Akzo Nobel N.v.

Teresa M Cheron

Paul K Hanna

Claude B Peterson

Gas phase process for forming polyketones

Polyketones can be formed in enhanced yield by conducting the polymerization of the carbon monoxide and olefin monomers used to form the polyketone in a gas phase polymerization process in the presence of a polyketone catalyst support which is substantially saturated with an amount of a liquid, non-polymerizable diluent which is effective in increasing the amount of polyketone formed over that which would be formed in the substantial absence of the diluent. The catalyst support which is substantially saturated with the liquid, non-polymerizable diluent is formed in a previous solution polymerization step in which the polyketone catalyst support is formed by polymerizing carbon monoxide and an olefin in the diluent comprising a catalyst so that the polymer which is formed adsorbs substantially all the diluent followed by continuation of the reaction substantially in the gas phase in the presence of the saturated polyketone catalyst support.

Polyketones can be formed in enhanced yield by conducting the polymerization of the carbon monoxide and olefin monomers used to form the polyketone in a gas phase polymerization process in the presence of an effective amount of a liquid, non-polymerizable diluent which is effective in increasing the amount of polyketone formed over that which would be formed in the substantial absence of the diluent. Preferably, the catalyst is supported on a high surface area support (e.g., a carbon monoxide-ethylene high surface area support). Hydrogen gas can be used to reduce the molecular weight and increase the bulk density and thermal stability of the polyketone product.

Growing community of inventors

Yonkers, NY, United States of America

Teresa M Cheron