Statements of Excellence in Chemical Engineering

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Great Accomplishments in Chemical Engineering

What do bubble gum, PVC and tires have in common, you might ask? Well, they all owe their commercial success to the same US-born chemical engineer – Waldo Semon.

To be perfectly honest, actually: PVC and tires certainly do, but—while Semon did invent a synthetic chewing gum that was great for blowing bubbles—his employer failed to capitalize on that particular patent!

However, with 216 national and international patents to choose from, one could be forgiven for missing the potential of one of them; especially if it’s as far removed from the core business as chewing gum is from a rubber specialist like BFGoodrich, Semon’s employer.

PVC had actually been discovered twice, independently, by the German chemist Eugen Baumann in 1872 and the inventor Friedrich Klatte in 1913 (who also patented an associated polymerization process using sunlight). But the material was brittle and no one had any commercial applications for it.

“People thought of PVC as worthless back then [in the 1920s]” Semon says, when inducted to the US National Inventors Hall of Fame in 1995. They had abandoned the idea completely.

How wrong they were, though: today, PVC is the world’s second most-produced plastic after polyethylene. Two-out-of-three water pipes are made from PVC, as are three quarters of sanitary sewer pipes. Other applications range from electrical insulation tape and window frames to phonographic records and credit cards.

The secret ingredient that turned PVC from undesirable waste into million-use product was a solvent that turned PVC from a hard unworkable waste of space into the flexible, bouncy and chemically-resistant multi-use polymer we know today. A breakthrough was needed.

Like so many discoveries, Semon’s PVC breakthrough happened by accident. While trying to develop an adhesive that would bond rubber to metal – already big business for BFGoodrich, which had taken on Semon months earlier in mid-1926, he was shocked to find that he had made something new and very interesting. But it involved a unique process.

“I thought if I could start with vinyl chloride, polymerize it and then remove the chlorine by some method or other that I might be able to find the conditions to obtain an adhesive material,” Semon tells the American Chemical Society in 1966.

Synthesizing vinyl chloride and letting the sunlight on the roof of the laboratory polymerize it was easy enough, but removing the chlorine proved to be more problematic. “Among the things I tried was to solvate the PVC in high-boiling solvent and then treat it with zinc or a strong organic amine—imagine my surprise when I found that the solvated PVC was flexible, resilient and would bounce! When I later found that the plasticized PVC would resist alkaline, strong acids and most solvents it seemed to me that it would have quite a range of commercial possibility.”

PVC was clearly no adhesive, but Semon saw its potential and decided to carry on anyway. Plasticized PVC required a lot of energy to heat up and then had to be cooled in the mold, which made the process both time-consuming and expensive.

The solution was to produce the raw PVC in the form of a fine powder and then mix it with plasticizer till it resembled a thick paste. “I found I could spread this paste on cloth or put it in molds. When it was heated it assumed the same properties that would have been obtained if I’d mixed it first and then molded the product, but the processing was much easier,” Semon said. Known as plastisol technology, this process is still used today.

As so often happens, Semon found that it is one thing to find a new product with obvious and promising commercial application, and another thing entirely to sell it to management. “It took a long time to really interest anyone in PVC,” says Semon.

“BFGoodrich was a rubber company at the time. They thought of nothing but rubber and this was not a rubber product, so I had a very interesting experience selling the idea to management.”

The company marketed PVC for a few niche applications such as shoe heels and PVC-coated wire racks for chemical labs, but the market was too limited to fund the continued development of PVC.

It was actually the ability to apply PVC to fabrics – coupled with a senior executive’s penchant for camping holidays – that catalyzed the real breakthrough.

“My wife had been making curtains for the living room,” Semon says, in an interview with National Public Radio in the US. “I brought some of the fabric into the lab and coated it with PVC. Lo and behold, it looked like silk and it was waterproof. I got so excited, I forgot about protocol and went directly to the vice president of sales (who, as it happens, had a great love for the outdoors, and a long-standing experience of getting soaked in his supposedly waterproof tent), and he looked at it and he says, ‘Hell, what do you mean, waterproof?’ So I grabbed the fabric and put it on top of his incoming mail and took a decanter of water and poured it. He was really frightened, but it didn’t leak...! I’ve often wondered what would have happened to me and PVC if it had leaked.”

Semon received the patent for plasticized PVC in 1933, and PVC-coated umbrellas, raincoats and shower curtains followed, as did vinyl records, garden hoses, and a host of other interesting products.

Meanwhile, Hitler’s rise in Germany fueled US fears that instability in Europe could cut North America off from the Asian natural rubber suppliers it was totally dependent on for everything from car tires to air planes and footwear.

Semon’s personal mission was to find a synthetic elastomer that could replace natural rubber in automotive tires.

Even without war in Europe threatening to cut off supply lines, natural rubber was in short supply: by the late 1930s, the US consumed over half the world’s supply of natural rubber, and the rise of the automotive industry in particular fuelled continuing strong growth, as did the prospect of war.

The start of WWII in 1939 brought the feared cut in supplies, leaving the US with a stockpile that would last no more than 18 months. If no viable synthetic alternative was found during that time, there was no way the US could have won the war.

World War I had catalyzed the development of the first synthetic rubber, polymerized methyl isoprene, but methyl rubber was an expensive poor imitation and quickly abandoned.

German researchers in the 1920s developed ‘Buna’ (sodium-polymerized butadiene) and found that when they further added styrene and carbon black, the resulting polymer, known as Buna-S, was strong and durable.

Hence, when Semon visited Germany in 1937 with the aim of getting them to share the technology, he found them somewhat reluctant to divulge the exact details of the process.

“However, it was really a great experience for me to ride around Germany on tires made from Buna-S! I came back more enthused than ever and convinced that if Germany would not give us their method for making synthetic rubber, we could develop a process of our own,” says Semon.

It was common knowledge that Buna-S consisted of butadiene and styrene, so the only thing Semon and his team needed to do was to find some other system of monomers that would not infringe the German patent. What followed was an experimental marathon during which Semon and his team tested every combination of diene monomers and co-monomers they could think up.

“Of the 14,492 experiments carried out, there were only around 111 promising enough for further detailed development, and of them were only six that looked good enough to be pilot planted,” Semon says.

Commercial availability ultimately made the decision in favor of butadiene and methyl methacrylate, already commonly used to make Lucite windows. Semon found that copolymerizing 70% butadiene and 30% MMA resulted in a good, abrasion-resistant synthetic rubber, This wasn’t the cheapest solution, but one that was practically available and that would do the job, he says.