PP Resin Pelletizing

Processes
Background and History:
The history of polypropylene began in 1954 when a German chemist
named Karl Rehn and an Italian chemist named Giulio Natta first
polymerized it .Figure 1 Italian chemist .[1]

Commercial production of polypropylene began in 1957 with

Hercules Incorporated, Montecatini and Farbwerke Hoechst AG. ICI Figure 1. Italian chemist Giulio Natta

produced polypropylene resin as Propathene in 1954. Natta and

Ziegler were awarded the Nobel Prize for Chemistry in 1963 in
recognition of their work on "Ziegler-Natta" catalysts.[2]
Introduction:
Polypropylene (PP) is a typical commodity plastic and has been widely used in many application
fields including packaging films, industrial components and miscellaneous goods, due to its
excellence in properties such as stiffness, heat resistance and process ability in addition to light
weight material density and also a relatively low price [3]. Polypropylene (PP) has the physical
characteristics of a low specific gravity, rigidity, heat resistance and superior workability. In
addition, since it is comparatively low in cost, it is used in a variety of applications, such as films,
industrial components for automobiles, furniture, etc., and miscellaneous goods. It has been
more than 50 years since 1954, when G. Natta et al. of Italy were successful in synthesizing high
molecular weight, highly crystalline PP,1) and the total worldwide demand for PP has currently
reached an amount of approximately 47 million tons (prediction for 2008). [4].
Uses and Market Data:
Polypropylene's (PP) intrinsic properties of high stiffness, good tensile strength and inertness
toward acids, alkalis and solvents, plus its traditional cost advantage over other thermoplastic
polymers, has secured its position in a wide range of consumer and industrial products,
manufactured by several high-volume forming methods. In addition, its low density and earlier
cost advantage over other thermoplastic polymers made it suitable for applications that were
weight and cost conscious.
There are three forms of PP that can be produced isotactic, syndiotactic and atactic but
isotatic PP is the main form manufactured. Small amounts of other monomers (most
usually ethylene) can be added to make either random or block PP copolymers.

Injection moulding applications are the largest outlet for PP. Uses here include packaging,
parts for electronic and electrical appliances, caps and closures, toys, luggage and a variety of
household goods and miscellaneous products.

PP and its alloys have become the plastic of choice in the automobile market where it can
provide substantial weight savings.[5]
Production:
The global polypropylene (PP) market is the second largest polymer business in the world
making up more than 25% of global polymer demand. Global demand growth continues to be
led by emerging economies, especially China. Global demand for polypropylene is expected to
increase to 120 mln tons by 2030 from 60 mln tons in 2015.[7] This market is highly dependent
on commodity prices, and has a large number of global and regional manufacturers.
Competition in this market is considered to be on one of the highest levels among other markets
of polymeric materials. PP prices have declined significantly and amounted to just USD1,028
per ton, as of November 2016.Figer 2

Figer2 Global PP prices, USD per ton (2010-2016)[6]

Source: Bloomberg, Samruk Kazyna
Production:
Largest exporters of PP include Saudi Arabia (12.9% of global exports), Belgium (9.7%),
Korea (9.3%) and US (8%). Figure 3

Figure 3 Largest exporters of polymers of propylene, incl. PP, USD th. (2008-
2015)[7]
Source: International Trade Center, Samruk Kazyna
Production:
China remains the largest global importer of propylene and other polymers of propylene
with USD6.9bln in imports. Europe is also a big market for PP with 2.5 mln tons imported in
2015. Figure4

Figure 4 Imports of polymers of propylene, incl. PP, USD th. (2008-2015)

Properties of polypropylene :

Table 1. Some properties of used different polymers[7]

PP Resin Pelletizing Processes
 gas
phase
Stirred

reactor

Discharge vessel

Purge vessel

Powder Silo
Vent
Process description
Solid catalyst is introduced to the reactor to kick-start the formation of polymer while this
happening a lot kete is created which is unfavorable in polymer formation so this heat needs
to be dissipated Once the polymer is made it is removed from the reactor through dipping
tubes where the polymer goes through the polymer gas separation process the start with
carrier gas where steam and additive are infused with polymer to deactivate the catalyst the
product is filled into a discharge vessel where unreacted monomer is recovered when all the
unreacted is extracted the polymer is then pumped out and goes into the purge vessel mix
nitrogen which is pumped into the purge vessel nitrogen helps stabilize the polymer and
removes any moisture and volatile materials the nitrogen also used to propel the powder to
the powder silo where awaits its last leg the extrusion and mixing process this starts by
feeding the plastic material along with water additive through a hopper into a barrel of the
extruder the polymer powder gradually melted .