Polysulfone Plant

Polysulfone (PSU) is a tough, high-performance plastic known for its ability to handle heat, resist chemicals, and stay strong under pressure. It’s a go-to material for demanding jobs where regular plastics or even metals might fail. Here’s why it’s so useful:

Heat Resistance: Works non-stop at 160–180°C (hotter than boiling water) and can briefly handle over 200°C.
Chemical Resistance: Won’t break down when exposed to acids, oils, alcohol, or harsh cleaning agents.
Lightweight & Strong: As tough as some metals but much lighter, perfect for reducing weight in cars or planes.
Safe for Medical Use: Approved for tools that need repeated sterilization (like surgery equipment) and direct contact with food.

Application of PSU:

Medical Tools: Reusable surgical instruments, dialysis machines, and containers that survive steam sterilization.
Electronics: Insulating parts for circuits, sensors in car engines, and heat-resistant LED components.
Auto Parts: Fuel lines, battery cases, and parts near hot engines.
Water Filters: Membranes for cleaning seawater or industrial wastewater.
Aerospace: Lightweight cabin parts and components for satellites.
Energy Tech: Critical parts in hydrogen fuel cells and pipelines.

Introduction

Polysulfone is an engineering plastic with high temperature resistance, good creep resistance, and excellent mechanical strength. It can be prepared into various high-performance separation membranes and applied in various fields, such as fuel cells, seawater desalination, organic and inorganic purification, etc. And polysulfone has good anticoagulant effect and good biocompatibility, and is used as a raw material for hemodialysis membranes in the pharmaceutical field.

The company is focusing on the processing and modification of general-purpose polysulfone resins. With the trend of light-weighting in the automotive industry and the decreasing steel production year by year, the market prospects for modified universal resins are very broad. The company's current membrane grade polysulfone products have been recognized by multiple professional organizations and have reached the advanced level of global membrane grade polysulfone products, breaking the monopoly of international membrane grade products and filling the domestic gap.

Key Features of Polysulfone Production Process

Reaction Type
- Polycondensation Reaction: Uses Bisphenol A and 4,4'-dichlorodiphenyl sulfone as monomers, forming sulfone groups via nucleophilic substitution, with HCl as a byproduct.
- High-Boiling Solvent System: Polar solvents like DMAC or NMP ensure homogeneous reactions and dissolve polymer chains.
Critical Process Controls
- Inert Gas Protection: Nitrogen atmosphere prevents oxidation, ensuring molecular chain regularity.
- Optimized Temperature and Time: Reaction at 150–200°C for 4–12 hours to precisely control molecular weight and distribution.
- Byproduct Management: Neutralize or remove HCl promptly to avoid equipment corrosion and enhance reaction efficiency.
Environmental and Cost Efficiency
- Solvent Recycling: DMAC/NMP can be reused, reducing costs and environmental impact.
- Waste Treatment: HCl neutralized with alkali, organic wastewater treated via distillation, aligning with green production standards.

Material Characteristics of Polysulfone

Exceptional Thermal Properties
- High Glass Transition Temperature (Tg ≈ 185°C): Long-term service temperature up to 160–180°C; short-term resistance above 200°C.
- Low Thermal Expansion Coefficient: Excellent dimensional stability for precision components.
Outstanding Chemical Resistance
- Resistance to Acids, Alkalis, and Solvents: Stable in strong acids (e.g., sulfuric acid), alkalis (e.g., NaOH), and alcohols.
- Hydrolysis Resistance: Suitable for high-temperature/pressure steam environments (e.g., medical sterilization).
Superior Mechanical Performance
- High Strength and Rigidity: Tensile strength ≥70 MPa, flexural strength ≥100 MPa, comparable to some metals.
- Creep Resistance: Minimal deformation under long-term load, ideal for structural parts.
Functional Properties
- Transparency: High light transmittance (similar to PC), suitable for transparent medical devices or optical components.
- Electrical Insulation: High dielectric strength for high-frequency electronic components.

Integrated Advantages of Process and Material

Aspect	Advantages
Process	① Recyclable solvents reduce costs and environmental impact; ② Controllable molecular weight ensures consistent performance; ③ Corrosion-resistant equipment design extends lifespan.
Performance	① Combines heat/chemical resistance, replacing metals/ceramics; ② High strength-to-weight ratio for lightweight designs; ③ Biocompatibility (medical-grade certifications).
Applications	① Versatile (medical, electronics, automotive, water treatment); ② Flexible processing (injection molding, extrusion, 3D printing); ③ Long service life reduces maintenance costs.

Unique Advantages vs. Other Engineering Plastics

Compared to Polycarbonate (PC):
- Higher heat resistance (PC’s Tg ≈ 150°C) and stronger chemical resistance.
Compared to Polyether Ether Ketone (PEEK):
- Lower cost and processing temperatures (PEEK requires >380°C), suitable for mass production.
Compared to Polyphenylene Sulfide (PPS):
- Better transparency and mechanical toughness, less prone to brittleness.

Polysulfone achieves an optimal balance of high-temperature resistance, mechanical strength, and chemical stability through its precision polycondensation process and advanced molecular design, making it a leading high-performance engineering plastic. Its eco-friendly production, versatile properties, and broad applicability in medical sterilization, electronic insulation, and automotive components underscore its irreplaceable role in advanced materials development.