A New Age of Innovation in Plastics Custom Polyolefins by Molecular - PowerPoint PPT Presentation

Custom Polyolefins A New Age of Innovation in Plastics Custom Polyolefins by Molecular Design: Dr. Jim Stevens Research Fellow The Dow Chemical Company JCS 12/02/2008 Page 1

Custom Polyolefins Polyethylene is Everywhere • Global demand exceeds 120 Billion pounds per year! • Growing at ~5% per year, faster growth in emerging economies Consumer Durables and Appliances Electrical and Electronics Food and Specialty Packaging Health and Hygiene Industrial and Consumer Packaging Pipes and Fittings Rigid Packaging JCS 12/02/2008 Page 2

Custom Polyolefins • Polyolefins are often considered first to use in any application • Excellent cost / performance value • Ease of recycling • Low energy to process and fabricate into films, parts, etc. • State of the Business in 1990 • Industry-wide overcapacity and low profitability • Producers discussing exit strategies such as mergers and outright sales of assets • Feeling that the big discoveries had already been made in this area • Feeling that the future belonged to those with low cost energy and feedstocks JCS 12/02/2008 Page 3

Custom Polyolefins Polymer Properties Determined by Catalysis Composition and molecular structure of each polymer chain determined by relative kinetic rates: catalyst Molecular structure of polymer chains determines bulk structure: Lamella: long sequences of ethylene units fold into crystallites Interfacial regions: “defects” are excluded into amorphous regions Tie molecule: Bridge more than one lamellar crystallite Catalysis Molecular Structure Bulk Structure Properties JCS 12/02/2008 Page 4

Custom Polyolefins The Evolution of Polyethylene: An Evolution of Catalysis! LDPE Radical mechanism (1933) Highly Branched: • High Temperature & Pressure • Excellent flow properties • Many reactions possible • Fast extrusion rates • Poor mechanical properties Linear Backbone: LLDPE Coordination catalysis (1950’s) • Flexible and tough • Low Temperature & Pressure • Chains are random lengths • Multiple catalytic sites • Nobel Prize Ziegler & Natta 1963 mPE “Single Site” catalysts (1990’s) Homogeneous Polymers: • Molecular catalysts • Chains are similar lengths • Ability to design control into the • Complete control of branching catalyst molecule We now have the tools to control molecular structure (and properties) with exquisite precision! JCS 12/02/2008 Page 5

Custom Polyolefins Two Important Discoveries in Basic Science Funded by DOE Office of Basic Energy Sciences • Prof. John Bercaw – Caltech • Prof. Tobin Marks – Northwestern • Poor catalyst but provided important • New idea for activators for catalysts new information on catalyst structure • Grant # DE-FG02-86 ER13511 • Grant # DE-FG03-85 ER13431 • Published in Journal of the American • Published in Organometallics Chemical Society JCS 12/02/2008 Page 6

Custom Polyolefins Dow Chemical Constrained Geometry Catalyst • Over 400 people involved in commercialization • >2 billion pounds/yr plastics and elastomers produced using INSITE catalyst • Extremely efficient process for making elastomers Constrained Geometry Catalyst (CGC) • Less energy, less environmental impact, higher utilization of resources From this To this JCS 12/02/2008 Page 7

Custom Polyolefins Polyolefin Products Launched Using New Catalysts AFFINITY* Polyolefin Plastomers 1993 ENGAGE* Polyolefin Elastomers 1994 ELITE* Enhanced Polyethylene 1996 NORDEL*IP EPDM (Solution Process EPDM) 1996 AFFINITY* Adhesives 1998 INDEX* Interpolymers 1999 Thermoplastic Polyolefins (TPO’s) 2000 INSPIRE* Performance Polymers 2000 Gas Phase Polyethylene (Sold to BP) 2001 Slurry Phase Polyethylene (Sold to Univation) 2001 DOW XLA* Elastic Fibers 2002 NORDEL* MG EPDM (Gas Phase EPDM) 2002 VERSIFY* Propylene Plastomers and Elastomers 2004 INFUSE* Olefin Block Copolymers 2007 JCS 12/02/2008 Page 8

Custom Polyolefins Polyolefins are now bio-polymers! Bio-Ethanol to Polyethylene CO 2 350 kT of LLDPE (700 MM lbs) � 120,000 hectares of sugar cane in Brazil (450 square miles) � Recyclable plastic (CO 2 fixation) � Cheaper than many fossil sources � Lower capital footprint � 8% of Dow LLDPE capacity � � Walled off from oil volatility JCS 12/02/2008 Page 9

Custom Polyolefins Manipulating Light with Self-Assembled Polyolefins 70 60 50 % Reflectance 40 30 20 10 0 350 400 450 500 550 600 650 700 Wavelength, nm White Plate Black Plate Clear Glass SampleA SampleA SampleA Reflected light Reflected light Transmitted Light on solid white plate on solid black plate thru clear glass plate JCS 12/02/2008 Page 10

Custom Polyolefins Everyday Products Using INSITE * Technology • Car bumpers, belts, window seals, and hoses • Athletic shoes ‡ shoes • Crocs • “Plastic” wine corks • Electrical wire jackets • “Comfort-stretch” clothing • Roofing membranes • Food packaging * Trademark of The Dow Chemical Company ‡ Trademark of Crocs, Inc. JCS 12/02/2008 Page 11