Professional Documents
Culture Documents
ABSTRACT
Production of low-density polyethylene (LDPE) is undergoing the
kind of revolution not seen in the field since the discoveries by
Ziegler and Natta. Union Carbide has developed a unique and versa-
tile low-pressure, fluid-bed process (UNIPOL) that yields vastly
improved polyethylene resins, linear low-density polyethylenes
(LLDPE), at greatly reduced costs. Proprietary catalysts are key to
success of the UNIPOL process. Catalysts have an important effect
on productivity, polymer molecular weight, polymer molecular weight
distribution, copolymerization kinetics, and degree of stereoregu-
larity. Moreover the size, shape, and porosity (morphology) of the
catalyst particle play an important role in regulating the morphol-
ogy of the resultant polymer.
Today, Union Carbide and its more than twenty-five licensees are
operating or constructing polyethylene plants based on the UNIPOL
process in fifteen countries. By 1986 the combined capacity of UNI-
POL reactors will be sufficient to supply 25% of the world's total
demand for polyethylene. A recent development has been the produc-
tion of polypropylene by the UNIPOL process. This is a result of a
cooperative undertaking between Union Carbide and Shell Chemical,
USA, and combines for the first time a high activity catalyst with
simplicity and improved economics of gas-phase, fluidized-bed tech-
nology. A new polypropylene plant of 80,000 tons per year based on
the UNIPOL process is starting production in 1985 at Seadrift, Texas.
32 3
324 F.J. Karol a n d F.I. J a c o b s o n
PROCESS OPTIONS
The UNIPOL Process is available in three versions, i.e., Grass
Roots Plant, Waterborne Option, and Facility Modernization System
(FMS) (Figures 3 - 4 ) . The Waterborne Option involves construction of
UNIPOL LLDPE plants on ocean-going barges and delivered as turnkey
operations anywhere in the world accessible by deep water. The FMS
Option offers high-pressure LDPE producers a highly efficient way to
enter the LLDPE market immediately and minimizes investment costs by
making maximum use of existing plant facilities.
Waterborne ODtion
Union Carbide has completed the first "Waterborne" plant f o r
Ipako S.A., Argentina (Figure 5). The plant was constructed in the
shipbuilding facilities of Ishikawajima-Harima Heavy Industries near
Nagoya, Japan. It has a design capacity of 135,000 metric tons-per-
year of LLDPE. The plant was delivered to Ipako's waterside site in
Bahia Blanca, Argentina in late 1981. Construction of the plant
from keel-laying to shipyard commissioning was completed in just
eight months. The plant was in full commercial operation by Decem-
ber 1981--just 22 months from signing of the sales agreement. This
represents a reduction in construction time of at least a year from
that required for land-based construction of a traditional polyeth-
ylene plant.
FMS Ostion
UNIPOL FMS offers process and product technology equal to that
formerly possible only with a "grass roots" UNIPOL facility. North-
ern Petrochemical Company in Illinois chose FMS to upgrade its ex-
isting high-pressure facility to produce LLDPE. With this approach
326 F.J. K a r o l and F . I . Jacobson
MM T o n s / Y r .
LDPE LLDPE HDPE pp
1980 16.10 8.48 6.86
F i g u r e 1:
Fluid-Bed P l a n t at Seadrift, T e x a s for P o l y e t h y l e n e P r o d u c t i o n
32 7
reactor
Purge
Catalyst
Product
discharge
I UNIPOL F Y I
---
Figure 3: UNIPOL Facilities Modernization System (FMS)
I
UNIPOL Proceao
Low/Controiled
Investment Coat Investment Coat
Figure 5 :
Ipako Barge-Mounted Plant
Figure 6:
Union Carbide/Shell Chemical UNIPOL PP Plant at Seadrift, Texas
6Product
DIasharge
Purging/
Figure 7:
Schematic of Union Carbide/Shell Chemical UNIPOL PP Plant
C a t a l y s i s a n d the U n i p o l Process 333
IIomopo1vmer
High, Controllable Stereoregularity (I1 93-98%)
Broad Mi4 Range ((0.1 to >lo0 MF)
Random Copolvmers
Broad Range of Comonomer Content ((7%)
Not Limited to Ethylene
Broad hlW Range ((0.1 to > l o 0 MF)
4
TiCl4/Mg(OC2H5l2 11
TiCl4/MgCl2/Ethy1-p-Toluate PP
Chromium Composition
Cr03/Si02 + Modifiers PE
(C5H5I2Cr/SiO2 PE
Comonomer Incorporation
Comonomer incorporation rates are highly dependent on the nature
of the specific catalyst used to produce the copolymers. Improve-
ments in comonomer incorporation lead to higher comonomer effi-
ciency, and less dilution of the more reactive ethylene monomer.
Generally heterogeneous catalysts, based on titanium or chromium,
produce copolymers of broad compositional heterogeneity.
Morphology
Heterogeneous olefin polymerization catalysts can replicate
their morphology into the morphology of the polymer particles. The
catalyst particles act as a template for growth of the polymer par-
ticles. For high activity catalysts in olefin polymerization, the
average particle size of the polymer is about 15-20 times larger
than the size of the catalyst particle. Polymer particle growth can
be influenced by the specific catalyst activity, the nature of the
support matrix, the kinetic profile of the polymerization, and the
nascent polymer viscosity.
336 F.J. Karol and F.I. Jacobson
Isotactic Index
Addition of electron donors to high activity catalysts for poly-
propylene production raises the isotactic index of the polymer.
With many high activity catalysts, electron donors added to both the
titanium precursor and the aluminum alkyl cocatalyst provide a route
to polypropylene of very high isotactic content. In addition to
raising the isotactic index of polypropylene, the addition of elec-
tron donors to high activity catalysts provides a means of stabiliz-
ing catalyst crystallites and a route to accelerating the rate of
reaction of the magnesium/titanium compounds.
and the UNIPOL process will provide worldwide focus for future new
developments in the polyolefin arena.
REFERENCES
1. Abstracts of Papers Presented at Golden Jubilee Conference for
Polyethylene, 1933-1983, London, June 8-10, 1983.
2. Digest of Polymer Developments, Springborn Laboratories, Inc.,
N. Platzer, Ed., Confidential Publ., October 1984, by permission
o f Editor.
3 . Chem. Eng., 1979, @ (Dec. 3 1 , 80-85 (1979 Kirkpatrick Chemical
Engineering Achievement Award [Union Carbide Corp.].
4. Plastics Industry Europe, V o l . 8, No. 1 8 , End-September 1984.
5 . D. E. James, Paper Presented at 11th CDC International Business
Conference, Brussels, Belgium, April 17-18, 1985.
6. S. P. Sawin and C. J. Baas, Chem. Eng., 1985 (May 2 7 ) 42-43.
7. G. S . Cieloszyk and B. J. Garner, Paper Presented at Achema
1985, June 1 4 , 1985 in Frankfurt, W . Germany.
8. F. J. Karol, Chemtech, pp. 222-228 (April 1 9 8 3 ) .
9. F . J . Karol, Paper Presented at 189th National Meeting of Ameri-
can Chemical Society, "History of Polyolefins,' I Miami Beach,
Florida, April 28-May 3 , 1985.
10. F. J. Karol, Catal. Rev.-Sci. Ena., 26 ( 3 & 4 ) , 557-595 ( 1 9 8 4 ) .
11. R . D . Quirk, Ed., Transition Metal Catalyzed Polymerizations,
MMI Press Symposium Series, V o l . 4 , Parts A and B ( 1 9 8 3 ) .