Pskov Newsline: General Director of Pskov plant «Titan-Polymer» on plastic processing and the safety of modern polymers

Please find herein below a text version of the new issue of the program “Hyde Park” on the air of Echo of Moscow radio in Pskov, the guest of which was German Petrushko, General Director of Pskov plant “Titan-Polymer”. Radio host Konstantin Kalinichenko talked with him about what constitutes modern polymer production, what stereotypes and misconceptions the residents of Pskov will have to get rid of. Also during the program, he discussed with the guest of the studio the following issues: Is waste-free polymer production actually possible and is plastic recyclable and safely disposable? Why are modern polymers environmentally friendly and are increasingly used in everyday life?

Konstantin Kalinichenko: Good afternoon, dear listeners. On the waves of Echo of Moscow in Pskov, "Hyde Park" is a territory where we openly speak on a variety of topics. The host is Konstantin Kalinichenko, our guest is German Petrushko, General Director of Pskov Plant “Titan-Polymer”. German Lvovich, good afternoon.

German Petrushko: Good afternoon, residents of Pskov.

Konstantin Kalinichenko: In the next 30 minutes, we’ll talk about what modern polymer production actually represents, and what stereotypes Pskovians will have to get rid of. We shall discuss whether waste-free production of polymers and plastics is possible, and whether all of it is subject to recycling or safe disposal. We shall also talk about why modern polymers are environmentally friendly and are being increasingly used not only in chemistry, but also at home, and in everyday life. German Lvovich, let's explain generally: what is plastic in our life? Obviously, people have long been captive to stereotypes. For example, there is an opinion that the entire civilized world refuses plastic in favor of environmentally friendly materials. However, nobody specifies which ones, and probably, everyone thinks that in favor of wood: pine, birch, or something else. Is it really so?.

German Petrushko: I think that talking about plastic is not quite correct. Polymers is a very broad term; humanity has already been living with these materials for more than hundred years. For instance, everybody knows that there are natural polymers: amber, cellulose, various polysaccharides. By the way, viscose (artificial rayon) is obtained from natural cellulose, this production process is more than 100 years old. Simply stated, it is obtained from fir tree. However, from an environmental point of view, production process is rather complicated as it involves the use of a huge amount of water and all kinds of acids. Anyway, a great and hygienic material can be produced. Other examples are nylon or capron — this material is more than 90 years old, polyethylene terephthalate is 70 years old. Polyacrylonitrile has remarkable properties: this material resembles fluff and is particularly used in the manufacture of jackets. If this material is subjected to special processing, we will get carbon fiber, which is used in the wings of aircraft; moreover, civil missiles can be made from this material. Polyamide is used in the manufacture of sportswear....

Konstantin Kalinichenko: Loosely speaking, do we actually put these very plastics and polymers on a naked body?

German Petrushko: Yes, we do. You and I wear shirts now, there is polyester in them. And these are just PET threads obtained from polyethylene terephthalate.

Konstantin Kalinichenko: I hope we won’t die wearing these shirts and T-shirts?

German Petrushko: Of course, not. Today's clothing production process is being continuously improved; fabrics are more and more suited for textile manufacture, so you do not feel any itching or burning of the skin. These are things we can't live without today. We will not be able to wear a purely natural material, such as cotton, because it has rather difficult conditions of use: cotton will shrink after being washed. Therefore, to create a wear resistant and marketable fabric, weavers add certain threads of another material. It may be polyamide fiber, or PET fiber, or any other fiber with different properties.

Konstantin Kalinichenko: So, it appears to be a thing of our everyday life.

German Petrushko: Yes, this is our everyday life, we can't do without it. I believe that the development of science and today's progress is simply impossible without the development of plastics and attaining some new valuable properties.

Konstantin Kalinichenko: We'll talk about science a little bit later. Here's one more stereotype that has been actively discussed. You probably remember that in the spring there were publications and broadcasts actively circulated in the media that Europe decided to abandon plastic disposable tableware. Apparently, at McDonald's now everyone will be served on chinaware... The question is: Does Europe really stop using polymers to a certain extent? Are polymer factories being built in civilized countries today? I mean civilized countries, not China or Mongolia.

