Heterophasic Polypropylene Flowability via Silane Additive Coating
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Solution Overview
Problem
Heterophasic polypropylene (HECO) with high elastomeric content becomes sticky, leading to agglomeration and blockages in transfer lines and vessels, posing challenges in conveying and extrusion processes.
Innovation Solution
Surface coating of HECO with an additive after polymerization before conveying to other units in the polymerization facility, specifically at the outlet of the second reactor system, purge bin, feeder, or powder silo, to improve flowability and reduce stickiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high amounts of elastomeric material are used in heterophasic polypropylene to achieve high impact levels, then impact behaviour is improved, but the material becomes sticky and causes agglomeration and blockages in conveying systems
Solution Approach 1:
A silane-modified polyethylene additive is introduced as an intermediary substance that coats the surface of the sticky heterophasic polypropylene powder. This additive acts as a mediator between the elastomeric material and the conveying system components, reducing direct adhesion and friction. The additive forms a protective layer that prevents agglomeration and blockages while allowing the high elastomeric content to maintain its impact-enhancing properties.
Solution Approach 2:
The invention changes the surface properties of the heterophasic polypropylene powder by modifying its chemical composition through the addition of silane-modified polyethylene. This parameter change in surface chemistry reduces stickiness and improves flowability, enabling the material to be conveyed smoothly through processing equipment without agglomeration or blockages, while preserving the bulk impact behaviour.
2Strength
If high amounts of elastomeric material are used in heterophasic polypropylene to achieve high impact levels, then impact behaviour is improved, but the material causes sheeting in transfer lines, hoppers and vessels
Solution Approach 1:
The silane-modified polyethylene additive serves as a intermediary coating that facilitates smooth conveying operation. By reducing surface stickiness and friction, the additive enables the heterophasic polypropylene to flow freely through transfer lines, hoppers, and vessels without adhering to surfaces or forming sheets, thus improving ease of operation while maintaining high impact performance.
Solution Approach 2:
The invention modifies the surface parameters of the polymer powder through additive incorporation, changing its rheological properties to improve flowability. This parameter change enables the material to be handled and conveyed more easily through various processing equipment without causing sheeting or blocking, while the core elastomeric content preserves the high impact behaviour.
3Device complexity
If heterophasic polypropylene powder is conveyed through transfer lines and vessels without surface coating, then the process is simple, but the material agglomerates and blocks the system
Solution Approach 1:
The silane-modified polyethylene additive is applied to the heterophasic polypropylene powder surface before it enters the conveying system. This preliminary surface treatment prevents agglomeration and blockages from occurring during conveyance, ensuring reliable system operation. The additive is introduced at a point where it can effectively coat the powder particles before they encounter the transfer lines, hoppers, and vessels.
Solution Approach 2:
The silane-modified polyethylene acts as a protective intermediary layer between the heterophasic polypropylene and the conveying system components. This intermediary coating prevents direct contact and adhesion that would lead to agglomeration and blockages, ensuring reliable system operation without requiring complex modifications to the conveying infrastructure.
4Device complexity
If heterophasic polypropylene powder is conveyed without surface coating, then the conveying system remains simple, but sheeting occurs in the bottom of the purge bin, rotary feeder and conveying line
Solution Approach 1:
The silane-modified polyethylene additive serves as a surface intermediary that prevents sheeting in the purge bin, rotary feeder, and conveying line. By coating the heterophasic polypropylene powder particles, the additive reduces surface friction and adhesion to the conveying system surfaces, eliminating the sheeting problem without requiring complex modifications to the conveying infrastructure.
Solution Approach 2:
The invention changes the surface parameters of the heterophasic polypropylene powder by incorporating silane-modified polyethylene. This parameter change in surface chemistry and physics reduces stickiness and friction, preventing sheeting in the conveying system while maintaining the simplicity of the conveying infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly enhances the flowability of HECO, preventing agglomeration and blockages, allowing for smooth transportation from the polymerization unit to the extrusion unit.
Implementation Method 1
the produced heterophasic polypropylene (HECO) is provided with an additive (A), said additive (A) is fed to the produced heterophasic polypropylene (HECO)
Data Source
AI summary
Method for the preparation of a sticky high impact heterophasic polypropylene (HECO) in a reactor facility comprising in series (i) a first reaction system, (ii) a first conveying line connecting the first reactor system with a second reactor system comprising an outlet, (iii) a second conveying line connecting the outlet with a purge bin comprising a feeder, and (iv) a conveying system being connected with the feeder, and the preparation of said heterophasic polypropylene (HECO) comprises the steps in the order of (a) producing in said first reactor system the polypropylene matrix (M), (b) transferring at least a part of said polypropylene to said second reactor system via the first conveying line, (c) producing in said second reactor system the elastomeric copolymer obtaining the heterophasic polypropylene (HECO), (d) discharging said heterophasic polypropylene (HECO) from said second reactor system via the outlet, (e) transferring said discharged heterophasic polypropylene (HECO) via the second conveying line to said purge bin comprising said feeder, and (f) transferring further said discharged heterophasic polypropylene (HECO) from said purge bin via said feeder to said conveying system, the produced heterophasic polypropylene (HECO) is provided with an additive, said additive is fed to the produced heterophasic polypropylene (α) at the outlet of the second reactor system, or (β) at the feeder (F) of the purge bin (PB).