Abstract: A process is disclosed for the carbonylation of an organic compound selected from the group consisting of an olefin, an alcohol, an acid and an ester. In this process the organic compound is reacted with carbon monoxide in the presence of a Group VIII metal-containing catalyst. The liquid carbonylation product solution of this reaction is conveyed to a separation zone maintained at a lower total pressure than is the pressure in the reaction zone. Simultaneously with the conveyance of the liquid product solution to the separation zone is the introduction therein of a carbon monoxide-containing gaseous stream, the carbon monoxide therein contributing a partial pressure of up to 30 psia of the total pressure in said separation zone. A portion of the liquid carbonylation product solution is flashed and removed from the separation zone. The unflashed liquid carbonylation product solution is recycled back into the reaction zone.

Abstract: A new catalyst component useful in the polymerization of at least one olefin is disclosed. The catalyst component comprises the product obtained by contacting silica, in random order, with (1) at least one hydrocarbon soluble magnesium-containing compound; and (2) a first modifying compound selected from the group consisting of silicon halides, boron halides, aluminum halides and mixtures thereof followed by a second modifying compound selected from the group consisting of halides having the structural formula SiH.sub.r X.sup.2.sub.s, where X.sup.2 is halogen; r is an integer of 1 to 3; and s is an integer of 1 to 3 with the proviso that the sum of r and s is 4, a hydrogen halide and mixtures thereof. The product of this step is contacted with a titanium-containing compound having the structural formula TiX.sup.1.sub.p (OR.sup.1).sub.q, where X.sup.1 is halogen; R.sup.

Abstract: A bimodal silica gel particle, its method of preparation and its use as a catalyst support in the polymerization of olefins is disclosed. The bimodal silica gel particle exhibits a bimodal pore radius distribution, wherein the silica gel particle has a first average pore radius and a second average pore radius differing by at least about 20 .ANG.. The bimodal silica gel particle is useful as a support for a transition metal-based catalyst to provide a polyolefin having a broad or bimodal molecular weight distribution.

Abstract: The present invention relates to improved polymeric compositions based on ethylene-vinyl ester and ethylene-alkyl acrylate copolymers which can be crosslinked to provide insulation coatings for wire and cable products. The copolymer compositions contain a hydrated inorganic filler, an alkoxysilane, an antioxidant and a polymeric processing additive. Organic peroxides are preferably employed to facilitate crosslinking. An improved method for providing the improved compositions and electrical conductors coated with the crosslinkable polymeric compositions are also provided by the invention.

Abstract: The present invention relates to improved flame retardant insulation/jacketing compositions for wire and cable products based on ethylene-vinyl ester and ethylene-alkyl acrylate copolymers. The copolymers are formulated with a hydrated inorganic filler, an alkoxysilane, a crosslinking agent, a processing additive and a combination of specific antioxidants, namely, a pentaerythritol betaalkylthiopropionate and a hindered phenol. The formulations stabilized with the pentaerythritol betaalkylthiopropionate/ hindered phenol combination have good heat stability and do not tarnish or discolor the surface of the copper conductor upon steam vulcanization.

Abstract: A novel catalyst support and a method for preparation thereof, characterized by the presence of selected amounts of a hydrocarbon soluble magnesium-containing compound applied to the support relative to solvent, wherein a surface uniformly and essentially continuously moistened with the solvated magnesium compound is achieved in a condition of incipient precipitation to permit the formation of a regular essentially continuous distribution of the magnesium compound onto and conforming to the support material The drying process under these conditions is effective in maintaining to a high degree the effective surface area and pore volume of the material. The support containing the adsorbed magnesium is then dried in a controlled manner to essential incipient wetness conditions providing a regular spatial distribution of stacked reticular magnesium values at a level of one to five molecular monolayers on the support.

