US20170259458A1 - Process for preparing a polyolefin composition - Google Patents
Process for preparing a polyolefin composition Download PDFInfo
- Publication number
- US20170259458A1 US20170259458A1 US15/532,016 US201515532016A US2017259458A1 US 20170259458 A1 US20170259458 A1 US 20170259458A1 US 201515532016 A US201515532016 A US 201515532016A US 2017259458 A1 US2017259458 A1 US 2017259458A1
- Authority
- US
- United States
- Prior art keywords
- polyolefin
- hopper
- flow rate
- additives
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229920000098 polyolefin Polymers 0.000 title claims abstract description 285
- 239000000203 mixture Substances 0.000 title claims abstract description 81
- 238000004519 manufacturing process Methods 0.000 title description 4
- 239000000843 powder Substances 0.000 claims abstract description 127
- 239000000654 additive Substances 0.000 claims abstract description 119
- 239000008188 pellet Substances 0.000 claims abstract description 64
- 238000000034 method Methods 0.000 claims abstract description 52
- 230000002902 bimodal effect Effects 0.000 claims abstract description 17
- 238000005453 pelletization Methods 0.000 claims abstract description 10
- 238000002844 melting Methods 0.000 claims abstract description 6
- 230000008018 melting Effects 0.000 claims abstract description 6
- 238000002156 mixing Methods 0.000 claims description 28
- 238000003860 storage Methods 0.000 claims description 17
- 229920000642 polymer Polymers 0.000 claims description 16
- 238000006116 polymerization reaction Methods 0.000 claims description 16
- -1 polyethylene Polymers 0.000 claims description 15
- 239000004698 Polyethylene Substances 0.000 claims description 14
- 229920000573 polyethylene Polymers 0.000 claims description 14
- 239000007787 solid Substances 0.000 claims description 14
- 239000006229 carbon black Substances 0.000 claims description 9
- 230000000379 polymerizing effect Effects 0.000 claims description 8
- 230000005484 gravity Effects 0.000 claims description 6
- 238000007599 discharging Methods 0.000 claims description 4
- 229920001903 high density polyethylene Polymers 0.000 claims description 4
- 239000004700 high-density polyethylene Substances 0.000 claims description 4
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 3
- 239000002245 particle Substances 0.000 description 13
- 230000000996 additive effect Effects 0.000 description 10
- 150000001336 alkenes Chemical class 0.000 description 8
- 239000003054 catalyst Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 6
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 6
- 239000005977 Ethylene Substances 0.000 description 6
- 238000009826 distribution Methods 0.000 description 6
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 5
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical compound CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 3
- 239000011261 inert gas Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 239000002861 polymer material Substances 0.000 description 3
- XWJBRBSPAODJER-UHFFFAOYSA-N 1,7-octadiene Chemical compound C=CCCCCC=C XWJBRBSPAODJER-UHFFFAOYSA-N 0.000 description 2
- ZGEGCLOFRBLKSE-UHFFFAOYSA-N 1-Heptene Chemical compound CCCCCC=C ZGEGCLOFRBLKSE-UHFFFAOYSA-N 0.000 description 2
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 2
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- LPIQUOYDBNQMRZ-UHFFFAOYSA-N cyclopentene Chemical compound C1CC=CC1 LPIQUOYDBNQMRZ-UHFFFAOYSA-N 0.000 description 2
- 150000001993 dienes Chemical class 0.000 description 2
- 238000005227 gel permeation chromatography Methods 0.000 description 2
- 238000000265 homogenisation Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 238000010557 suspension polymerization reaction Methods 0.000 description 2
- OJOWICOBYCXEKR-APPZFPTMSA-N (1S,4R)-5-ethylidenebicyclo[2.2.1]hept-2-ene Chemical compound CC=C1C[C@@H]2C[C@@H]1C=C2 OJOWICOBYCXEKR-APPZFPTMSA-N 0.000 description 1
- PRBHEGAFLDMLAL-GQCTYLIASA-N (4e)-hexa-1,4-diene Chemical compound C\C=C\CC=C PRBHEGAFLDMLAL-GQCTYLIASA-N 0.000 description 1
- BKWNZVQQIYSORG-UHFFFAOYSA-N 3-ethylbicyclo[2.2.1]hepta-1,3-diene Chemical compound C1CC2=CC(CC)=C1C2 BKWNZVQQIYSORG-UHFFFAOYSA-N 0.000 description 1
- RMDKEBZUCHXUER-UHFFFAOYSA-N 4-methylbicyclo[2.2.1]hept-2-ene Chemical compound C1CC2C=CC1(C)C2 RMDKEBZUCHXUER-UHFFFAOYSA-N 0.000 description 1
