Technical Problem Solving

Troubleshooting Polyolefin Grafting via Reactive Extrusion

Troubleshooting Polyolefin Grafting via Reactive Extrusion
Language: English
Length: 90 min
Apr 30, 2025 03:00 PM
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Course Description

Troubleshoot critical challenges to develop high quality grafted PP, PE & EVA products by understanding free radical chemistry, PE, PP & EVA reactions, & design of the extruder.

In this course Dr. Trevor Hutley will help you in controlling grafting reaction, interaction b/w components, optimize compounding to ensure that the grafted monomer is fully bound to the polymer. Get tips to counter challenges (black specks, gel defects…).

Explore the use of grafted polymers as compatibilizers in polymer blends, and gain real-world insights through case studies.

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Trevor Hutley
Trevor Hutley
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Dr. Trevor J. Hutley is a leading polymer and petrochemical industry specialist. He is a research & innovation advisor with global experience in many pioneering and complex situations. Dr. Hutley possesses a rare combination of broad and deep technology and science knowledge, combined with expertise in finance, marketing, manufacturing, and business. He has consistently demonstrated success in new product development, new market expansion, and technology innovation, with a proven track record of commercializing cutting-edge technologies and scientific advancements.

Dr. Hutley has worked for and consulted/advised for companies including:

  • Ford
  • Lotus Engineering
  • SABIC
  • PIRA
  • AMI
  • OneChem
  • Arizona Chemicals
  • Royal Commission in Saudi Arabia
  • GPCA (The Gulf Petrochemical and Chemical Association) in Dubai
  • The Dhahran TechnoValley Company
  • Pan Gulf Holding
  • Polykem Sàrl
  • The Kuwait Institute for Scientific Research (KISR)
  • SCG in Thailand

His past roles include Dunlop (5 years), DuPont Engineering Polymers (almost 15 years), and Sipchem (5.25 years), with work based in the UK, Switzerland, Hong Kong, and for 10 years in the Middle East.

Dr. Hutley's qualifications include:

  • PhD in Polymer Engineering from Cranfield Institute of Technology
  • Executive MBA summa cum laude in finance and marketing from BSL (Business School Lausanne)
  • First-class BTech in Polymer Technology from Brunel University
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Why should you view this course?

To achieve high quality grafted polyolefin products, you need to ensure that the grafted monomer is fully bound to the polymer. This can be tricky as several competing reactions are usually present! Also, the same free radical chemistry in a reactive extruder gives different results with PE, PP & EVA. 

To understand how tocontrol the chemistry & process and troubleshootrecurring issues, join this course and:

  1. Achieve desired quality by understanding the mechanism of grafting & free radical chemistry in a reactive extruder and how PP differs from PE during reaction.

  2. Optimize your compounding process by understanding the interactions b/w components, type of mixing required, how to control melt temp., screw designs..

  3. Troubleshoot efficiently current & future challenges (black specks, gel defects, varying melt viscosities, high volatiles...) with practical tips from Dr. Trevor.

Who should join this course?

  • Engineers and lead operators (polymer converters) looking to resolve critical issues to achieve high quality grafted polyolefin products using reactive extrusion.

  • Complete the course and (unlock your personalized certificate) – your badge of accomplishment awaits!

  • This course is suitable for advanced level proficiency
    Advanced
Course Outline

Grafting of polypropylene, polyethylene & EVA grafting

  • Key differences between PP and PE during the reaction
  • Why opting for reactive extrusion vs. other methods for polyolefins?
  • Typical challenges that you can avoid providing you know a little more about chemistry and process

Feeding of liquids

  • How to adjust pressure?
  • Positive displacement pump

Understanding Free Radical Chemistry

  • Typical peroxides used (Dicumyl peroxide, Di-tert-butyl peroxide…)
  • How to choose which peroxide is best for the process?
  • Safe handling of peroxides
  • Alternate initiators/catalysts
  • AIBN
  • UV

Highlights on the process of Screw Design Considerations

  • Reactions with Polypropylene
  • Understanding the process flow
  • Controlled rheology of PP/Grafting of MaH to PP
  • How to measure MAH content?
  • How to troubleshoot quality issues?

Reactions with Polyethylene

  • Understanding the process flow & Crosslinking
  • Differences between HDPE/LLDPE and LDPE
  • Silane grafting process
  • Twin-screw grafting

Grafting of Maleic Anhydride to PP

  • Controlling MAH content
  • Is the MAH fully bound?
  • Controlling melt viscosity for PP

Grafting Maleic Anhydride to PE

  • Generation of gels and specs
  • Controlling melt viscosity for PE
  • Safety concerns with Maleic Anhydride

Using grafted polymers as  compatibilisers to make polymer blends 

Reactive Extrusion - the future

  • Trends
  • Applications
  • Market Insights
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30 min Q & As for this course
Interact directly with your tutor and clarify your doubts
  1. 30 mins per session for Questions and Answers
  2. Clarify your doubts.
  3. If your questions are not answered, dont worry you will recieve tutor’s reply via email after sessions.
Troubleshooting Polyolefin Grafting via Reactive Extrusion
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