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Step-growth or condensation polymerization is a stepwise reaction of bi or multifunctional monomers to form long-chain polymers. As all the monomers are reactive, most of the monomers are consumed at the early stages of the reaction to form small chains of reactive oligomers, which then combine to form long polymer chains in the late stages. Hence, the reaction has to proceed for a long time to achieve high molecular weight polymers.
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Polymers are classified as linear or branched on the basis of their chain architecture. The polymer chains in linear polymers have a long chain-like structure with minimal to no branching at all. Even if a polymer features large substituent groups on the monomer, which appear as branches to the skeleton, it is not considered a branched polymer. A branched polymer contains secondary polymer chains that arise from the main polymer chain. The branching occurs when the polymer growth shifts from...
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Polymerization in the Borstar Polypropylene Hybrid Process: Combining Technology and Catalyst for Optimized Product

Michiel F Bergstra1, Peter Denifl2, Markus Gahleitner2

  • 1Borealis Polymers N.V., Industrieweg 148, 3580 Beringen, Belgium.

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|November 11, 2022
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Summary
This summary is machine-generated.

This review details how the Borstar® process aligns technology, catalysts, and polymer structure to produce versatile isotactic polypropylene (iPP) homo- and copolymers. It highlights advancements in Ziegler-Natta catalysts for tailored iPP properties.

Keywords:
applicationcatalystnucleationpolymerization processpolypropylene

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Area of Science:

  • Polymer Science and Engineering
  • Catalysis
  • Materials Science

Background:

  • Producing tailored isotactic polypropylene (iPP) requires precise control over process technology, catalyst systems, and resulting polymer structures.
  • The Borstar® PP process, a hybrid liquid bulk and gas phase technology, offers a platform for achieving a wide range of iPP properties.

Purpose of the Study:

  • To demonstrate the alignment of process design, catalyst evolution, and polymer architecture in the Borstar® PP process.
  • To showcase the development of advanced multimodal random and multiphase copolymers.
  • To highlight key elements enabling a broad performance range in iPP production.

Main Methods:

  • Review of process design principles for the Borstar® PP hybrid technology.
  • Analysis of two generations of Ziegler-Natta catalyst development history.
  • Examination of copolymer design strategies for multimodal and multiphase structures.

Main Results:

  • Successful alignment of Borstar® process technology, Ziegler-Natta catalysts, and polymer structure enables production of diverse iPP materials.
  • Advancements in catalyst systems have facilitated the creation of sophisticated multimodal random and multiphase copolymers.
  • Key process and catalyst design elements have been identified as crucial for achieving a wide performance spectrum.

Conclusions:

  • The Borstar® PP process effectively integrates process technology, catalyst innovation, and polymer design to meet diverse customer demands for iPP.
  • Continued development in catalyst and process engineering holds potential for further expanding the capabilities of iPP production.
  • The review provides a comprehensive overview of achieving tailored iPP properties through a holistic approach.