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Polymer chemistry

Chemistry (B.Sc) · Industrial chemistry · free study notes for exams, placements and interviews

In short

Polymer chemistry deals with macromolecules built by linking thousands of small repeating units (monomers) into chains, and with how chain length, architecture and intermolecular forces decide whether the material behaves like a pipe, a fibre, a rubber or a varnish. It is the backbone of India's largest chemical industry segment - petrochemicals, plastics, paints, adhesives, tyres and synthetic textiles - with Reliance Industries, IOCL, GAIL, OPaL, Haldia Petrochemicals, Supreme Industries, Finolex, SRF, Pidilite, Asian Paints, Apollo Tyres and Indorama among the big employers. In B.Sc/M.Sc papers it carries full questions on mechanisms, kinetics, molecular-weight averages and Tg; in CSIR-NET, GATE (CY/XL) and IIT-JAM it appears as numericals on Carothers' equation, Mn/Mw and Mark-Houwink. In placement technical rounds for QC, polymer processing and plant roles, interviewers ask about melt flow index, crystallinity, additives, and compliance with BIS standards and the Plastic Waste Management Rules.

Explained

Basic definitions and classification

Chain-growth (addition) polymerisation

Addition of unsaturated monomers with no loss of small molecules; the repeat unit has the same formula as the monomer.

Step-growth (condensation) polymerisation

FeatureChain-growth (addition)Step-growth (condensation)
GrowthOnly at active chain endAny two molecules with end groups
MonomerConsumed slowly, present throughoutVanishes at low conversion
Mn versus conversionHigh from the startRises steeply only near p = 1
By-productNoneUsually water/HCl/alcohol
Typical PDI~1.5-2 (radical), ~1 (living)~2 (most probable distribution)
ExamplesPE, PP, PVC, PS, PMMAPET, nylon, PC, PU, bakelite

Industrial polymerisation techniques and processing

Molecular weight: averages, distribution and measurement

Structure, thermal transitions and mechanical behaviour

Degradation, recycling and Indian regulation

Key points

Formulas and examples

Mn = Σ(ni Mi) / Σ(ni) — ni = number of molecules of molar mass Mi (g/mol); Mn in g/mol
Mw = Σ(ni Mi²) / Σ(ni Mi) — weight-average molar mass, g/mol
Mz = Σ(ni Mi³) / Σ(ni Mi²); PDI = Mw / Mn (dimensionless)
Mn = (repeat-unit molar mass) × DP; DP = Mn / M₀
Carothers: DP = 1 / (1 − p) — p = extent (fraction) of functional-group reaction, equal stoichiometry
With stoichiometric imbalance: DP = (1 + r) / (1 + r − 2rp); at p = 1, DP = (1 + r)/(1 − r), r = NA/NB ≤ 1
Gel point (Carothers): p_c = 2 / f_av — f_av = average functionality of the mixture
Rate of initiation Ri = 2 f kd [I]; Rate of termination Rt = 2 kt [M•]²
Steady state ⇒ [M•] = (f kd [I] / kt)½; Rp = kp [M] (f kd [I] / kt)½ (mol L⁻¹ s⁻¹)
Kinetic chain length ν = Rp / Ri (and DPn = 2ν for termination by combination, ν for disproportionation)
Mayo equation: 1/DPn = 1/DPn(0) + CS [S]/[M] — CS = chain-transfer constant
Mark–Houwink: [η] = K Ma — [η] intrinsic viscosity (dL/g), K and a are polymer-solvent-temperature constants (a ≈ 0.5 random coil in theta solvent to ~0.8 good solvent)
Specific viscosity ηsp = (η − η₀)/η₀; [η] = lim(c→0) ηsp/c
Fox equation for copolymer/plasticised Tg: 1/Tg = w1/Tg1 + w2/Tg2 (Tg in kelvin, w = mass fractions)
% crystallinity (density) = (ρ − ρa) / (ρc − ρa) × 100
Mn by end-group titration = (mass of sample × functionality) / (moles of end groups)

Example 1 - molecular-weight averages. A sample has 10 chains of 10,000 g/mol and 5 chains of 100,000 g/mol.

Example 2 - Carothers' equation, nylon-6,6. Adipic acid + hexamethylenediamine, exact stoichiometry, p = 0.990.

Example 3 - free-radical kinetics. [M] = 5.0 mol/L, [I] = 1.0 × 10⁻² mol/L, kd = 1.0 × 10⁻⁵ s⁻¹, f = 0.5, kp = 200 L mol⁻¹ s⁻¹, kt = 3.0 × 10⁷ L mol⁻¹ s⁻¹.

Example 4 - Mark-Houwink. For a polymer-solvent pair K = 1.0 × 10⁻⁴ dL/g and a = 0.74; measured [η] = 1.00 dL/g.

Example 5 - copolymer Tg (Fox). SBR with 70% styrene (Tg = 373 K) and 30% butadiene (Tg = 173 K) by mass.

PolymerMonomerMechanism/processTypical use in India
HDPEEtheneZiegler-Natta, low pressureWater pipes (IS 4984), jerrycans, crates
LDPE/LLDPEEtheneHigh-pressure radical / solutionFilms, packaging, lamination
PPPropeneZiegler-Natta, isotacticWoven sacks, BOPP film, auto parts, fibre
PVCVinyl chlorideSuspension/emulsion radicalPipes (IS 4985), wire insulation, flooring
PS / EPSStyreneBulk/suspension radicalPackaging, disposables, insulation
PETTPA/DMT + ethylene glycolMelt polycondensation + SSPBottles, polyester fibre, BOPET film
Nylon-6CaprolactamRing-opening (hydrolytic)Tyre cord, textiles, engineering parts
Phenol-formaldehydePhenol + HCHOStep-growth, networkElectrical fittings, laminates, plywood glue

Where it is used

Interview questions

Common mistakes

Related topics

Green chemistry · Chemistry careers: QC labs, R&D and pharma · Chemical kinetics and reaction mechanisms · Petrochemicals and unit processes · Instrumental analysis: DSC, TGA, FTIR and chromatography · Physical chemistry of solutions and colligative properties

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