German Petrushko: First of all, we must understand what exactly Europe refuses. We have already mentioned that there are a great many polymers. Of course, some polymers are used in the packaging of food products. We are now mostly talking about materials, such as polyethylene, high-density and low-density polyethylene, because these materials are involved in the packaging of our food products.

Konstantin Kalinichenko: Ranging from food bags...

German Petrushko: Yes, but it doesn't mean that Europe refuses to use these materials. Europe is switching to so-called biodegradable materials, including, among other things, the same polymers we are talking about. It doesn't mean that the entire Europe is moving away from this or that all fast food refuses plastic. Here we are talking about bags that are very difficult to fabricate. There is no problem in recycling them, but they are quite difficult to fabricate. These bags will fly smashed by the wind. In Europe, they consider, wherever possible and really necessary, to switch to biodegradable packaging. This is to say that a special bacterium is implanted into the plastic, which is further decomposed under certain conditions.

Konstantin Kalinichenko: So, this bacterium seems to be living in plastic?

German Petrushko: Yes. Or a storage area is prepared, wherein accelerated decomposition of plastic occurs at certain temperatures. These are the challenges facing Europe. In other words, high-density polyethylene in its pure form is now being replaced by a more advanced material. However, this is the same plastic, only, globally speaking, it has other properties.

Konstantin Kalinichenko: Let's touch upon Europe a little more. Just before going on the air I came across such information: Germany produces 7 kg of polyethylene terephthalate per capita, while Russia makes about 1.5 kg. So, it turns out that we produce 4-5 times less. Does this mean that today Russia has to purchase these products abroad, or we simply exist in the mode of underproduction of polyethylene terephthalate?

German Petrushko: You are absolutely right and understand it correctly. I can say more: in the United States, this figure reaches 15 kg per capita.

Konstantin Kalinichenko:: I came across news that China produces 22 kg plastic per capita, however, China is not the powerhouse in this respect.

German Petrushko: The question is that today the Russian Federation is severely lagging behind the whole civilized world in the production and processing of polymers. For some reason, plastic in our minds means utensils.

Konstantin Kalinichenko:: Plastic cup or bottle...

German Petrushko: But this is not so. Here you have a computer — this is also plastic, and all the components in it are also made of plastic. And how can we dress a firefighter and send him to extinguish the fire? He will simply burn, the fire temperature is extremely high. If we don’t provide him with protective clothing made of fabric containing polyamide threads that can withstand temperatures up to 700 degrees or some polyacrylic yarns that can withstand even 1,000 degrees, we will not be able to solve these urgent problems. In the Russian Federation, the question is about satisfying our own needs for various types of polymers, i.e. polyamides, polyethylene terephthalate, and polyethylenes with special properties, for example, ultra-molecular polyethylenes. We produce very small quantities of these materials, while they are strategically important products. We are now talking about the fact that Russia is going to produce these materials, and this is a strategic task facing our country.

Konstantin Kalinichenko:: And in terms of technology, are we a sufficiently developed nation so as not to "foul up"? There is a desire to produce, as well as the need to do it. But can we afford it from technological point of view?

German Petrushko: Certainly. There are long-standing traditions in the Russian Federation. For example, we have been producing polyamides for a very long time, we are also producing polyethylene. The manufactures are located in Kazan, Tomsk, in Siberia... I can list a lot of them. I can scarcely remember any accidents related to these manufactures. That is to say that these manufacturing enterprises use the most advanced technologies. Science is developing, and all kinds of components involved in the production of polymers are also developing. This includes process automation, early stages of detecting any critical temperatures in the process, etc. The Russian Federation has all the capabilities to increase the production of polymers.

Konstantin Kalinichenko:: You have just said that there were no accidents. When preparing for the broadcast, I was trying many times to find at least one case of any accident at the enterprises producing specifically polyethylene terephthalate. I tried to reach some Chinese resources, too. However, there was no information related thereto. Although, it would seem that everything should burn and explode at this country's enterprises, and Chinese would not give a damn about it, because they've never really cared about people. But nothing happens even in China. This is probably a disappointing fact for journalists, because there are no newsworthy events. But for people, this is obviously an encouraging fact as the most important thing here is technology, which does not allow emergency situations to take place. We have already started to touch upon this issue a little bit. What are today's technologies for the utilization and processing of polymers? Still, we understand that the world is already covered with a layer of plastic. Are there any actually recycling technologies, some kind of humane and efficient type of recycling? Isn't it dangerous for people, for the inhabitants of the regions? Where will all this be organized?

