Nova Chemicals (international) S.a.

Nova Chemicals Inc.

Stephen John Brown

Antonio Pietro Nicola

Fazle Sibtain

Linda Jean Santry

Sibtain, Fazle

Price, Terri A.

Cheluget, Eric

Kenneth Edward Taylor

Hamidreza Khakdaman

XiaoChuan Wang

Christopher John Brooke Dobbin

Tieqi Li

Niousha Kazemi

Monika Kleczek

Stephen Salomons

Mehdi Keshtkar

Shivendra K Goyal

Zengrong Zhang

Brian Molloy

Christopher Dobbin

Kenneth Taylor

Vinod Konaganti

Sepideh Kasiri

Bronwyn Gillon

Qinyan Wang

Peter Zoricak

Lawrence VanAsseldonk

Charles Carter

Eric Cheluget

P Scott Chisholm

Patrick Lam

Eric Clavelle

Celine Bellehumeur

Daniel Ward

Philippa Hocking

Michael Li

Terri A Price

Marzieh Ebrahimi

Donald Gary Hartlen

Soheil Sadeghi

Shivendra Goyal

Yves Lacombe

Renee Laurel Anseeuw

Geoffrey Harding

Graham Lee

Lawrence Van Asseldonk

Robert Van Asseldonk

Marcelo Yamane

Gurpreet Kooner

Marcia Pires Fortes Ferreira

Donald Hartlen

Terri Price

Disclosed herein are processes for producing blends of recycled polymeric material and virgin polyethylene. Post-consumer recycled plastic (PCR) can vary widely with respect to composition which includes mixtures of variable amounts of different polar and non-polar polymers such as polyethylene, polypropylene, ethylene vinyl alcohol, and polyamide. Mixing PCR and virgin polyethylene is inconsistent, partially due to variability, and frequently results in a final product with poor mechanical and optical properties. The process described herein of adding PCR to a solution polymerization process provides another option for blending PCR and virgin polyethylene that offers an ability to exert greater control on the properties of the final product, independent of the composition of the PCR.

Processes for producing polyethylene containing recycled non-polar polymeric material

Disclosed herein are polymerization processes where recycled polymeric material is fed to polymerization process to produce a blend of virgin polymer with recycled polymeric content.

Processes for producing polyethylene containing recycled polymeric material

This disclosure relates to ethylene interpolymer products comprising a Melt Flow-Intrinsic Viscosity Index value, MFIVI, of from ≥0.05 to ≤0.80; a first derivative of a melt flow distribution function, formula (I) at a loading of 4000 g, of from ≥−1.85 to ≤−1.51; a sum of unsaturation, SUM, from ≥0.047 to ≤0.100 unsaturations per 100 carbon atoms; and a residual QC catalytic metal of from ≥0.03 to ≤5 ppm of hafnium. Ethylene interpolymer products comprise at least two ethylene interpolymers. Ethylene interpolymer products are characterized by a melt index (I) from 0.3 to 500 dg/minute, a density from 0.855 to 0.975 g/cc and from 0 to 25 mole percent of one or more a-olefins. Ethylene interpolymer products have polydispersity, M/M, from 1.7 to 25; and CDBIvalues from 1% to 98%. These ethylene interpolymer products have utility in flexible as well as rigid applications.

Ethylene interpolymer products having unique melt flow-intrinsic viscosity (MFIVI) and high unsaturation

This disclosure relates to ethylene interpolymer product having intermediate branching. Intermediate branching was defined as branching that was longer than the branch length due to comonomer and shorter than the entanglement molecular weight (M). Intermediately branched ethylene interpolymer products were produced in a continuous solution polymerization process employing an intermediate branching catalyst formulation. Intermediately branched ethylene interpolymer products were characterized by a Non-Comonomer Index Distribution (NCID), a melt index from 0.3 to 500 dg/minute, a density from 0.858 to 0.965 g/cm, a polydispersity (M/M) from about 2 to about 25 and a CDBIfrom about 10% to about 98%. A method based on triple detection cross fractionation chromatography (3D-CFC) was disclosed to measure NCID.

