Gas-phase polymerization

Radical polymerization can be carried out under homogenous as well as heterogenous conditions. This difference is classified based on whether the initial mixture and/or final product are homogenous or heterogenous. Some homogenous mixtures become heterogenous as polymerization proceeds as a result of insolubility of the resulting polymer in the reaction media. There are many other specialized processes that are used to synthesize materials via free-radical polymerization. These include interfacial polymerization, gas phase reactions ( popcorn polymerization ), as well as the use of specialized media like supercritical fluids. Current research efforts include the study of such... 

Exxpol Exxon Chemical s trade name for its metallocene catalyst polymerization gas-phase processing system, eyebolt See mold eyebolt and hole, eye magnification See macroscopy. 

The different polymerization classes discussed above can be implemented in several ways bulk polymerization, solution polymerization, gas-phase polymerization, slurry polymerization, suspension polymerization and emulsion polymerization. 

Bulk or mass polymerization" Gas-phase pol3mierization Precipitation polymerization Suspension polymerization Microsuspension polymerization Dispersion polymerization Emulsion polymerization Miniemulsion polymerization Microemulsion polymerization... 

Garcia-Franco and Mead [142] proposed the use of the parameters of Eq. 5.65 to describe the behavior of polyethylenes prepared by means of anionic polymerization, gas-phase metallocene catalysis, and Ziegler-Natta catalysis. They reported that Eqs. 5.67 gave a good fit of their data and suggested that it is valid for all linear, flexible polymers with monomodal molecular weight distributions except in the terminal zone. They found that except in the terminal zone it provides a representation of the data that is similar to that given by the double-reptation model. They... 

Polymerization in the Gas Phase. Many polymerization catalysts can be adapted for use in the gas phase. A gas-phase reactor contains a bed of small PE particles that is agitated either by a mechanical stirrer or by employing the fluidized-bed technique. These processes are economical because they do not requite solvent tecitculation streams. 

AH technologies employed for catalytic polymerization processes in general are widely used for the manufacture of HDPE. The two most often used technologies are slurry polymerization and gas-phase polymerization. Catalysts are usuaHy fine-tuned for a particular process. 

Processes for HDPE with Broad MWD. Synthesis of HDPE with a relatively high molecular weight and a very broad MWD (broader than that of HDPE prepared with chromium oxide catalysts) can be achieved by two separate approaches. The first is to use mixed catalysts containing two types of active centers with widely different properties (50—55) the second is to employ two or more polymerization reactors in a series. In the second approach, polymerization conditions in each reactor are set drastically differendy in order to produce, within each polymer particle, an essential mixture of macromolecules with vasdy different molecular weights. Special plants, both slurry and gas-phase, can produce such resins (74,91—94). 

Typical heterogeneous Ziegler catalysts operate at temperatures of 70— 100°C and pressures of 0.1—2 MPa (15—300 psi). The polymerization reactions are carried out ia an iaert Hquid medium (eg, hexane, isobutane) or ia the gas phase. Molecular weights of LLDPE resias are coatroUed by usiag hydrogea as a chain-transfer ageat. 

Eluidized-bed reactors are highly versatile and can accommodate many types of polymerization catalysts. Most of the catalysts used for LLDPE production are heterogeneous Ziegler catalysts, in both supported and unsupported forms. The gas-phase process can also accommodate supported metallocene catalysts that produce compositionaHy uniform LLDPE resins (49—51). 

Gas-phase polymerization of propylene was pioneered by BASF, who developed the Novolen process which uses stirred-bed reactors (Fig. 8) (125). Unreacted monomer is condensed and recycled to the polymerizer, providing additional removal of the heat of reaction. As in the early Hquid-phase systems, post-reactor treatment of the polymer is required to remove catalyst residues (126). The high content of atactic polymer in the final product limits its usefiilness in many markets. 

Polypropylene. One of the most important appHcations of propylene is as a monomer for the production of polypropylene. Propylene is polymerized by Ziegler-Natta coordination catalysts (92,93). Polymerization is carried out either in the Hquid phase where the polymer forms a slurry of particles, or in the gas phase where the polymer forms dry soHd particles. Propylene polymerization is an exothermic reaction (94). 

Most commercial processes produce polypropylene by a Hquid-phase slurry process. Hexane or heptane are the most commonly used diluents. However, there are a few examples in which Hquid propylene is used as the diluent. The leading companies involved in propylene processes are Amoco Chemicals (Standard OH, Indiana), El Paso (formerly Dart Industries), Exxon Chemical, Hercules, Hoechst, ICl, Mitsubishi Chemical Industries, Mitsubishi Petrochemical, Mitsui Petrochemical, Mitsui Toatsu, Montedison, Phillips Petroleum, SheU, Solvay, and Sumimoto Chemical. Eastman Kodak has developed and commercialized a Hquid-phase solution process. BASE has developed and commercialized a gas-phase process, and Amoco has developed a vapor-phase polymerization process that has been in commercial operation since early 1980. 

Direct Oxidation of Propylene to Propylene Oxide. Comparison of ethylene (qv) and propylene gas-phase oxidation on supported silver and silver—gold catalysts shows propylene oxide formation to be 17 times slower than ethylene oxide (qv) formation and the CO2 formation in the propylene system to be six times faster, accounting for the lower selectivity to propylene oxide than for ethylene oxide. Increasing gold content in the catalyst results in increasing acrolein selectivity (198). In propylene oxidation a polymer forms on the catalyst surface that is oxidized to CO2 (199—201). Studies of propylene oxide oxidation to CO2 on a silver catalyst showed a rate oscillation, presumably owing to polymerization on the catalyst surface upon subsequent oxidation (202). 

Catalyst Development. Traditional slurry polypropylene homopolymer processes suffered from formation of excessive amounts of low grade amorphous polymer and catalyst residues. Introduction of catalysts with up to 30-fold higher activity together with better temperature control have almost eliminated these problems (7). Although low reactor volume and available heat-transfer surfaces ultimately limit further productivity increases, these limitations are less restrictive with the introduction of more finely suspended metallocene catalysts and the emergence of industrial gas-phase fluid-bed polymerization processes. 

EPR and EPDM have been made by either solution or emulsion polymerization processes. More recently a new process involving gas-phase polymerization and metallocene catalysts promises to capture large shares of these markets. These new polymers will be especially attractive in automotive apphcations and wine and cable where theh favorable pricing should be welcome. 

The Phillips-type catalyst can be used in solution polymerization, slurry polymerization, and gas-phase polymerization to produce both high density polyethylene homopolymers and copolymers with olefins such as 1-butene and 1-hexene. The less crystalline copolymers satisfy needs for materials with more suitable properties for certain uses that require greater toughness and flexibiUty, especially at low temperatures. 

A more recent development in ethylene polymerization is the simplified low pressure LDPE process. The pressure range is 0.7—2.1 MPa with temperatures less than 100°C. The reaction takes place in the gas phase instead of Hquid phase as in the conventional LDPE technology. These new technologies demand ultra high purity ethylene. 

The low-pressure gas-phase dehydrohalogenation of iV-chloroazetidine (270) using potassium t-butoxide supported on silica gives the parent 1-azetine (2) in excellent yield (81JA468>. This can be trapped at -196 °C, but rapidly undergoes polymerization at room temperature cf. Section 5.09.4.2.2). The 2-phenyl analogue of (2) can be prepared via a similar route (71IZV893). 

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