Nova Chemicals (international) S.a.

Nova Chemicals S.a.

Monika Kleczek

Fazle Sibtain

Kenneth Edward Taylor

Stephen Salomons

Niousha Kazemi

Mehdi Keshtkar

Zengrong Zhang

Shivendra K Goyal

Vinod Konaganti

Sepideh Kasiri

Bronwyn Gillon

XiaoChuan Wang

Qinyan Wang

Peter Zoricak

Hamidreza Khakdaman

Brian Molloy

Lawrence VanAsseldonk

Charles Carter

Christopher Dobbin

Soheil Sadeghi

Shivendra Goyal

Stephen John Brown

Marzieh Ebrahimi

John Bayley

Kenneth Taylor

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

Large volumes of recycled polyethylenes are available for reuse. It would be desirable to prepare films from recycled polyethylene, however, the technical demands for many types of films can make this very difficult. Provided herein are films, for example, stretch films; shrink films; films for vacuum packages and films for dunnage packaging, that may be prepared from a blend of recycled polyethylene with 'virgin' polyethylene.

Films from recycled polyethylene

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%.

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

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

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

Growing community of inventors

Calgary, Canada

Monika Kleczek