- 241000217266 Ansonia Species 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000012685 gas phase polymerization Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- SJYNFBVQFBRSIB-UHFFFAOYSA-N norbornadiene Chemical compound C1=CC2C=CC1C2 SJYNFBVQFBRSIB-UHFFFAOYSA-N 0.000 description 1
- JFNLZVQOOSMTJK-KNVOCYPGSA-N norbornene Chemical compound C1[C@@H]2CC[C@H]1C=C2 JFNLZVQOOSMTJK-KNVOCYPGSA-N 0.000 description 1
- 239000002667 nucleating agent Substances 0.000 description 1
- RGSFGYAAUTVSQA-UHFFFAOYSA-N pentamethylene Natural products C1CCCC1 RGSFGYAAUTVSQA-UHFFFAOYSA-N 0.000 description 1
- 239000011990 phillips catalyst Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 150000003440 styrenes Chemical class 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- XBFJAVXCNXDMBH-UHFFFAOYSA-N tetracyclo[6.2.1.1(3,6).0(2,7)]dodec-4-ene Chemical compound C1C(C23)C=CC1C3C1CC2CC1 XBFJAVXCNXDMBH-UHFFFAOYSA-N 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Images
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- B29B7/00—Mixing; Kneading
- B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
- B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
- B29B7/38—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary
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- B29B9/00—Making granules
- B29B9/02—Making granules by dividing preformed material
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- B29B9/00—Making granules
- B29B9/02—Making granules by dividing preformed material
- B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
- B29B9/065—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion under-water, e.g. underwater pelletizers
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92009—Measured parameter
- B29C2948/92085—Velocity
- B29C2948/92104—Flow or feed rate
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92504—Controlled parameter
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2948/00—Indexing scheme relating to extrusion moulding
- B29C2948/92—Measuring, controlling or regulating
- B29C2948/92819—Location or phase of control
- B29C2948/92828—Raw material handling or dosing, e.g. active hopper or feeding device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/06—PE, i.e. polyethylene
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/06—PE, i.e. polyethylene
- B29K2023/0608—PE, i.e. polyethylene characterised by its density
- B29K2023/065—HDPE, i.e. high density polyethylene
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2507/00—Use of elements other than metals as filler
- B29K2507/04—Carbon
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
- C08F2500/18—Bulk density
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/08—Copolymers of ethene
Definitions
- the present disclosure relates to the field of chemistry. More specifically, the present disclosure relates to a process for continuously preparing a polyolefin composition made from or containing a bimodal or multimodal polyolefin and one or more additives. In particular, the present disclosure relates to a process for continuously preparing a polyolefin composition made from or containing a polyolefin and one or more additives, wherein the polyolefin is a bimodal or multimodal high density polyethylene.
- polyolefin compositions may contain additional substances. These additives can influence the properties of the polyolefin compositions, even when added in small quantities. In some processes, the additives are combined with polyolefins directly after their polymerization during the pelletizing step.
- Bimodal or multimodal polyolefins can be prepared in a cascade of two or more polymerization reactors which can have different polymerization conditions.
- the individual particles of the polyolefin powder obtained in such polymerization processes may vary widely in their composition. Accordingly, some processes seek to homogenize these polyolefins in the pelletizing step.
- a goal is to ensure that the plastics additives are uniformly distributed within the polymer. This uniformity includes an even homogenization throughout the polymeric material, the ratio of plastics additives to polyolefinic material, and the ratio between the different additives for the polyolefin pellets. Furthermore, it a goal is that the homogenization method be reliable and economic.