Ethylene interpolymer products having intermediate branching

This disclosure relates to an improved continuous solution polymerization process wherein production rate is increased. Process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a first reactor to form a first ethylene interpolymer. Optionally, process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a second reactor forming a second ethylene interpolymer. The first and second reactors may be configured in series or parallel modes of operation. Optionally, a third ethylene interpolymer is formed in a third reactor, wherein a homogeneous catalyst formulation or a heterogeneous catalyst formulation is employed. In solution, the first, optional second and optional third ethylene interpolymers are combined, the catalyst is deactivated, the solution is optionally passivated and following a phase separation process an ethylene interpolymer product is recovered.

Manufacturing ethylene interpolymer products at higher production rate

This disclosure relates to ethylene interpolymer compositions and films prepared therefrom. Specifically: ethylene interpolymer products having: a dimensionless Long Chain Branching Factor, LCBF, greater than or equal to 0.001; a residual catalytic metal of from &#x2265;0.03 to &#x2264;5 ppm of hafnium, and; a dimensionless unsaturation ratio, UR, of from &#x2265;&#x2212;0.40 to &#x2264;0.06, wherein UR is defined by the following relationship; UR=(SC&#x2212;T)/T, where SCis the amount of a side chain unsaturation per 100 carbons and Tis amount of a terminal unsaturation per 100 carbons, in said ethylene interpolymer product. The disclosed ethylene interpolymer products have a melt index from about 0.3 to about 500 dg/minute, a density from about 0.855 to about 0.975 g/cc, a polydispersity (M/M) from about 1.7 to about 25 and a Composition Distribution Breadth Index (CDBI) from about 1% to about 98%.

Ethylene interpolymer products and films

This disclosure relates to ethylene interpolymer compositions and films prepared therefrom. Specifically: ethylene interpolymer products having: a dimensionless nonlinear rheology network parameter, &#x394;, greater than or equal to 0.01, satisfying 0.01&#xd7;(Z&#x2212;50)&#x2264;&#x394;&#x2264;0.01&#xd7;(Z&#x2212;60)inequality wherein Z is a normalized molecular weight defined by where Mand Mare the weight average and entanglement molecular weights, and; a residual catalytic metal of from &#x2265;0.03 to &#x2264;5 ppm of hafnium. The disclosed ethylene interpolymer products have a melt index from about 0.3 to about 500 dg/minute, a density from about 0.855 to about 0.975 g/cc, a polydispersity, from about 1.7 to about 25 and a Composition Distribution Breadth Index (CDBI) from about 1% to about 98%.

This disclosure relates to a continuous solution polymerization process wherein production rate is increased. Process solvent, ethylene, optional comonomers, optional hydrogen and a single site catalyst formulation are injected into a first reactor forming a first ethylene interpolymer. Process solvent, ethylene, optional comonomers, optional hydrogen and a heterogeneous catalyst formulation are injected into a second reactor forming a second ethylene interpolymer. The first and second reactors may be configured in series or parallel modes of operation. Optionally, a third ethylene interpolymer is formed in an optional third reactor, wherein an optional heterogeneous catalyst formulation may be employed. In a solution phase, the first, second and optional third ethylene interpolymers are combined, the catalyst is deactivated, the solution is passivated and following a phase separation process an ethylene interpolymer product is recovered.

Solution polymerization process

A continuous solution polymerization process is disclosed wherein at least two catalyst formulations are employed. A first homogeneous catalyst formulation is employed in a first reactor to produce a first ethylene interpolymer and a first heterogeneous catalyst formulation is employed in a second reactor to produce a second ethylene interpolymer. Optionally a third ethylene interpolymer is formed in a third reactor. The resulting ethylene interpolymer products possess desirable properties in a variety of end use applications, for example in film applications. A means for increasing the molecular weight of the first ethylene interpolymer is disclosed and/or a means for increasing the temperature of the first reactor, relative to a third homogeneous catalyst formulation. A means for reducing the (&#x3b1;-olefin/ethylene) weight ratio in the first reactor is disclosed and/or reducing the density of the first ethylene interpolymer, relative to a third homogeneous catalyst formulation.