German Petrushko: Certainly. Actually, the world has long been processing and recycling polymers. The question is that there are various polymer processing and recycling technologies. One of the most common technologies today, which is used almost throughout the world, consists in polymer collection, sorting out, washing, cleaning, crushing, and converting them back into granules. These granules are then delivered to lithium production, some type of boxes, buckets.

Konstantin Kalinichenko: Again, some kind of household products.

German Petrushko: Yes. For example, Coca-Cola, which today markets its products in plastic bottles. Why are they doing it? Because polyethylene terephthalate is one of the safest and the most environmentally friendly materials. All scientific communities that tried to find a negative impact of this material on human health failed to do it. Meanwhile, Coca-Cola's production process stipulates that each bottle should contain 30% of recycled plastic. In a way, this is also a fight for the environment. There are many examples. For instance, players of Bayern Munich wear a special kit made entirely of recycled plastic.

Konstantin Kalinichenko: Perhaps, this is the recipe for success? Provide Spartak and CSKA football players with such kits...

German Petrushko: Such technology exists. Plastic is reused in some less significant goods or other derivatives of finished products, i.e. threads, nonwoven materials, etc. The spectrum is very wide. Yet, there is another technology: a certain plastic may be converted virtually into its primary form. Such technology also exists, and it is widely distributed throughout the world. This is not a secret in the Russian Federation either, so today German and American companies come here to offer their technologies and equipment. This business will continue to grow. In Russia, the plastic recycling business is gaining momentum. Believe me, very soon we shall witness how all plastic goes into recycling. It's a separate and very serious topic.

Konstantin Kalinichenko: Incidentally, I saw with my own eyes in one of the new districts of Vienna a Starlinger company — a fairly large family-owned enterprise that deals with recycling. The company is located in the city limits, in a very fashionable, built-up area, and is engaged in the processing and recycling of plastics. You can be skeptical about production in Russia or China, but the Austrians really care about their health. Otherwise, they would never build a harmful production in the city center for recycling of plastics, polymers, etc. So, it turns out that this is not only a technology of the future, but also a safe technology?

German Petrushko: These are technologies of the future and technologies of today. I know Starlinger company very well, I had to work a lot with them using their equipment and setting up their enterprises in the Russian Federation. By the way, you should know them very well, too. These are the leading enterprises for the production of yarn used in sack tare for sugar packing. They have long ago developed and continue to develop polymer processing and recycling equipment. Polymer processing does not involve any environmental harm or danger. These are mainly closed-loop processes which involve a minimal release of some gases or something else when the plastic is heated. You correctly noted that Austrians would never set an enterprise that could do any harm in the city center. I can tell you even more: why the topic of polymer processing/recycling is gaining momentum in Russia? Last year, China imported to Russia about 55,000 tons of processed primary material — flakes. These very flakes, from which other materials will be made later. Today it is a state-managed program. Today I already know enterprises in the Russian Federation that process about 70,000 tons per year. They are located both in Moscow region and in Tatarstan. It's a very good business.

Konstantin Kalinichenko: I believe that in the context of the garbage reform, which is half-heartedly developing in our country, all of this should be used.

German Petrushko: Certainly. There is a problem of collection and sorting out. This is all included in one set of problems. Where there is processing, recycling business is interested in receiving waste directly from the primary collection point, or already from landfills.

Konstantin Kalinichenko: Let's look at it closer to our region... We understand that operations with polymers involve fairly complex, high-tech technologies. Let's take Pskov, for instance. To put it mildly, a university was created there several years ago and, in my opinion, nobody still understands what to do with this university. How urgent is the issue of personnel in general, are there enough skilled labor in Russia?

German Petrushko: The question is rather complicated, indeed. After the fall of the Soviet Union, a lot of departments were simply closed, some were considered unclaimed, especially when the factories stopped. It is clear that precisely the technical personnel...

Konstantin Kalinichenko:Why shall we turn out chemists if they have nowhere to work?

