To produce polypropylene (PP) homopolymer, random copolymer and impact copolymer using the Innovene PP gas-phase process with proprietary 4th generation supported catalyst.
Catalyst in mineral-oil-slurry is metered into the reactor together with co-catalyst and modifier. The proprietary supported catalyst developed by INEOS has controlled morphology, super-high activity and very high sterospecifity. The resulting PP product is characterized by narrow particle size distribution, good powder flowability, minimum catalyst residues, noncorrosiveness, excellent color and low odor.
The horizontal stirred-bed reactor (1) is unique in the industry in that it approaches plug-flow type of performance, which contributes to two major advantages. First, it minimizes catalyst bypassing, which enables the process to produce very high-performance impact copolymer. Second, it makes product transitions very quick and sharp, which minimizes off-spec transition materials. The reactor is not a fluidized bed, and powder mixing is accomplished by very mild agitation provided by a proprietary-designed horizontal agitator. Monomer leaving the reactor is partially condensed (2) and recycled. The condensed liquid together with fresh makeup monomer is sprayed onto the stirred reactor powder bed to provide evaporative cooling (remove the heat of polymerization) and control the bed temperature. Uncondensed gas is returned to the reactor.
For impact copolymer production, a second reactor (4) in series is required. A reliable and effective gas-lock system (3) transfers powder from the first (homopolymer) reactor to the second (copolymer) reactor, and prevents cross contamination of reactants between reactors. This is critically important when producing the highest quality impact copolymer. In most respects, the operation of the second reactor system is similar to that of the first, except that ethylene in addition to propylene is fed to the second reactor. Powder from the reactor is transferred and depressurized in a gas/powder separation system (5) and into a purge column (6) for catalyst deactivation. The deactivated powder is then pelletized (7) with additives into the final products.
Products: A wide range of polypropylene products (homopolymer, random copolymer and impact copolymer) can be produced to serve many applications, including injection molding, blow molding, thermoforming, film, extrusion, sheet and fiber. Impact copolymer produced using this process exhibits a superior balance of stiffness and impact resistance over a broad temperature range.
Licensor: INEOS Technologies