Means for increasing the molecular weight and decreasing the density of ethylene interpolymers employing homogeneous and heterogeneous catalyst formulations

This disclosure relates to a continuous solution polymerization process where ethylene interpolymer products having an improved color index; for example, products having higher whiteness (Whiteness Index (WI)) and lower yellowness (Yellowness Index (YI)). Product color was improved by adjusting selected solution polymerization reaction conditions. The disclosed ethylene interpolymer products have improved color relative to comparative polyethylene compositions.

Ethylene interpolymers having improved color

An ethylene copolymer composition comprises: a first ethylene copolymer having a density of from 0.855 to 0.913 g/cm, a molecular weight distribution, M/Mof from 1.7 to 2.3, and a melt index, Iof from 0.1 to 20 g/10 min; a second ethylene copolymer having a density of from 0.875 to 0.936 g/cm, a molecular weight distribution, M/Mof from 2.3 to 6.0, and a melt index, Iof from 0.3 to 100 g/10 min; and optionally a third ethylene copolymer; where the first ethylene copolymer has more short chain branches per thousand carbon atoms than the second ethylene copolymer and the density of the second ethylene copolymer is equal to or higher than the density of the first ethylene copolymer. The ethylene copolymer composition has a density of from 0.865 to 0.913 g/cm; a melt index, Iof from 0.5 to 10 g/10 min; and a fraction eluting at from 90 to 105&#xb0; C., having an integrated area of greater than 4 weight percent in a CTREF analysis; and at least 0.0015 parts per million (ppm) of hafnium. Blown film made from the ethylene copolymer composition has a hot tack window (HTW) of at least 45&#xb0; C. (at a film thickness of about 2 mil) and a seal initiation temperature (SIT) of less than 95&#xb0; C. (at a film thickness of about 2 mil).

Ethylene copolymers and films with excellent sealing properties

A continuous solution polymerization process is disclosed wherein at least two homogeneous catalyst formulations are employed. A first homogeneous catalyst formulation is employed in a first reactor to produce a first ethylene interpolymer and a second homogeneous catalyst formulation is employed in a second reactor to produce a second ethylene interpolymer. Optionally a third ethylene interpolymer is formed in a third reactor. The resulting ethylene interpolymer products possess desirable properties in a variety of end use applications, for example in film applications. A means for increasing the molecular weight of the first ethylene interpolymer is disclosed and/or a means for increasing the temperature of the first reactor, relative to the third homogeneous catalyst formulation. A means for reducing the (&#x3b1;-olefin/ethylene) weight ratio in the first reactor is disclosed and/or reducing the density of the first ethylene interpolymer, relative to the third homogeneous catalyst formulation.

Means for increasing the molecular weight and decreasing the density of ethylene interpolymers employing mixed homogeneous catalyst formulations

This disclosure relates to a method and an apparatus for the delivery of a multi-component olefin polymerization catalyst to a polymerization reactor. The apparatus includes: a first catalyst component delivery conduit; a second catalyst component delivery conduit which is disposed within the first catalyst component delivery conduit; a first catalyst component mixing conduit; a third catalyst component delivery conduit which is disposed within the first catalyst component mixing conduit; a second catalyst component mixing conduit comprising an upstream section and a downstream section, the downstream section terminating within the polymerization reactor; and a diluent delivery conduit; the first and second catalyst component delivery conduits each being open-ended and co-terminating at the first catalyst component mixing conduit; the first catalyst component mixing conduit and the third catalyst component delivery conduit each being open-ended and co-terminating at the upstream section of the second catalyst component mixing conduit; and the diluent delivery conduit terminating at the downstream section of the second catalyst component mixing conduit.

Multistage catalyst injection system for an olefin polymerization reactor

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Calgary, Canada

Fazle Sibtain