- the present disclosure provides a process for continuously preparing a polyolefin composition made from or containing a bimodal or multimodal polyolefin and one or more additives in an extruder device equipped with at least one hopper, wherein polyolefin pellets are prepared from the polyolefin composition in the extruder device, the process including the steps of
- the flow rate of the polyolefin powder is measured.
- the flow rate of the polyolefin pellets prepared in the extruder device is measured.
- the flow rate of the polyolefin powder or the flow rate of the polyolefin pellets is measured by a solids flow meter.
- the polyolefin powder is supplied from a storage vessel, into which the polyolefin powder is kept in free flowing state by a discharging aid.
- the polyolefin powder and the additives are first supplied to a mixing device, which mixes the polyolefin powder and the additives. Then, the mixture of polyolefin powder and the additives is transferred from the mixing device to the hopper, wherein (a) the flow rates of the additives are measured while being supplied to the mixing device and the flow rates of the additives supplied to the mixing device are adjusted in response to the measured flow rate of the polyolefin powder supplied to the mixing device or (b) the flow rates of the additives and the polyolefin powder supplied to the mixing device are adjusted in response to the measured flow rate of the polyolefin pellets.
- the mixing device is a paddle mixer containing two horizontally orientated counter-rotating shafts.
- the polyolefin powder is transferred from the storage vessel to the hopper by gravity.
- the polyolefin powder is obtained by polymerizing one or more 1-olefins in a cascade of at least two polymerization reactors.
- the polyolefin is a polyethylene
- the polyethylene is a high density polyethylene having a density determined according to ISO 1183 at 23° C. from about 0.945 to about 965 g/cm 3 .
- an additive is carbon black.
- the carbon black is fed in form of a carbon black masterbatch.
- the process additionally includes the following steps
- the extruder device is a continuous mixer with counter rotating and intermeshing double screw or the extruder device contains at least one co-rotating double screw extruder.
- FIG. 1 shows schematically an embodiment of a set-up for preparing a polyolefin composition in which the polyolefin powder and the additives are supplied directly to the hopper of the extruder device.
- FIG. 2 shows schematically an embodiment of a set-up for preparing a polyolefin composition in which the polyolefin powder and the additives are first supplied to a mixing device before being transferred to the hopper of the extruder device.
- the present disclosure provides a process for preparing a polyolefin composition made from or containing a bimodal or multimodal polyolefin and one or more additives.
- the polyolefins are obtained by polymerizing olefins, alternatively, by polymerizing 1-olefins, that are hydrocarbons having terminal double bonds, without being restricted thereto.
- the monomers are nonpolar olefinic compounds, including aryl-substituted 1-olefins.
- the 1-olefins are linear or branched C 2 -C 12 -1-alkenes, including linear C 2 -C 10 -1-alkenes such as ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene or branched C 2 -C 10 -1-alkenes such as 4-methyl-1-pentene, conjugated and nonconjugated dienes such as 1,3-butadiene, 1,4-hexadiene or 1,7-octadiene or vinylaromatic compounds such as styrene or substituted styrene.
- linear C 2 -C 10 -1-alkenes such as ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene or branched C 2 -C 10 -1-alkenes such as 4-methyl-1-
- the polyolefin is obtained by polymerizing mixtures of various 1-olefins.
- the olefins also include olefins in which the double bond is part of a cyclic structure which can have one or more ring systems.
- the cyclic-containing olefin is cyclopentene, norbornene, tetracyclododecene or methylnorbornene or dienes such as 5-ethylidene-2-norbornene, norbornadiene or ethylnorbornadiene.
- the polyolefin is obtained by polymerizing mixtures of two or more olefins.
- the process of the present disclosure is a process for preparing polyolefin compositions made from or containing polyolefins which were obtained by homopolymerization or copolymerization of ethylene or propylene.
- polyolefins which were obtained by homopolymerization or copolymerization of ethylene or propylene.
