Polyethylene polymerisation

Due to both kinds of branching leading to chain irregularities, the crystallisation of radical chain-polymerised polyethylene is strongly hindered. Its maximum degree of crystallinity is limited to about 50%, its melting temperature ranges from 80°C to 115°C and its density remains low ( 0.92). From this latter property, it received the name of low-density polyethylene (LDPE). 

Keywords 2-6-Bis(arylimino)pyridine, Cobalt catalysts, Iron catalysts, Olefin polymerisation, Polyethylene... 

Polyolefins can be toughened with any of several modifiers. Polyethylene is componnded with chlorinated polyethylene, and polypropylene with around 10 to 40% EPDM rubber, which has better weathering characteristics than polybutadiene, or EVA. Ethylene-octene copolymers and metallocene-polymerised polyethylenes are also effective. 

High density polyethylene (HDPE) is defined by ASTM D1248-84 as a product of ethylene polymerisation with a density of 0.940 g/cm or higher. This range includes both homopolymers of ethylene and its copolymers with small amounts of a-olefins. The first commercial processes for HDPE manufacture were developed in the early 1950s and utilised a variety of transition-metal polymerisation catalysts based on molybdenum (1), chromium (2,3), and titanium (4). Commercial production of HDPE was started in 1956 in the United States by Phillips Petroleum Company and in Europe by Hoechst (5). HDPE is one of the largest volume commodity plastics produced in the world, with a worldwide capacity in 1994 of over 14 x 10 t/yr and a 32% share of the total polyethylene production. 

The chemical iadustry manufactures a large variety of semicrystalline ethylene copolymers containing small amounts of a-olefins. These copolymers are produced ia catalytic polymerisation reactions and have densities lower than those of ethylene homopolymers known as high density polyethylene (HDPE). Ethylene copolymers produced ia catalytic polymerisation reactions are usually described as linear ethylene polymers, to distiaguish them from ethylene polymers containing long branches which are produced ia radical polymerisation reactions at high pressures (see Olefin POLYMERS, LOWDENSITY polyethylene). 

Polypropylene polymers are typically modified with ethylene to obtain desirable properties for specific applications. Specifically, ethylene—propylene mbbers are introduced as a discrete phase in heterophasic copolymers to improve toughness and low temperature impact resistance (see Elastomers, ETHYLENE-PROPYLENE rubber). This is done by sequential polymerisation of homopolymer polypropylene and ethylene—propylene mbber in a multistage reactor process or by the extmsion compounding of ethylene—propylene mbber with a homopolymer. Addition of high density polyethylene, by polymerisation or compounding, is sometimes used to reduce stress whitening. In all cases, a superior balance of properties is obtained when the sise of the discrete mbber phase is approximately one micrometer. Examples of these polymers and their properties are shown in Table 2. Mineral fillers, such as talc or calcium carbonate, can be added to polypropylene to increase stiffness and high temperature properties, as shown in Table 3. 

Organic peroxides are used in the polymer industry as thermal sources of free radicals. They are used primarily to initiate the polymerisation and copolymerisation of vinyl and diene monomers, eg, ethylene, vinyl chloride, styrene, acryUc acid and esters, methacrylic acid and esters, vinyl acetate, acrylonitrile, and butadiene (see Initiators). They ate also used to cute or cross-link resins, eg, unsaturated polyester—styrene blends, thermoplastics such as polyethylene, elastomers such as ethylene—propylene copolymers and terpolymers and ethylene—vinyl acetate copolymer, and mbbets such as siUcone mbbet and styrene-butadiene mbbet. 

The low vinyl acetate ethylene—vinyl acetate copolymers, ie, those containing 10—40 wt % vinyl acetate, are made by processes similar to those used to make low density polyethylene for which pressures are usually > 103 MPa (15,000 psi). A medium, ie, 45 wt % vinyl acetate copolymer with mbber-like properties is made by solution polymerisation in /-butyl alcohol at 34.5 MPa (5000 psi). The 70—95 wt % vinyl acetate emulsion copolymers are made in emulsion processes under ethylene pressures of 2.07—10.4 MPa (300—1500 psi). 

The thermoplastic or thermoset nature of the resin in the colorant—resin matrix is also important. For thermoplastics, the polymerisation reaction is completed, the materials are processed at or close to their melting points, and scrap may be reground and remolded, eg, polyethylene, propjiene, poly(vinyl chloride), acetal resins (qv), acryhcs, ABS, nylons, ceUulosics, and polystyrene (see Olefin polymers Vinyl polymers Acrylic ester polymers Polyamides Cellulose ESTERS Styrene polymers). In the case of thermoset resins, the chemical reaction is only partially complete when the colorants are added and is concluded when the resin is molded. The result is a nonmeltable cross-linked resin that caimot be reworked, eg, epoxy resins (qv), urea—formaldehyde, melamine—formaldehyde, phenoHcs, and thermoset polyesters (qv) (see Amino resins and plastics Phenolic resins). 

