Polypropylene

Overview Polypropylene remains one of the fastest growing propylene from upstream refinery and petrochemical
polymers, with historic and forecasted demand growth units.
higher than GDP for the foreseeable future. Much of Lummus Technology also supplies the polymerization
this growth is attributed to polypropylene’s ability to catalysts required for the production of polypropylene.
displace conventional materials (wood, glass, metal) Our Ziegler-Natta based NHP® catalyst systems include
and other thermoplastics at lower cost and with a much the industry-standard NHP 401 series and the NHP
lower life-cycle energy consumption / CO2 equivalent 402 series, which utilize non-phthalate components as
emission. Lummus Technology licenses its NOVOLEN® internal donors. By applying NHP catalyst systems, our
gas phase polypropylene (PP) technology for the customers have a broad, flexible operational window
production of the full range of PP resins of homopolymer, for their NOVOLEN gas-phase PP plant covering
random copolymer, terpolymer, and impact copolymer standard, advanced and special polymer grades.
+ TPO. This reliable, versatile and environmentally clean
process makes products meeting the requirements of In addition to the NHP catalyst systems, the proprietary
even the most demanding applications. NOVOCENE® technology including a metallocene
based single-site catalyst, polymerization technology,
Lummus Technology is the only company to offer special polymer products (incl. ex-reactor melt-blown
technology integration between propylene and PP, resin with MFR up to 2,000 g/10min), and related
with four processes aimed at producing or maximizing services such as engineering can be supplied.

Advantages Process Features Process Benefits

Produces full range of PP products in two ■ Covers a variety of products for all markets/applications
identical reactors with state-of- the-art catalysts ■ Special products include bimodal grades for
biaxially oriented PP (BOPP), low melt flow
grades for pipes, and ultra-high (up to 50%)
rubber-content impact copolymers
Exceptional lot-to-lot and within-lot uniformity ■ Necessary for film and fiber applications, which
need consistent and tight specifications
Mechanically agitated gas-phase process ■ Among the lowest operating and maintenance
costs in the industry
• Fastest start-up times in the industry
• Agitation independent from powder
morphology, resulting in a unique product
portfolio
• No wall fouling and no shutdown
experienced due to lump formation
Low reactor volumes ■ Reduced monomer inventory results in
inherently safe process
■ Minimizes capital investment
Easy and highly reliable operation ■ Rapid grade changes generate minimal “off-
specification” product
■ Highest reported on-stream times in the industry
A solvent-free process with a unique vacuum ■ Very low taste and odor level for highly
degassing system in the extruder demanding applications
Two identical reactors without dedicated reactor ■ No unused parts or equipment maximizes ROI
for impact copolymers ■ Product mix can be adjusted to variable market
needs
■ Both reactors always in use
“Drop in” NOVOCENE® metallocene technology ■ Portfolio of superior PP products especially for
available fiber, film and injection molding applications
■ Most advanced metallocene catalysts with
highest activity currently available in the market
Performance Lummus Novolen Technology's PP process utilizes
Melt flow rate (MFR) 0.1 - 3,000 g/10 min.
Characteristics one or two identical vertical, stirred bed, gas-phase Isotacticity 90 - 99.5%+
NOVOLEN COMPPACT® reactors. Homopolymers and
random copolymers can be manufactured either in a Tensile modulus 400 - 2,400 MPa
single, parallel reactor or in cascade operation of two Tensile yield stress 10 - 40 MPa
reactors depending on the required capacity. Impact Impact strength No break at -30°C
copolymers require two reactors connected in series: Transparency (1 mm disc) Up to 96% for
in the first reactor, propylene homopolymer or random Ziegler/Natta PP
copolymer is polymerized; in the second reactor, rubber Up to 97.5% for
is added by polymerizing an ethylene/propylene metallocene PP
(rubber) mixture. The unique VRC® reactors is a Melting temperature 125 - 165°C
Versatile Reactor Concept (VRC) that allows switching Sealing initiation temperature (SIT) Down to 100°C
between the two operational modes and by this unique
process feature, it is possible to combine the broadest
product capability with minimum investment.

Process Flow Co-catalyst

Monomer Recycle
Stereomodifier
Diagram Single/Parallel mode

Catalyst Cascade mode

Compressor
Reactor Cooling

NOVOLEN Homopolymer / NOVOLEN Impact Powder

COMPPACT COMPPACT
Random Copolymer / Purge
Reactor 1 Reactor 2
Copolymer Random Silo
Copolymer /
Homopolymer

Condenser Condenser

Pump M M
Nitrogen
Reactor Cooling Gravity
Flow
Propylene Propylene

Ethylene Ethylene
Pelletizing
Hydrogen Hydrogen & Logistics

Process Propylene, ethylene, and any other desired monomer is compressed and recycled into the
Description comonomers are fed into the reactor(s). Hydrogen is reactors. The remaining part is returned to the
added to control the molecular weight. Polymerization upstream (or ISBL) olefins unit for recovery in order
conditions (temperature, pressure and reactant to remove accumulated propane. The polymer is
concentrations) are set by the polymer grade being flushed with nitrogen in a purge silo to strip it of
made. The reaction itself is exothermic and reactor residual propylene. The purge silo offgas is passed
cooling is achieved by flash heat exchange, where to a membrane unit to recover the remaining
liquefied reactor gas (mainly propylene) is mixed monomers and the nitrogen for reuse. The powder
with fresh feed and injected into the reactor. Flash is fed via gravity to the extruder, where it is then
evaporation of the liquid in the polymer bed ensures converted into pellets that incorporate a full range of
maximum heat exchange. well-dispersed additives.
The polymer powder is discharged from the reactor It is important to note that both reactors are always
and separated from the unreacted monomer in in use, regardless whether homopolymer, random
a discharge vessel at atmospheric pressure. The copolymers or impact copolymers are produced.

Contact Mail: BCohen@LummusTech.com | Phone: + 49 621 49 49 40 62 | www.NovolenTechnology.com

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10.01.20