THE REACTOR GRANULE TECHNOLOGY: THE ULTIMATE EXPANSION OF POLYPROPYLENE PROPERTIES?

Abstract

The progresses obtained in both catalyst performances and process technologies have made the continuous expansion of PP properties possible. The discovery of MgCl2-supported catalysts and the development of their controlled spherical morphology produced a real revolution in the catalytic-system performances. A series of definitive improvements in catalyst chemistry and an impressive increase in polymer productivity were allowed by the total control of the “replication” phenomenon of polymer generated by the parent catalyst. The Reactor Granule Technology started up with relevant consequences in terms of development of new polymer properties for new applications and new markets, and of new economic and versatile process technologies with the best environmental impact. Through this technology, it is also possible to use a mixed catalysis combining the heterogeneous Ziegler-Natta catalysts with homogeneous catalysts such as radicalic initiators, metallocenes and single site, and this possibility results in a dramatic development of the material potentials and properties. The recently conceived “Multizone Circulating Reactor Technology” represents the ultimate frontier in the polymeric materials science. It will allow the uniform phase homogenization of dissimilar materials generating novel polymeric alloys with an enormously expanded property/performance envelope.