Abstract: A processable thermoplastic conductive composite resin is formed by coating polypyrrole onto the surface of microbeads by in situ oxidative polymerization. The microbeads, generally having an average diameter from about 0.5 to about 500 microns, are coated with polypyrrole by combining pyrrole, oxidizing agent and the beads in a protic solvent such as water, methanol, ethanol, ethylene glycol and the like. The pyrrole polymerizes on the surface of the microbeads. The microbeads, which are thermoplastic, can then be processed and the conductivity of the processed polymer remains high, generally about 0.1 to about 10 S/cm. This is suitable for use as a conductive film. By incorporating a sulfonate counterion, the conductivity of the composite is significantly improved. Further, by incorporating a heat activated cross-linking agent such as a peroxide, the tensile strength of the processed polymer is significantly improved.

Abstract: Processes for converting vinyl alcohol polymers to poly(keto-esters) and the novel products obtained therefrom are disclosed. The process involves reacting a vinyl alcohol polymer, such as PVA or EVOH, with an organic peroxyacid oxidizing agent in an inert liquid medium at a temperature from -20.degree. C. to 150.degree. C. to convert the secondary hydroxyl groups of the vinyl alcohol polymer to carbonyl and oxycarbonyl groups. In another aspect of the invention, the vinyl alcohol copolymer is first reacted with an oxidizing agent capable of converting the secondary hydroxyl groups to carbonyl but not to oxycarbonyl and then subsequently oxidized using a peroxyacid to form oxycarbonyl. The poly(keto-esters) comprised of carbonyl units, oxycarbonyl units, hydroxyl-containing units and units which are primarily hydrocarbons in nature are photodegradable and biodegradable.

Abstract: A catalyst component useful in propylene polymerization in combination with a dialkyl aluminum halide cocatalyst comprises the product of reaction of TiCl.sub.3 which is substantially free of extraneous halide with a selected electron donor compound which is dissolved in a liquid hydrocarbon solvent in which the TiCl.sub.3 is dispersed. The electron donor compound is selected from certain organic acid esters, hindered phenolic compounds and silyl esters.The catalyst of the invention provides increased activity, molecular weight control, increased isotacticity of propylene polymer products and prevents catalyst feed line pluggage, among other advantages.

Abstract: The present invention relates to crosslinkable microfine ethylene copolymer powders which are substantially spherical in shape and range in size from about 10 up to about 500 microns and to the process of crosslinking the powders to reduce their melt flow rate. The powders are crosslinked by contacting with water in the presence of a silanol condensation catalyst at temperatures from ambient up to about 110.degree. C. The reduction in melt flow rate is accomplished without substantially changing the powder characteristics, i.e., particle size and particle size distribution.

Abstract: Methods and apparatus for the removal of hydrocarbons from polymer slurries are disclosed. The invention includes feeding a hydrocarbon-containing polymer slurry to a flash tank to flash a portion of the hydrocarbon from the slurry. A fraction of the residual slurry is circulated through a heating means and recirculated back to the flash tank to flash additional hydrocarbon from the slurry. The invention is applicable to remove isobutane solvent from an aqueous polyethylene slurry. It is also applicable to the removal of other hydrocarbons, including solvents, monomer and comonomer from polymer slurries.

Abstract: An improved blown-film extrusion process with particular application for high modulus thermoplastic resins. A cylinder is mounted above the cooling air ring. The film bubble passes through this cylinder, which has a diameter approximating the final diameter of the bubble. The frost line remains at or slightly higher than the top of the cylinder, leaving a small gap between the top of the cylinder bubble. The improvement enhances bubble cooling and stability and results in wrinkle-free film.

Abstract: A vanadium-containing catalyst is prepared as the product of admixing an inorganic oxide, inorganic phosphate or mixtures thereof, a zinc-containing composition, and a vanadium-containing composition. An auxiliary compound such as, for example, an aluminum halide compound may optionally be admixed. The catalyst may be combined with a co-catalyst such as an aluminum alkyl and, optionally, a halocarbon promotor to yield an olefin polymerization catalyst system. The resulting catalyst system exhibits high activity, excellent hydrogen response and produces a polymer having a narrow to broad molecular weight distribution with a bimodal profile. The catalyst is especially useful in ethylene homopolymerization and co-polymerization.

