ABS was patented in 1948 and introduced commercially by Borg-Warner in 1954. There are three main polymerisation processes used:
- Emulsion process (oldest and least clean);
- Suspension (blending high rubber content medium with SAN);
- Continuous mass (clean, cost effective but lacks flexibility).
The continuous mass process is seen as the preferred route because the reaction does not take place in the aqueous phase. There is less effluent that needs disposal and energy requirements are lower. With its improved technology, the process can produce resins with enhanced colour consistency, making painting unnecessary in certain applications.
However, the emulsion polymerisation process, which was commonly used in plants built before the mid-1980s, provides more flexibility in its product range than the mass process. The batch emulsion is used in the production of high impact grades.
A hybrid emulsion/mass process has also been developed. It combines the features of the emulsion process, which forms polybutadiene latex and grafts styrene and acrylonitrile, and the mass process, which makes the styrene acrylonitrile component. This approach permits the production of a wide range of ABS products.
Advances in technology include claims by BASF of improved efficiencies and output. LG Chemical claims to have developed a new high productivity route and EniChem has invested in a new flexible process.
Acrylonitrile-butadiene-styrene copolymer
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