Fig. 22.1. (a) The ethylene molecule or monomer (b) the monomer in the activated state, ready to polymerise with others (<)-(f) the ethylene polymer ("polyethylene") the chain length is limited by the addition of terminators like —OH. The DP is the number of monomer units in the chain. 

Commercial interest in PVC also commenced at about this time. The Russian, I. Ostromislensky, had patented the polymerisation of vinyl chloride and related substances in 1912, but the high decomposition rate at processing temperatures proved an insurmountable problem for over 15 years. Today PVC is one of the two largest tonnage plastics materials, the other being polyethylene. 

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. 

Following the considerable commercial success of Ziegler-Natta polymerisation systems which made possible high density polyethylene, polypropylene, ethylene-propylene rubbers and a number of speciality materials, a considerable... 

There is much evidence that weak links are present in the chains of most polymer species. These weak points may be at a terminal position and arise from the specific mechanism of chain termination or may be non-terminal and arise from a momentary aberration in the modus operandi of the polymerisation reaction. Because of these weak points it is found that polyethylene, polytetrafluoroethylene and poly(vinyl chloride), to take just three well-known examples, have a much lower resistance to thermal degradation than low molecular weight analogues. For similar reasons polyacrylonitrile and natural rubber may degrade whilst being dissolved in suitable solvents. 

Assuming that in polyethylene the polarisation is solely electronic, that the degree of polymerisation is r and that the repeating unit is as shown in Figure 6.7. 

Although polyethylene is virtually defined by its very name as a polymer of ethylene produced by addition polymerisation, linear polymers with the formula (CH2), have also been prepared by condensation reactions. For example in 1898 von Pechmann produced a white substance from an ethereal solution of... 

Commercially, polyethylene is produced from ethylene, the polymer being produced by this route in March 1933 and repotted verbally by Fawcett in 1935. The basic patent relating to the polymerisation of ethylene was applied for by ICI on 4th February 1936 and accepted on 6th September 1937. 

Mention has already been made in this chapter of metallocene-catalysed polyethylene (see also Chapter 2). Such metallocene catalysts are transition metal compounds, usually zirconium or titanium. Incorporated into a cyclopentadiene-based structure. During the late 1990s several systems were developed where the new catalysts could be employed in existing polymerisation processes for producing LLDPE-type polymers. These include high pressure autoclave and... 

Both polymers are linear with a flexible chain backbone and are thus both thermoplastic. Both the structures shown Figure 19.4) are regular and since there is no question of tacticity arising both polymers are capable of crystallisation. In the case of both materials polymerisation conditions may lead to structures which slightly impede crystallisation with the polyethylenes this is due to a branching mechanism, whilst with the polyacetals this may be due to copolymerisation. 

The molecules join together to form a long chain-like molecule which may contain many thousands of ethylene units. Such a molecule is referred to as a polymer, in this case polyethylene, whilst in this context ethylene is referred to as a monomer. Styrene, propylene, vinyl chloride, vinyl acetate and methyl methacrylate are other examples of monomers which can polymerise in this way. Sometimes two monomers may be reacted together so that residues of both are to be found in the same chain. Such materials are known as copolymers and are exemplified by ethylene-vinyl acetate copolymers and styrene-acrylonitrile copolymers. 

Simple monodentate NHCs are somewhat susceptible to dissociation when coordinated to early transition metals [6], so in most cases multidentate chelating hgands are employed in which the carbene is tethered to a strongly coordinating anchoring group. This is not universally the case however, and simple monodentate NHC complexes of Zr 1 (Fig. 4.1) have been studied [7]. The complexes were activated with MAO and tested for ethylene polymerisation, leading to moderate activities between 7 and 75 kg mol bar h for linear polyethylene. 

A number of highly active ethylene polymerisation catalysts have resulted from the combination of functionalised NHC ligands with Ti, the first of these was the bis(phenolate)carbene ligated complex 3 [8], Upon activation with modified MAO (MMAO), this species gave an activity of 290 kg-mol bar h in the one test reported, making it one of the most active carbene-based olefin polymerisation catalysts known. In later work the same complex was evaluated with straight MAO activation, and activities of up to ca. 100 kg mol -bar" -h" were reported for linear polyethylene production [9],... 

The remainder of the work on Ni(II) complexes involves the use of chelating ligands in which the carbene is functionalised with pendant heteroatom donor(s). The picolyl-functionalised NHC dicationic complex 29 (Fig. 4.11) was tested for ethylene polymerisation after treatment with MAO [34]. This complex was found to be highly active in a preliminary test (330 kg moF bar h" ), giving predominantly linear polyethylene. Unfortunately this work does not seem to have been followed up. The same system was active for norbomene polymerisation (TOF = 24 400 h" over 1 h). Maximum activity was achieved at 80°C whereafter thermal deactivation became significant, although the nature of this deactivation was not studied. The phenoxide-functionalised carbene complex 30 (Fig. 4.11) was also... 

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