Polypropylene manufacturing processes

As a result of the work of Ziegler in Germany, Natta in Italy and Pease and Roedel in the United States, the process of co-ordination polymerisation, a process related to ionic polymerisation, became of significance in the late 1950s. This process is today used in the commercial manufacture of polypropylene and polyethylene and has also been used in the laboratory for the manufacture of many novel polymers. In principle the catalyst system used governs the way in which a monomer and a growing chain approach each other and because of this it is possible to produce stereoregular polymers. 

Gas phase olefin polymerizations are becoming important as manufacturing processes for high density polyethylene (HOPE) and polypropylene (PP). An understanding of the kinetics of these gas-powder polymerization reactions using a highly active TiCi s catalyst is vital to the careful operation of these processes. Well-proven models for both the hexane slurry process and the bulk process have been published. This article describes an extension of these models to gas phase polymerization in semibatch and continuous backmix reactors. 

In solution polymerization, monomers mix and react while dissolved in a suitable solvent or a liquid monomer under high pressure (as in the case of the manufacture of polypropylene). The solvent dilutes the monomers which helps control the polymerization rate through concentration effects. The solvent also acts as a heat sink and heat transfer agent which helps cool the locale in which polymerization occurs. A drawback to solution processes is that the solvent can sometimes be incorporated into the growing chain if it participates in a chain transfer reaction. Polymer engineers optimize the solvent to avoid this effect. An example of a polymer made via solution polymerization is poly(tetrafluoroethylene), which is better knoivn by its trade name Teflon . This commonly used commercial polymer utilizes water as the solvent during the polymerization process,... 

Chemical reactions enhanced by catalysts or enzymes are an integral part of the manufacturing processes for the majority of chemical products. The total market for catalysts and enzymes amounts to 11.5 billion (2005), of which catalysts account for about 80%. It consists of four main applications environment (e.g., automotive catalysts), 31% polymers (e.g., polyethylene and polypropylene), 24% petroleum processing (e.g., cracking and reforming), 23% and chemicals, 22%. Within the latter, particularly the catalysts and enzymes for chiral synthesis are noteworthy. Within catalysts, BINAPs [i.e., derivatives of 2,2 -bis(diphenylphosphino) -1, l -bis-l,l -binaphthyl) have made a great foray into chiral synthesis. Within enzymes, apart from bread-and-butter products, like lipases, nitrilases, acylases, lactamases, and esterases, there are products tailored for specific processes. These specialty enzymes improve the volumetric productivity 100-fold and more. Fine-chemical companies, which have an important captive use of enzymes, are offering them to third parties. Two examples are described here ... 

Figure 2.45). Bulk sorbent phases can also be purchased. Typical column housings are manufactured of polypropylene or glass, and the sorbent is contained in the column by using porous frits made of polyethylene, stainless steel, or Teflon. Pesek and Matyska [87] describe three types of disk construction (1) the sorbent is contained between porous disks, which are inert with respect to the solvent extraction process (2) the sorbent is en-... 

The method for the manufacture of polypropylene by the Ziegler-Natta process, which has been in widespread use for several decades, involved some years ago a polymerization in a relatively volatile solvent, for example a light petroleum fraction. That was the drawback of this process, since in the separation and subsequent drying of the polymer formed the solvent could not be completely recovered. Problems are thus experienced in fulfilling environmental protection requirements. An additional obstacle was the large volume of aqueous waste that is generated during workup of the polymer suspension. 

Exxon and Phillips manufacture polypropylene in tubular reactors where the monomer is in the liquid form (see Section 6.8.2). One of the manufacturing processes for polyethylene involves the use of a loop reactor that has a recycle configuration. Here, under elevated pressure and temperature, a mixture of the catalyst, comonomer, hydrogen, and a solvent are introduced from one end of the reactor. The product and the unreacted starting materials are collected at the other end, and recycled back into the reactor. 

The MF membranes are usually made from natural or synthetic polymers such as cellulose acetate (CA), polyvinylidene difiuoride, polyamides, polysulfone, polycarbonate, polypropylene, and polytetrafiuoroethylene (FIFE) (13). Some of the newer MF membranes are ceramic membranes based on alumina, membranes formed during the anodizing of aluminium, and carbon membrane. Glass is being used as a membrane material. Zirconium oxide can also be deposited onto a porous carbon tube. Sintered metal membranes are fabricated from stainless steel, silver, gold, platinum, and nickel, in disks and tubes. The properties of membrane materials are directly reflected in their end applications. Some criteria for their selection are mechanical strength, temperature resistance, chemical compatibility, hydrophobility, hydrophilicity, permeability, permselectivity and the cost of membrane material as well as manufacturing process. 

Ziegler-Natta catalysts play a dominant role in polyolefins manufacture. More than 50 million tonnes per annum of polyethylene and polypropylene are now produced by means of Ziegler-Natta catalysis. Since the first discoveries, more than 50 years ago, many breakthroughs and innovations have been made in catalyst and process chemistry and technology, leading to ever more efficient manufacturing processes, and also to increasing control over polymer structure and properties. 

The products of the thermal phase-separation membranes form a wide range of styles and configurations. Three pore sizes are currently In commercial production In polypropylene flat stock, rated at 0.45, 0.2, and 0.1 micrometers, having maximum pore sizes of about 1.0, 0.55, and 0.3 micrometers, respectively. The last two are particularly attractive for depyrogenatlon work which has been described by J. R. Robinson, et al W. A similar membrane-manufacturing process Is also used for making hollow fibers and tubes which are especially useful in cross-flow applications (10) and plasmapheresis ( ). 

Discovery of Linear (High-Density) Polyethylene Use of Comonomers Linear Low-Density Polyethylene Stereospecific Polymerization Discovery of Polypropylene Manufacturing Processes High-Pressure LDPE Low-Pressure, Linear HOPE LLDPE... 

It is very important to quality control the plasticware that comes in contact with the samples, buffers, and solvents because lubricants and plasticizers added to the plastic resin during the manufacturing process may leak out and possibly affect the quality of the spectrum (16). We use colorless polypropylene pipette tips, microcentrifuge tubes, and thin-wall PCR strip tubes from Eppendorf. For storage of buffers and solvents, we use Nalgene Teflon bottles with Telfon caps. We also use Corning PYREX bottles with Teflon-lined caps to store buffers. 

Because polypropylene contains no polar groups, it contains no dye sites capable of reacting permanently with dye molecules. Since monomers containing polar groups react with the catalysts used to make polypropylene, it has thus far proven difficult to incorporate dye sites during polymerization. Therefore, coloration of polypropylene fibers has been accomplished either by (1) modification of polypropylene as part of the fiber-manufacturing process to render the resultant fiber dyeable or by (2) the addition of pigments. 

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