Advancements in process technology and structure-property relationship-based design of high-density polyethylene has led to development of high-performance bimodal polyethylene grades suitable for large diameter thick-walled pressure pipe applications. These high-density bimodal products have enhanced design life, high pressure rating and sag resistance for fabrication of large diameter thick-walled pipe. Achieving optimal balance of these performance properties require controlled microstructural characteristics. The design characteristics are intricately influenced by catalyst type and process technology employed in resin manufacturing. In this study, we systematically establish correlations between microstructural characteristics of seven commercially available bimodal PE resins, produced using dual slurry or gas phase reactors, and their most relevant performance properties. We conducted comprehensive microstructural characterization of all samples using GPC-IR (high-temperature gel permeation chromatography coupled with an infrared composition detector), 13C NMR (nuclear magnetic resonance), TREF (temperature rising elution fractionation) and DSC (differential scanning calorimetry) techniques. Additionally, we measured mechanical, thermal, and rheological properties, focusing on crystallization kinetics, density, slow crack growth resistance (PENT and strain hardening modulus SHM) and low-frequency shear rheology of these products. Comparisons were made between key properties of interest, including slow crack growth resistance and low-frequency rheology (relevant for sag resistance), and microstructural characteristics. Theoretical and empirical correlations based on phenomenological models were employed for this analysis. The detailed study contributes to determining the critical levels of short and long chain branching, as well as molecular weight distribution characteristics essential to produce bimodal PE-4710 certifiable high-density polyethylene resins with low sag resistance. These design principles may serve as a foundation for the efficient design of reactor recipes and post-reactor modification processes, contributing to the evolution of pressure pipe polyethylene resin development and paving the way for design of next-generation pressure pipe grades.
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