Abstract: A multiple site solid catalyst component capable of producing polyolefins having a broad or multimodal molecular weight distribution, such as a bimodal molecular weight distribution, is prepared by contacting a particulate solid support with a zirconium compound or complex to bind the zirconium compound or complex to the support, optionally followed by contacting the supported zirconium compound or complex with a Lewis acid to produce an intermediate product, optionally isolating and washing the supported zirconium compound or complex or resulting intermediate product to remove soluble by-products therefrom, and reacting the washed or unwashed supported zirconium compound or complex or intermediate product with a titanium or vanadium compound to produce a solid catalyst component.

Abstract: A catalyst, a method of preparing the catalyst, and a method of using the catalyst with a suitable cocatlayst in the polymerization or copolymerization of 1-olefins are disclosed. The catalyst is prepared by: a) contacting a group IIA organometallic compound, like 2-methylpentanoxymagnesium chloride, or a Group III organometallic compound, like triethylaluminum, or a combination thereof, with a porous or nonporous biodegradable substrate having active surface hydroxyl groups, like cellulose, to provide a modified biodegradable substrate; then b) contacting the modified biodegradable substrate with a transition metal compound, such as a transition metal halide or alkoxide, like titanium tetrachloride or vanadium(V)trichloride oxide, to form discrete catalyst particles. The catalyst particles are used in conjunction with a suitable cocatlalyst, like triethylaluminum, in the homopolymerization or copolymerization of 1-olefins.

Abstract: Mixed catalyst compositions comprised of a first supported chromium-containing catalyst component and a second supported chromium-containing catalyst component and which additionally have one or more metallic or non-metallic catalytic agents associated therewith are provided. The additional metallic or non-metallic elements associated with the catalyst components can be aluminum, titanium, zirconium, boron, phosphorous or combinations thereof. The pore volume of the silica supports used for the first and second catalyst components differs by at least 0.3 cc/g. The mixed catalyst compositions of the invention are useful for the preparation of polyolefins. They are particularly useful of polymerization of ethylene in particle form polymerizations to produce high density polyethylene blow molding resins having good processability and physical properties. The improved particle form polymerization process and products obtained thereby using the above-described mixed catalyst compositions are also described.

Abstract: A method for pretreatment of a palladium-gold catalyst useful in the synthesis of vinyl acetate. A virgin catalyst, following reduction to the metallic palladium and gold, is first heated at elevated temperatures in the presence of an oxidizing agent such as air. The oxidizing agent is withdrawn and an inert gas such as nitrogen is introduced. The catalyst is heated against at a temperature up to 500.degree. C. in the presence of a reducing agent such as hydrogen or ethylene. Improvement in selectivity and yield are obtained.

Abstract: An improved system and method for effectively controlling the operation of a continuous mixer/melter having an adjustable exit opening and connected to a melt pump is provided. The melt pump, which is preferably a gear pump, is operatively connected to an extruder/pelletizer. Operation of the gear pump is controlled in proportional relation to the energy requirements of the mixer/melter motor, the energy applied to adjust and maintain the exit opening of the mixer/melter, and the suction pressure measured at the interface between the mixer/melter and the gear pump. A microprocessor unit which receives and processes the input signals, calculates the energy requirements of the gear pump motor and compares these requirements with the actual torque, makes the necessary adjustments to the gear pump.

Abstract: The invention relates to improved flame retardant crosslinkable compositions useful as insulation coatings for wire and cable based on ethylene-vinyl ester and ethylene-alkyl acrylate copolymers. The compositions contain a hydrated inorganic filler, an alkoxysilane, an antioxidant and a hydrocarbon processing oil. Organic peroxides are preferably employed to facilitate crosslinking. A method for providing the improved flame retardant crosslinkable compositions and electrical conductors coated therewith are also provided.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitor as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. the sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.