- propylene polymerization up to 40 wt. % of ethylene and/or 1-butene is used, based upon the total weight of the final copolymer.
- the process of the present disclosure refers to preparing a polyolefin composition made from or containing polyolefins obtained by homopolymerizing or copolymerizing ethylene.
- the polyolefin compositions is made from or contains polyethylenes in which ethylene is copolymerized with up to 40 wt. % of C 3 -C 8 -1-alkenes.
- the 1-alkene is 1-butene, 1-pentene, 1-hexene, 1-octene, or mixtures thereof.
- the ethylene is copolymerized with up to 20 wt. % of 1-butene, 1-hexene, or mixtures thereof.
- the process for making the polyolefin includes solution processes, suspension processes, and gas-phase processes.
- the process is a suspension polymerization.
- the process uses a suspension polymerization with loop reactors or stirred tank reactors.
- the process is a gas-phase polymerization.
- the process uses gas-phase fluidized-bed reactors or multi-zone circulating gas phase reactors. The polymerization can be carried out batchwise or continuously in two or more stages. In some embodiments, the process is continuous.
- the process of the present disclosure may be employed for preparing polyolefin compositions of many types of polyolefin polymers.
- the process of the present disclosure can be used for preparing polyolefin compositions made from or containing bimodal or multimodal polyolefins whereby the terms “bimodal” and “multimodal” refer to the modality of the molecular weight distribution.
- the polymers can be obtained from polymerizing olefins in a cascade of two or more polymerization reactors under different reaction conditions.
- the “modality” indicates how many different polymerization conditions were utilized to prepare the polyolefin, without regard to whether the modality of the molecular weight distribution can be recognized as separated maxima in a gel permeation chromatography (GPC) curve.
- the term multimodal can include bimodal.
- the polyolefin polymer can also have a comonomer distribution.
- the average comonomer content of polymer chains with a higher molecular weight is higher than the average comonomer content of polymer chains with a lower molecular weight.
- identical or very similar reaction conditions in the polymerization reactors of the reaction cascade can be used to prepare narrow molecular weight polyolefin polymers.
- the resulting multimodal polyolefins may contain individual polyolefin particles of the polyolefin powder that have composition that vary widely.
- the polymerization can be carried out using a variety of olefin polymerization catalysts.
- the polymerization can be carried out using Phillips catalysts based on chromium oxide, using titanium-based Ziegler- or Ziegler-Natta-catalysts, using single-site catalysts, or using mixtures of such catalysts.
- the polyolefins are obtained as powder that means in the form of small particles.
- the particles have a more or less regular morphology and size, depending on the catalyst morphology and size, and on polymerization conditions.
- the particles of the polyolefin powder have a mean diameter of from a few hundred to a few thousand micrometers.
- the mean particle diameter can be from about 300 to about 1600 ⁇ m.
- the mean particle diameter can be from about 100 to about 3000 ⁇ m.
- the polyolefin powders have a mean particle diameter of from about 150 to about 250 ⁇ m.
- the polyolefins for preparing the polyolefin compositions of the present disclosure are polyethylenes having an ethylene content of from about 50 to about 100 wt. %, alternatively from about 80 to about 100 wt. %, and alternatively from about 98 to about 100 wt. %, based upon the total weight of the polyethylene. Accordingly, the content of other olefins in the polyethylenes is from about 0 to about 50 wt. %, alternatively from about 0 to about 20 wt. %, and alternatively from about 0 to about 2 wt. %, based upon the total weight of the polyethylene.
- the density of the polyethylene compositions obtained by the process of the present disclosure is from about 0.90 g/cm 3 to about 0.97 g/cm 3 .
- the density is in the range of from about 0.920 to about 0.968 g/cm 3 and alternatively in the range of from about 0.945 to about 0.965 g/cm 3 .
- the density is determined according to DIN EN ISO 1183-1:2004, Method A (Immersion) with compression molded plaques of 2 mm thickness which were pressed at 180° C., 20 MPa for 8 minutes with subsequent crystallization in boiling water for 30 minutes.
