing of 5-6 ingredients was prone to weighing inaccuracies, especially of the minor ingredients. The stabiliser manufacturers used to mix the one pack recipes in bulk, and the mix was then meter measured and packed in easy to use packets, say for 25 kgs. PVC, 50 kgs, etc.

There was a lot of resistance to this concept in the early eighties. My personal experience is that having formulated with single stabilisers for nearly a decade at Shriram and PRC (DCW), I was introduced to the convenience of One pack systems when I went to Kuwait. The One packs from Baerlocher GMBH were an eye opener, and I wanted to introduce the concept in India when I returned to India in 1978 and joined Waldies, a prominent Lead oxides and PVC stabiliser company.

当时，PVC管市场开始使用大容量进口挤出机，与Wavin，Finolex，Garware和Chemplast这样的领导者开始迅速增长，而其他大多数则配备了Vensoble Windsor RC-100。请记住，当时，小规模保留了高达110毫米的流行尺寸的PVC管道，只有RC-100（意味着100磅/小时，约40 kgs/hr）才能提供许多进入该公司的人现场为小型行业。

当时，管道的PVC食谱是由工厂技术负责人控制的严密守卫秘密。我的朋友Ala和我本人的Anil Anand先生很沮丧，他们正试图推动一个包装概念，我们发现技术负责人根本不感兴趣地转向一个预先构造的一包。这将严重降低他们对公司的重要性！！

八十年代初在国外可用的有效的一包系统类型，还有另一个因素。RC-100及其共旋转螺钉，低输出和高停留时间，需要更高的剂量，有时需要4-5 phr，必须像单螺钉挤出机配方一样配制。由于PVC管道行业始于小直径导管，因此将许多单螺钉挤出机压力为水管。甚至ChemPlast都按照其美国加工DNA使用大型单螺钉挤出机。除了较高的稳定成本中，单螺钉管需要昂贵的流动启动器，以匹配新进口的反旋转双螺丝挤出机上制造的管道的强度。

该行业迅速转移到了辛辛那提和克劳斯·马菲，巴滕费尔德等公司的进口双螺丝挤出机，并且由于WHO资助的饮用水项目，因此管道市场蓬勃发展。挤出机实际上是空运的，这就是需求。在80年代和90年代初期，有更多的现代高输出挤出机是常态，一个包装概念开始占据。

The next step from premixed powders was to safer handling, non-dusting forms. One big drawback with handling Lead Stabilisers in the factory is susceptibility to lead poisoning of workmen, if handling, housekeeping and dusting was not kept under control. Newer one pack delivery systems were developed by heating the mix to about 160C so that the Lubricants, Calcium Stearate, Lead Stearate and Dibasic Lead Stearate melted and formed a dough with the non-melting TBLS. The dough was then extruded into pellets or pressed and chipped into flakes. This form was much safer to handle and gradually found acceptance.

This has been further refined by Stabiliser manufactures who start with Litharge (PbO). They react this with carefully prepared proportions of Sulfuric Acid, Stearic acid and some other lubricants like Calcium Stearate and special waxes. On completion of the reaction, all the PbO is converted to TBLS, DBLS and LS as per the formulation proportions. The reactor discharges to a rotating drum, where the paste is cooled and flaked off.


非润滑一包领导者not have enough lubricants to coat all the solids in the mix and are sold as powders. They are widely used for applications like Cables & Wires, Profiles, both Rigid and Flexible sleevings, Injection Moulded fittings etc.

除PVC窗口配置文件和注入模制配件等特殊应用还需要更多的成分，除了稳定剂和润滑剂（例如冲击修饰符和流动启动子）。

窗口轮廓需要3.5-5phr冲击修饰符和1.5-2Phr流动启动子。当将其作为一个包装中的包装出售时，剂量必须以5-7phr的速度上升，即2.4+5 = 7.4和2.4+7 = 9.4phr。一个包装的价格上涨，因为添加剂非常昂贵。

In Injection moulded fitting, which are processed on single screw extruders, a flow promoter needs to be added. At 1.5PHR addition, the One pack dose goes up to 4PHR. Again, the one pack will be costlier than the normal pipe one packs.

One packs can also be offered with properties like UV Resistance, Antioxidants etc. if required. The one pack manufacturers invest a lot on developing the right lubricant mix for an application and offer several grades for the same application of PVC pipes, like Normal, Filled, Highly Filled, Single or Twin Screw etc. Even refinements like Conical and Parallel screw suitability can be provided. The price of the One pack would vary with the special ingredients chosen.


