Vinícius Galhard Grassi is the leader of polymer research at Braskem SA, a leading global chemical and petrochemical company and currently the largest producer of thermoplastic resins in the Americas. He holds a master’s degree in materials science and a doctorate in chemistry from Universidade Federal do Rio Grande do Sul (Brazil) and completed a short assignment at the Max Planck Institute for Polymer Research. Having held different positions at petrochemical companies, he has over 18 years of experience in the research and development of polyolefins and styrene-based polymers, from conception and lab tests to industrial scale-up, processing, advanced characterization, introduction, and market consolidation. Vinícius Galhard Grassi is the leader of polymer research at Braskem SA, a leading global chemical and petrochemical company and currently the largest producer of thermoplastic resins in the Americas. He holds a master’s degree in materials science and a doctorate in chemistry from Universidade Federal do Rio Grande do Sul (Brazil) and completed a short assignment at the Max Planck Institute for Polymer Research. Having held different positions at petrochemical companies, he has over 18 years of experience in the research and development of polyolefins and styrene-based polymers, from conception and lab tests to industrial scale-up, processing, advanced characterization, introduction, and market consolidation. Polymer scientists have been successfully keeping conventional polymers such as polyolefins and styrene-based polymers at the frontier of science by constantly stretching the performance boundaries. For this purpose, scientists have used a combination of tools, including new polymerization methods, new catalysts and co-monomers (from fossil and renewable sources), peroxides and reactor designs, new architectures, polymer modification during processing or by reactive extrusion, and new advanced characterization techniques. In addition to efforts focused on stretching the performance of these conventional polymers, the development of tools such as high-throughput experimentation, multiscale simulation, and machine-learning techniques aims to accelerate the research and development (R&D) of conventional polymers. Although scientists have been playing with the same monomers over the last few decades, the approach is always evolving. The technology has successfully transitioned from lab to market, establishing a clear reference for technology scale-up from grams to thousands of tons while also delivering new grades to fulfill specific customer needs. It is because of this constantly evolving combination of methods and approaches, especially for polyolefins, that these conventional polymers are truly old dogs with new tricks. All these technical efforts have been driven by a consistent commercial demand, wherein intellectual property plays a key role in supporting business strategies. It’s an almost perfect combination of technology push and market pull. Although in-reactor approaches are the preferred route for polymer R&D, post-reactor modification is an exciting alternative for adding special attributes to conventional polymers. This route can overcome some in-reactor restrictions such as catalyst poisoning by chemicals or a lack of economic feasibility due to low production volume. For polyolefins in particular, some nice examples of industrial success are the grafting of polar molecules onto polyethylene and polypropylene with the use of peroxide to increase adhesion or compatibility with polar polymers and high-melt-strength polypropylene for foam applications. Post-reactor modification, like reactive extrusion, is still underutilized as a route for obtaining conventional polymers with improved properties and specific characteristics. This approach has the potential to decrease the translation time from the lab to the market, thus decreasing the R&D expenses. The primary challenge in reactive extrusion technology is controlling the reaction within the very short processing time and complex fluid environment. An additional complication results from the difficulty in accurately characterizing the degree and location of modification when we consider the different mobility of short and long polymer chains. After decades of research on conventional polymers, many combinations of methods and approaches still require exploration, and new variables are constantly evolving. Areas such as artificial intelligence, machine learning, and 3D printing present exciting new technical opportunities; indeed, new tricks are emerging. Catalyst: Advancing Polymer Science by Revisiting Known PlasticsOlsen et al.ChemMay 10, 2018In BriefBradley Olsen earned his PhD in chemical engineering at the University of California, Berkeley, and is an associate professor in the Department of Chemical Engineering at MIT. Since December 2009, he has led a research group in the area of polymer and biopolymer science. Bryan Boudouris earned his PhD in chemical engineering at the University of Minnesota and is the Robert and Sally Weist Associate Professor in the Davidson School of Chemical Engineering and Department of Chemistry at Purdue. His team focuses on the polymer chemistry, polymer physics, and end-use application of macromolecules for energy and clean-water applications. Full-Text PDF Open Archive
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