- the melt flow rate MFR 21.6 at 190° C. under a load of 21.6 kg of the polyethylene compositions, determined according to DIN EN ISO 1133:2005 condition G is from about 1 g/10 min to about 80 g/10 min, alternatively from about 2 g/10 min to about 50 g/ 10 min and alternatively from about 5 g/10 min to about 25 g/10 min.
- the polyolefin compositions are prepared by combining the polyolefins with one or more additives.
- the additives are uniformly distributed within the polyolefin.
- the types of additives for preparing polyolefin compositions are antioxidants, light stabilizers, acid scavengers, lubricants, processing aids, antiblocking agents, slip agents, antistatics agents, antifogging agents, pigments or dyes, nucleating agents, flame retardants or fillers.
- several additives are added to the polyolefin compositions.
- the multiple additives can be different types of additives.
- several representatives of one type of additive are added to a polyolefin composition.
- the additives are described in Hans Zweifel, Plastics Additives Handbook, 5th Edition, Kunststoff, 2001 (incorporated herein by reference).
- one of the additives is carbon black.
- the carbon black is supplied to the hopper of the extruder device in form of a carbon black masterbatch.
- the process of the present disclosure is carried out using an extruder device equipped with at least one hopper.
- the hopper receives material to be fed to the extruder device.
- the material is then transferred from the hopper into the extruder device.
- the extruder device of the present disclosure is equipped with at least one hopper to which the polyolefin powder and at least one additive are supplied.
- the extruder device can be equipped with one or more additional hoppers for feeding additional materials to the extruder device.
- the extruder device applies heat and mechanical energy to the mixture of polyolefin powder and additives.
- the extruder device is an extruder or continuous mixer. These extruders or mixers can be single- or two-stage machines which melt and homogenize the polyethylene composition.
- the extruders are pin-type extruders, planetary extruders or co-rotating disk processors.
- the extruders are combinations of mixers with discharge screws and/or gear pumps.
- the extruders are screw extruders.
- the extruders are constructed as a twin-screw machine.
- the extruder devices are twin-screw extruders and continuous mixers with discharge elements.
- the extruder devices are continuous mixers with counter rotating and intermeshing double screw or the extruder device includes at least one co-rotating double screw extruder.
- Machinery of this type is manufactured by Coperion GmbH, Stuttgart, Germany; KraussMaffei Berstorff GmbH, Hannover, Germany; The Japan Steel Works LTD., Tokyo, Japan; Farrel Corporation, Ansonia, USA; or Kobe Steel, Ltd., Kobe, Japan.
- the extruder devices are further equipped with units for pelletizing the melt, such as underwater pelletizers.
- the process disclosed herein supplying the polyolefin in form of a polyolefin powder and the additives to one hopper and then transferring the combined material into the extruder device for melting and further mixing.
- the polyolefin powder is supplied from a storage vessel, alternatively, a storage vessel having a conical bottom.
- the storage vessel for supplying the polyolefin powder is equipped with a discharging aid which keeps the polyolefin powder in free flowing state.
- the discharging aid is the introduction of an inert gas into the bottom to the storage vessel.
- the inert gas is nitrogen.
- the inert gas is introduced into a conical bottom of the storage vessel.
- the polyolefin powder is transferred from the storage vessel to the hopper by gravity.
- the additives are supplied from dedicated storage vessels for the additives. In other embodiments, the additives are supplied directly from transport containers such as big bags.
- the additives which are utilized for preparing the polyolefin compositions of the present disclosure can be supplied in solid form, liquid or dissolved form. In some embodiments, when the additives are supplied in solid form, the additives are in the form of small particles. In some embodiments, the additives are supplied individually, in one or more mixtures made from or containing some of the selected additives, or as a mixture of the additives. In some embodiments, the additives are supplied in form of solid particles.
- the prepared polyolefin compositions is made from or contains a polyolefin and one or more additives.
- the prepared polyolefin compositions is made from a recipe which identifies the nature of the employed polyolefin powder, the nature of the additives, their number, their quantity and their ratio.
- the polyolefin compositions is made from or contains primarily the polyolefin.