German Petrushko: Naturally, our life is constantly changing. The formation of highly-demanded professions is the main task today. Throughout the country, there is a lack of qualified personnel — process engineers, mechanics, representatives of various technical areas. Ideally, a clear scheme shall be developed... Thus is what we tried to do and continue doing in Omsk — high school, professional education, university, science. This is an ideal variant...

Konstantin Kalinichenko:An educational cluster, if you want. An then you bring the person to perfection, control him, and he will understand that he will never be left without highly payable work.

German Petrushko: This is what we see, it's like a skeleton. The creation of this skeleton will allow a modular pattern of operations.

Konstantin Kalinichenko: Such a modular structure seems to be very relevant and urgent. It is clear that there is no sense in creating a special department to turn out "chemists-polyethylene-terephthalate-technologists". We shall spend five years to educate first graduates, and by that time, perhaps, the business trends will change, plastics will be modified, or something else will happen.

German Petrushko: Certainly. We must provide basic education, and then offer specialization either in the last year of study, or when the specialist is already employed by the enterprise. From our point of view, these issues cannot be resolved in one day. The main thing is that we have a common vision with Pskov State University. Just yesterday we had a round table, you can familiarize yourself with its materials. Honestly, I was pleased that we found a common language, we see this problem equally as it is important both for the region and for us in terms of providing personnel not only for our enterprise, but also for the entire Pskov region.

Konstantin Kalinichenko: As far as I understand, there will be a kind of modular programs, short enough in terms of training and quite domain-specific so that people do not waste time for studying philosophy, sociology, etc.

German Petrushko: Of course, everything must be brought closer to reality, to production.

Konstantin Kalinichenko: And what is the result? What is the purpose of all this? I saw jackets and puffer jackets, but to my surprise, I found out that the surgical self-degradable threads used to suture are also made from the same polyethylene terephthalate.

German Petrushko: Yes. These threads will be made from the material we intend to produce.

Konstantin Kalinichenko: As far as I understand, this material itself decomposes very easily. These threads decompose in a week or two, whatever is their term....

German Petrushko: Well, of course, it's a special material. We call it a special material because there is a basic polymer in it. And when we add something to it...

Konstantin Kalinichenko: Base polymer — a bag in Lenta or Pyatyorochka supermarkets...

German Petrushko: No, this is not our material, it's polyethylene. Our material has slightly different properties: other optics, physics, mechanics. Your computer here — this is exactly our material.

Konstantin Kalinichenko: Plastic is not as scary as stereotypical judgments about it.

German Petrushko: Certainly.

Konstantin Kalinichenko: In conclusion: it is clear that production always remains production, it always needs serious expert review and is subject to some kind of control. I have a completely narrow-minded question: can we trust Russian experts?

German Petrushko: Certainly. I have already said many times that the authority of Russian science is very high, it is not rejected by the world. Therefore, it is not worth saying that we have some kind of a weak expert community.

Konstantin Kalinichenko: Aren't we a third world country in the world of polymers?

German Petrushko: Of course, not. An we have never been. Believe me, in this matter we were somewhere behind, somewhere ahead. As anywhere in the world: we do something better, something worse, but, nevertheless, there is a basic science in this respect that brings up our problems as soon as they arise. If you take the same sanctions now, you may see how they pushed the development of all kinds of fibers.

Konstantin Kalinichenko: German Lvovich, now people will remind you that your fibers are in our cheese, which we have instead of parmesan. It is customary to say that we have chemical cheese.

German Petrushko: This is not our problem.

Konstantin Kalinichenko: It's a joke, of course.

German Petrushko: Look, the same MC 21 aircraft has a huge amount of plastic parts: from wings to a part of fuselage. And such an aircraft was first assembled in Russia. These include special threads, fibers, and resins. We shall not and may not say that Russian science is lagging behind in this matter. Yes, in some issues the West is ahead of us. In this case, we purchase their technology.

Konstantin Kalinichenko: Out broadcasting is coming to an end. Thank you, German Lvovich, for staying with us today. In my opinion, it was very interesting and informative for our listeners.

German Petrushko: Thank you very much.

Source: Pskov Newsline, 04.09.2019

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