2. Polyolefin Catalysts Development
National Petrochemical Company
Research and Technology Company
Polyolefin Catalysts Development
Dr. Ghafelebashi
Polymer Research Manager

3. Polymer Research Scope
1- Achievement new Know-how
2-Improvement of available know-how
in order to extend the boundaries of know-how
3- Development of NPC-RT know-how
4- Troubleshooting and solving problems
in production units in direction of increasing the quality and quantity of production

4. Overview of Polyolefin production in Iran
Up comming situation

5. NPC-R&T Polyolefin Catalysts Achievements
Science and technology Level
Process
NPC-RT
Catalyst
Pilot
Bench
Lab
Hostalene
SAC500
Spheripol
IRM
Spherilene
SAC518
SAC530
SAC512
SAC513
Innovene
IRSD
Mitsuie
IRZ
ACP
SAC511
Slurry
Metallocene

6. PP catalysts
Ziegler-Natta PP catalysts consumption in Iran : around 35 T/y
NPC-R&T researches in PP catalysts cover below fields
Support manufacturing
Internal donors
Synthesis of catalysts with competitive performance over imported catalysts

7. Ziegler Natta catalyst for PP : Internal DonorsID
Purity *(%)
Yiled* (%)
2,3-diisobutyl 1,3-dimethoxy propane 95 87
9,9-bismethoxy methyl flourene 98 60
Diethyl 2,3-diisopropylsuccinate 85

8. Ziegler Natta catalyst for PP : Catalyst
Adduct
NPC-RT Catalyst Microscopy Image
Polymer

9. Catalyst and Polymer Morphology
Commercial catalyst
NPC-RT catalyst
NPC-RT polymer 9 9

10. PP properties produced in Demo Plant
Property
Pilot Plant Product Properties
Commercial grade Properties
MFI (230/2.16) 18
Impact strength (J/g)
27.9
30.0
Yield Stress (MPa)
37.7
33.0
Yield Strain (%)
11.4
12.0
Break Stress (MPa) 20 -
Break Strain (%)
113
Capacity 250 Kg/h.

11. BFD of HDPE Demonstration Plant
capacity :150kg/h

12. Competitor catalysts in comparison with SAC 500
Catalyst system
Competitor 1
Competitor2
Competitor 3
Competitor 4
SAC 500
Yield (Kg PE/mmolTi)
0.6
1.8
5.4
15±3
18±3
% Ti3+
30-40
50-55
83-93
100
Application
Injection molding
Monofilament
Blow molding
Streched Tapes
Pipe PE80
Raffia
Pipe PE100

13. Morphology and Replication by PSD Analysis

14. Mechanical Properties
Microstructure and Properties of Tri&Bimodal HDPE for Pipe Application
GPC Results
Mechanical Properties
Break Strain (%)
Break Stress (MPa)
Yield Strain (%)
Yield Stress
(MPa)
Flexural Modulus (MPa)
Grade
280
16.3
10.1
24.3
960
93048
482
20.0
9.9
23.6
1015
93051

15. Hydrostatic test results (ISO 1167)
Pipe Performance Test of trimodal HDPE
Slow Crack Growth (SCG)
Analysis results
(ISO 13479)
SCG
(h)
Sample Lot No.
500
95048
95051
Hydrostatic test results (ISO 1167)
Hydrotest
(PE100: Stress = 5.5N/mm2: Temp = 80oC)
Sample Lot No.
>165 h
95048
95051

16. Comparison of Commercial Catalyst & SAC510 to Produce I4 Grade
NPC-RT & Basell
Comparison of Commercial Catalyst & SAC510 to Produce I4 Grade
SAC500
Competitor
Parameters
50-60 Kg poly/gr cat
20-25 Kg poly/gr cat
Catalyst Mileage
15-20 kg poly/gr cat. h
7-12 kg poly/gr cat. h
Activity
gr/Cm3
gr/Cm3
Bulk Density
9-11 g/10 min
MFI 190/5
1.3
Q=PH2/PC2
1.1%w
Wax Content
3.5 mj/mm2
Notched Impact
0.954
Density
5-6
PDI 16 16

17. Comparison of Commercial Catalyst& SAC510 to Produce EX3 Grade
HM5010T3N
(SAC500)
EX3
(competitor2)
(competitor1)
EX3 grades
33 kg poly/gr cat
18.8 kg poly/gr cat
6 kg poly/gr cat
Catalyst Mileage
gr/Cm3
gr/Cm3
Bulk Density final
0.43
0.45
MFI 190/5 final 25 28
FRR21.6/5
2.8-3
5-6
6-7
R1021 Q=PH2/PC2 %w
Wax Content 21 22 12
Notched Impact
0.9467
Density
261
160
PSD 20 13
IZOD (Iso 180E) 17

18. SSC Catalysts Families of ligand based SSC’s:

19. Ethylene-Antioxidant copolymerization using LTM catalysts
Ethylene-antioxidant copolymers may be used as highly efficient antioxidant master-batches possessing :
high thermo-oxidative stability
high compatibility with the polyolefin matrix
lower yellowing index compared to commercial antioxidants (Irganox 1010). HD
HD-
Masterbatch
HD-
Irganox1010
Their dendritic topology is clearly observed in AFM images.
Due to the high pressure response of LTM catalysts, besides their lower oxo-philicity compared to traditional Ziegler-Natta catalysts, they are good candidates for functional tailor-made polymers synthesis.
By decreasing ethylene pressure from 10 to 0.1 bar, the structure changes from linear to hyper-branch and dendritic architecture. The functional comonomer incorporation occurs at the branch ends and results in a core-shell like structure with the phenolic antioxidant moiety at the outside shell.

20. Thanks for your kind attention
This is my pleasure to research on Polyolefin fields as an interesting subject