- the polyolefin portion of the prepared polyolefin compositions is from about 80 to about 99.98 wt. %, alternatively from about 95 to about 99.95 wt. %, and alternatively from about 98 to about 99.9 wt. %, based upon the total weight of the polyolefin composition.
- the amount of polyolefin powder supplied to the hopper of the extruder device is regulated by a feeding device.
- the feeding device is a rotary valve or a screwfeeder. By varying the speed of the feeding device, the amount of polyolefin powder supplied to the extruder device can be altered. In some embodiments, the speed of the feeding device is controlled by a controller in a way that the fed amount of polyolefin powder corresponds to a preselected set-point corresponding to the selected amount of the polyolefin in the polyolefin composition.
- the ratio of additives to polyolefin in the polyolefin composition is kept constant by adjusting the flow rates of the additives to the extruder device based on the supplied amount of polyolefin powder. In some embodiments, the ratio is maintained with high flow rates of polyolefin powder.
- the flow rate of the polyolefin pellets prepared in the extruder device is measured and the flow rate of the polyolefin powder to the extruder device is adjusted based on the amount of polyolefin pellets produced in the extruder device.
- the flow rate of the polyolefin pellets is measured on dried polyolefin pellets.
- the flow rate is measured downstream of an underwater pelletizer and a centrifugal drier.
- the flow rates of the additives supplied to the hopper are either kept constant at a pre-determined value and the ratio of additives to polyolefin in the polyolefin composition is controlled by solely adjusting the flow rate of the polyolefin powder supplied to the hopper or both the flow rate of the polyolefin powder and the flow rates of the additives supplied to the hopper are adjusted based on the actual amount of polyolefin pellets produced in the extruder device, alternatively employing different control characteristics for controlling the flow rates of the additives and for controlling the feed of polyolefin powder.
- the flow rate of the polyolefin powder supplied to the hopper or the flow rate of the polyolefin pellets prepared in the extruder device are measured by a solids flow meter.
- solids flow meters can use impact plate, measuring chute or Coriolis measuring technologies. Such solids flow meters are commercially available from Schenck Process, Whitewater, Wis., USA or Coperion K-Tron, Gelnhausen, Germany.
- the solids flow meter is equipped with a controller. This controller allows adjusting the speed of the feeding device, which supplies the polyolefin powder to the extruder, based on information regarding the supplied amount of polyolefin powder.
- the measured flow rate of the polyolefin powder supplied to the hopper or the measured flow rate of the polyolefin pellets can be used to adjust the flow rates of the additives supplied to the hopper.
- the controller of the solid flow meter transmits a signal, which is indicative of the flow rate of the polyolefin powder to the hopper to a computing unit such as a computer.
- the computing device continuously calculates set points for selected flow rates of additives to the hopper which set points reflect the amounts of polyolefin powder supplied to the extruder device.
- the process for preparing a polyolefin composition further includes the step of supplying polyolefin pellets to the hopper of the extruder device. This option permits further adding pelletized polymer material to the polyolefin composition. In some embodiments, these pelletized polymer material are added in amounts smaller than the polyolefin powder. In some embodiments, the pelletized polymer material are previously produced polyolefin compositions, which do not comply with specified property requirements, or transition materials, which were obtained in a polymerization while transitioning from one polyolefin grade to another. In some embodiments, the polyolefin pellets are supplied to the same hopper as the polyolefin powder and the additives.
- the flow rate of the polyolefin pellets to the hopper is adjusted based on the measured flow rate of the polyolefin powder supplied to the hopper or based on the measured flow rate of the polyolefin pellets.
- the computing device then continuously calculates a set point for selected flow rates of polyolefin pellets to the hopper.
- the combination of polyolefin powder and additives is transferred from the hopper into the extruder device and then molten and homogenized within the extruder device.
- the melt is thereafter passed to a pelletizing unit and there transformed into pellets.
- the polyolefin powder and the additives are first mixed and then supplied as mixture to the hopper of the extruder device.
- the polyolefin powder and the additives are supplied to a mixing device.
