Polypropylene development

Polypropylene (PP) is a major thermoplastic polymer. Although polypropylene did not take its position among the large volume polymers until fairly recently, it is currently the third largest thermoplastic after PVC. The delay in polypropylene development may be attributed to technical reasons related to its polymerization. Polypropylene produced by free radical initiation is mainly the atactic form. Due to its low crystallinity, it is not suitable for thermoplastic or fiber use. The turning point in polypropylene production was the development of a Ziegler-type catalyst by Natta to produce the stereoregular form (isotactic). 

Addipol A process for making polypropylene, developed and licensed by Himont, in the United States, and commercialized in 1988. See also Spheripol. 

GPP [Gas-phase polypropylene] A gas-phase process for making polypropylene. Developed by Sumitomo and first commercialized in 1990. 

LIPP-SHAC [Liquid polymerization of propylene with super high activity catalyst] A process for making polypropylene. Developed by the Shell Chemical Company and used at Pemis, The Netherlands Carrington, England and Geelong, Australia. 

Sherpol A process for making polypropylene, developed and licensed by Himont. 

Table 3.23 illustrates various methods of modifying polypropylene developed over the years [146-149]. They may be classified as ... 

Angenstein, B.L. Northern Petrochemical Co., A Marbting View of Polypropylene Developments, paper presented at Polypropylene Position and Potential Symposium, September, 1977. 

Fig. 6. Syndiotacticity index for syndiotactic polypropylene developed based on the relative intensity of the Raman active 300 and 400 cm" bands. Solid trans SPP-orinted O 75% racemic-aging time Flory RIS calculations o spp melt —V— calculated curve -t- sjmdiotacticity index.

Rexene A process for making polypropylene. Developed by Appryl, a joint venture of BP and Atochem. Chem. Br., 1996, 32(8), 7. 

Before the development of the Ziegler-Natta catalyst systems (Section 6 21) polymer ization of propene was not a reaction of much value The reason for this has a stereo chemical basis Consider a section of polypropylene... 

Pulp-like olefin fibers are produced by a high pressure spurting process developed by Hercules Inc. and Solvay, Inc. Polypropylene or polyethylene is dissolved in volatile solvents at high temperature and pressure. After the solution is released, the solvent is volatilised, and the polymer expands into a highly fluffed, pulp-like product. Additives are included to modify the surface characteristics of the pulp. Uses include felted fabrics, substitution in whole or in part for wood pulp in papermaking, and replacement of asbestos in reinforcing appHcations (56). 

Because of poor therm oform ability, there are relatively few apphcations for polypropylene sheet. New soHd-phase pressure forming (SPPE) techniques are under development for forming PP sheet. Polypropylene is used in coextmded sheet to some extent for food packaging containers. Glass-filled, wood-filled, or other modified polypropylene sheet materials are used in limited automotive apphcations. 

Other Films. Although commercially less important than polyethylenes and polypropylenes, a number of other plastic films are in commercial use or development for special appHcations, including ethylene—vinyl acetate, ionomer, and polyacrylonitrile [25014-41-9]. 

After the discovery of isotactic polymerisation of propylene using shconocene catalysts, stmcturaHy analogous hafnium catalysts produced from hafnium tetrachloride [13499-05-3] were found to produce high yields of high molecular weight polypropylene (55), but not enough to lead to commercial development. 

The electrowinning process developed by Ginatta (34) has been purchased by M.A. Industries (Atlanta, Georgia), and the process is available for licensing (qv). MA Industries have also developed a process to upgrade the polypropylene chips from the battery breaking operation to pellets for use by the plastics industry. Additionally, East Penn (Lyons Station, Pennsylvania), has developed a solvent-extraction process to purify the spent acid from lead—acid batteries and use the purified acid in battery production (35). 

The uses of spunbonded fabrics as coverstock in diapers and other personal absorbent devices will most likely remain unchallenged for the near term. Virtually any other nonwoven production method appears to be at a cost disadvantage opposite spunbonded polypropylene. There have been composite products developed from meltblown and spunbonded combinations, where areas of either improved hydrophobicity or hydrophilicity are desired. These products can be produced on-line at relatively low additional cost and offer high value to diaper manufacturers. Any competitive threat is likely to come from advances in film technology such as large improvements in perforated film used in segments of absorbent product appHcations, particularly sanitary napkins. 

In the United States, fibers and injection mol ding are the main appHcations for polypropylene (Table 8), followed by film. In Europe and Japan, injection mol ding appHcations predominate (Table 10). This market area is more likely to decline in economic recession, as consumers postpone purchases of apphances and automobiles. Film appHcations are important in both regions, but fibers are a much less important use for polypropylene in Japan than in other developed regions. The heavy use of polypropylene nonwovens in the manufacture of disposable diapers and similar products, and the wide use of polypropylene carpets in the United States, account for the greater consumption of fibers. 

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