Dosage and Pricing
在竞争非常激烈的领域,PVC管,where the demand is for cheaper and cheaper inputs, CaCO3 fillers get added to the one pack to drop the price, However, to maintain the same stabilising efficiency, the one pack PHR has to be increased by the amount of inert filler added. This if 1 kg extra of filler is added, no doubt the price will go down, but the dosage goes up by 2.4+1=3.4. As most processors clamouring for cheaper one packs are making highly filled pipes, the one pack must be further boosted to maintain the same % of active PbO as in standard formulations.
必须清楚地理解添加填充剂以便宜的一包的含义，因为降低成本并不是唯一的因素。

这里有些例子：


在此示例中，我从一个标准的PVC管一包开始。如果使用了一个经济的填充物，则起点将为3.2 PHR，而不是2.4phr，并且在填充加载时达到100 phr，则必须将加载几乎翻倍以使无故障操作。处理器的一个常见错误是坚持使用BIS管中使用的同一PHR，因为它们会增加填充物。这会降低主动PBO含量和润滑平衡，并可能导致严重的处理问题。

A study has to be made by multiplying the One pack cost per Kilo and the addition level required in PHR to arrive at the stabilisation cost per 100 PHR Resin to determine how effective they are in cost reduction.

The amount of filler addition, especially at higher dosages will bring down the cost. But what is important is that whether the stabilisation cost is lower with the Standard or economical One packs.

另一个重要的因素是体积成本，每种成分的密度至关重要。与PVC相比，添加的任何密度都会增加密度（例如一个包装，填充剂，T​​io2）

为了准确的密度计算和评估，必须知道所有成分的实际密度。一个包密度很重要，因为这个数字通常不在技术数据表中给出。

为了进一步清楚密度和填充加载的影响，请参考我的文章//www.esper-magazine.com/plastic-technical-articles/Volume-Cost-and-its-importance-in-Plastic-applications/1561


钙锌一包。
随着世界远离铅稳定器。钙锌系统在制造无铅管以及满足ROHS要求的何处变得越来越突出。

硬脂酸钙是最常见的非铅稳定剂。但是，它的稳定功率很低，更被视为一种非常有效的内部润滑剂，在模具头润滑方面发挥了重要作用，可平滑挤压和完成。

Calcium Soaps have been combined with Zinc compounds and the resultant Calcium Zinc Stabilisers have steadily improved in stabilisation efficiency. Driven by the intensive R&D of the stabiliser industry, Calcium Zincs are rivalling Leads in dosages, 3PHR vs 2.4PHR.

The lubrication systems are quite complex in Calcium Zinc systems for boosting the efficiency, so many of the Calcium Zinc grades are available as one packs and not individual components.

另一个主要的稳定系统是在美洲非常受欢迎的罐子，因为它们在单螺钉挤出机中非常有效，这在美洲也转换为双螺钉之前是常态。

诸如Accaptide家族之类的锡稳定剂都是液体。这并不使其有利于一个包装输送系统。通常，锡稳定管是由单个组件制成的，润滑剂平衡对于出色的性能至关重要。锡稳定器比铅稳定更昂贵，但是由于它们的效率如此之高，据报道，挤出机顶部的加工机的加工者的含量降至0.3-0.5 PHR，具有强大的甲基罐头，并且与铅系统具有竞争力。

There are many suppliers of One pack systems, whose numbers have increased as one packs are now universally used by the huge PVC Pipes and Profiles sector

Siddhartha Roy

Siddhartha Roy先生是IIT Kharagpur（1968）的化学工程师。在整个职业生涯中，他都与塑料合作。他积极参与PVC市场和应用的开发，尤其是管道和配件。他与PVC树脂和化合物的制造商Shriram Vinyls，PRC（现为DCW）和Chemplast合作。他在科威特管理了PVC管道和配件工厂，并帮助Ja那教管道（现为Ja那教灌溉）建立了管道生产设施。 他在NASIK的VIP Industries领导研发，并且精通聚烯类，苯乙烯，聚酰胺和PC的处理。 他一直活跃于IPI活动，并发表了几次捐赠讲座。最近，IPI理事会为塑料行业的贡献而授予他奖学金。