- the flow rates of the additives supplied to the mixing device are then adjusted in response to the flow rate of the polyolefin powder supplied to the mixing device.
- the flow rate of the polyolefin powder supplied to the mixing device is adjusted in response to the measured flow rate of the polyolefin pellets.
- mixing devices are paddle mixers including two horizontally orientated counter-rotating shafts. The shafts are equipped with paddles of an appropriate geometry.
- the rotating shafts move the composition of polyolefin powder and additives horizontally along the axis of the shafts and at the same time mix the components intensively.
- Such paddle mixers are commercially available from Kollemann GmbH, Adenau, Germany or J. Engelsmann AG, Ludwigshafen, Germany.
- the mixture of polyolefin powder and additives exits the mixing device at the end of the shafts and is then transferred to the hopper of the extruder device. In some embodiments, the transfer to the hopper of the extruder device occurs by gravity.
- FIG. 1 shows schematically an embodiment of a set-up for preparing a polyolefin composition.
- Polyolefin powder is provided via line ( 1 ) to a polyolefin powder storage vessel ( 2 ). Nitrogen is introduced into storage vessel ( 2 ) from the bottom via line ( 3 ). The polyolefin powder is supplied via line ( 4 ) to rotary valve ( 5 ) which is operated by a motor M. The polyolefin powder is then further transferred by gravity via line ( 6 ) to hopper ( 7 ) of extruder device ( 8 ) which is also operated by a motor M. By varying the speed of motor M of rotary valve ( 5 ), the flow rate of the polyolefin powder supplied to hopper ( 7 ) can be adjusted.
- Solid flow meter ( 9 ) measures the flow rate of the polyolefin powder to hopper ( 7 ), that is the amount of polyolefin powder delivered to hopper ( 7 ) per time unit.
- Solid flow meter ( 9 ) is equipped with a controller ( 10 ).
- Controller ( 10 ) sends a signal ( 11 ) to motor M of rotary valve ( 5 ) for adjusting the flow rate of the polyolefin powder if the flow rate measured by solid flow meter ( 9 ) differs from the targeted set point of the flow rate previously implemented in controller ( 10 ).
- Controller ( 10 ) also sends a signal ( 12 ), which is indicative of the flow rate of polyolefin powder from storage vessel ( 2 ) to hopper ( 7 ), to a computing unit ( 13 ).
- FIG. 1 shows two similar units including dosing devices ( 15 ) for feeding additives in particulate form to hopper ( 7 ).
- the process includes one or three or more additive feeding units.
- an additive or an additive mixture is provided via a line ( 14 ) to a dosing device ( 15 ) being operated by a motor M.
- Dosing devices ( 15 ) are capable of weighing the amount of the additive or additive mixture dosed into lines ( 16 ) through which the additives are supplied to hopper ( 7 ).
- Each dosing device ( 15 ) is equipped with a controller ( 17 ). Controllers ( 17 ) receive signals that indicate the amounts of additive dosed by respective dosing devices ( 15 ) into respective lines ( 16 ).
- the set points for the amounts of additives to be dosed are continuously calculated by computing unit ( 13 ) based on signal ( 12 ), which indicate the flow rate of polyolefin powder from storage vessel ( 2 ) to hopper ( 7 ), and based on a recipe for the polyolefin composition which recipe was previously entered into a computing unit ( 13 ).
- the polyolefin powder and the additives are supplied via lines ( 6 ) and ( 16 ) to hopper ( 7 ), wherein the polyolefin powder and the additives are brought into contact with each other.
- the combination of polyolefin powder and additives is then transferred into the extruder device ( 8 ) and therein molten and homogenized.
- the melt is conveyed within extruder device ( 8 ) to pelletizing unit ( 18 ) from which the pelletized polyolefin composition is withdrawn via line ( 19 ).
- the set-up shown in FIG. 1 further includes a unit for supplying polymer pellets to hopper ( 7 ).
- This unit has a pellet storage vessel ( 20 ), to which polymer pellets are provided via line ( 21 ).
- the polyolefin pellets are supplied via line ( 22 ) to rotary valve ( 23 ) which is operated by a motor M.
- the polyolefin pellets are then further transferred via line ( 24 ) to hopper ( 7 ) of extruder device ( 8 ).
- the amount of polyolefin pellets supplied to hopper ( 7 ) is given by the speed of motor M of rotary valve ( 23 ), which speed is set by computing unit ( 13 ) based on signal ( 12 ), indicating the flow rate of polyolefin powder from storage vessel ( 2 ) to hopper ( 7 ), and based on the recipe for the polyolefin composition which was previously entered into a computing unit ( 13 ).
- FIG. 2 shows schematically an embodiment of a set-up for preparing a polyolefin composition in which the polyolefin powder and the additives are first mixed in a mixing device ( 25 ) before being supplied to the hopper ( 7 ) of extruder device ( 8 ).
- the set-up for preparing a polyolefin composition shown in FIG. 2 is identical to that shown in FIG. 1 , except that the polyolefin powder and the additives are supplied via lines ( 6 ) and ( 16 ) to mixing device ( 25 ).
- the mixing device ( 25 ) is a paddle mixer including two horizontally orientated counter-rotating shafts.
- the mixture of polyolefin powder and additives is transferred by gravity from mixing device ( 25 ) to hopper ( 7 ) of extruder device ( 8 ) via line ( 26 ).
- a combination of polyolefin and additives can be transferred into the extruder device, thereby allowing a uniform distribution of additives throughout produced polymer pellets.
- a mixing device before supplying the components to the hopper of the extruder device, a more homogeneous distribution can be achieved even if the individual particles of the polyolefin powder employed for preparing the polyolefin compositions vary widely in their composition.
- selecting the flow rate of the polyolefin powder supplied to the extruder device as a parameter for adjusting the flow rates of additives allows feeding of the components of the polyolefin composition accurately at a constant ratio and facilitates consistent properties of the polyolefin composition due to the homogeneity of the additive distribution within the produced polyolefin compositions.
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PCT/EP2015/078473 WO2016087566A1 (en) | 2014-12-04 | 2015-12-03 | Process for preparing a polyolefin composition |
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US16/423,829 Active 2036-11-17 US11104036B2 (en) | 2014-12-04 | 2019-05-28 | Process for preparing a polyolefin composition |
US16/507,987 Active 2036-01-20 US10899041B2 (en) | 2014-12-04 | 2019-07-10 | Process for preparing a polyolefin composition |
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US16/507,987 Active 2036-01-20 US10899041B2 (en) | 2014-12-04 | 2019-07-10 | Process for preparing a polyolefin composition |
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US (4) | US20170259458A1 (ja) |
EP (2) | EP3186052B2 (ja) |
JP (2) | JP6411656B2 (ja) |
KR (2) | KR101997375B1 (ja) |
CN (2) | CN107000257B (ja) |
BR (2) | BR112017009533B1 (ja) |
RU (2) | RU2678264C2 (ja) |
SA (2) | SA517381557B1 (ja) |
WO (2) | WO2016087564A1 (ja) |
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WO2021168422A1 (en) * | 2020-02-20 | 2021-08-26 | Birla Carbon U S A., Inc. | Filler structure retention inpolymeric compositions |
EP4144518A1 (en) * | 2021-09-06 | 2023-03-08 | Kikusui Seisakusho Ltd. | Powdery material mixing and feeding system |
WO2023208664A1 (en) * | 2022-04-26 | 2023-11-02 | Basell Poliolefine Italia S.R.L. | Process for preparing a polyolefin composition |
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EP3450127A1 (en) | 2017-09-01 | 2019-03-06 | Basell Polyolefine GmbH | Process for preparing a polyolefin composition |
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- 2015-12-03 KR KR1020177016420A patent/KR101963061B1/ko active IP Right Grant
- 2015-12-03 US US15/532,016 patent/US20170259458A1/en not_active Abandoned
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- 2015-12-03 US US15/532,274 patent/US20170341266A1/en not_active Abandoned
- 2015-12-03 WO PCT/EP2015/078470 patent/WO2016087564A1/en active Application Filing
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