Abstract: A process for producing high impact polystyrene including feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture. Polymerizing the reaction mixture in the first linear flow reactor to a point below the point at which phase inversion occurs to produce a first polymerization mixture and feeding the first polymerization mixture from the first linear flow reactor to a second linear flow reactor. Polymerizing the reaction mixture in the second linear flow reactor to at least a phase inversion point of the mixture to produce a second polymerization mixture and feeding the second polymerization mixture from the second linear flow reactor to at least a third linear flow reactor for post-inversion polymerization of the second polymerization mixture. The product stream can have an ESCR value of at least 10% toughness retained with less than 10 wt % rubber content.

Abstract: A process for producing high impact polystyrene including feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture. Polymerizing the reaction mixture in the first linear flow reactor to a point below the point at which phase inversion occurs to produce a first polymerization mixture and feeding the first polymerization mixture from the first linear flow reactor to a second linear flow reactor. Polymerizing the reaction mixture in the second linear flow reactor to at least a phase inversion point of the mixture to produce a second polymerization mixture and feeding the second polymerization mixture from the second linear flow reactor to at least a third linear flow reactor for post-inversion polymerization of the second polymerization mixture. The product stream can have an ESCR value of at least 10% toughness retained with less than 10 wt % rubber content.

Abstract: A process for producing high impact polystyrene including feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture. Polymerizing the reaction mixture in the first linear flow reactor to a point below the point at which phase inversion occurs to produce a first polymerization mixture and feeding the first polymerization mixture from the first linear flow reactor to a second linear flow reactor. Polymerizing the reaction mixture in the second linear flow reactor to at least a phase inversion point of the mixture to produce a second polymerization mixture and feeding the second polymerization mixture from the second linear flow reactor to at least a third linear flow reactor for post-inversion polymerization of the second polymerization mixture. The product stream can have an ESCR value of at least 10% toughness retained with less than 10 wt % rubber content.

Abstract: Disclosed is a bimodal Ziegler-Natta catalyzed polyethylene, having a density of from 0.930 g/cc to 0.960 g/cc, and a molecular weight distribution of from 10 to 25, wherein an article formed therefrom has a PENT of at least 1500. Also disclosed is a method of preparing a tubular article including obtaining a bimodal polyethylene having a density of from 0.930 g/cc to 0.960 g/cc and a molecular weight distribution of from 10 to 25, and processing the polyethylene under conditions where a specific energy input (SEI) is less than 300 kW·h/ton, and wherein the article has a PENT of at least 1500. Further disclosed is a method for controlling the degradation of polyethylene including polymerizing ethylene monomer, recovering polyethylene, extruding the polyethylene, and controlling the degradation of polyethylene by measuring the SEI to the extruder and adjusting throughput and/or gear suction pressure keep SEI less than 300 kW·h/ton, and forming an article.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: A process for producing high impact polystyrene including feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture. Polymerizing the reaction mixture in the first linear flow reactor to a point below the point at which phase inversion occurs to produce a first polymerization mixture and feeding the first polymerization mixture from the first linear flow reactor to a second linear flow reactor. Polymerizing the reaction mixture in the second linear flow reactor to at least a phase inversion point of the mixture to produce a second polymerization mixture and feeding the second polymerization mixture from the second linear flow reactor to at least a third linear flow reactor for post-inversion polymerization of the second polymerization mixture. The product stream can have an ESCR value of at least 10% toughness retained with less than 10 wt % rubber content.

Abstract: Disclosed is a bimodal Ziegler-Natta catalyzed polyethylene, having a density of from 0.930 glee to 0.960 glee, and a molecular weight distribution of from 10 to 25, wherein an article formed therefrom has a PENT of at least 1500. Also disclosed is a method of preparing a tubular article including obtaining a bimodal polyethylene having a density of from 0.930 glee to 0.960 Wee and a molecular weight distribution of from 10 to 25, and processing the polyethylene under conditions where a specific energy input (SET) is less than 300 kW.h/ton, and wherein the article has a PENT of at least 1500. Further disclosed is a method for controlling the degradation of polyethylene including polymerizing ethylene monomer, recovering polyethylene, extruding the polyethylene, and controlling the degradation of polyethylene by measuring the SEI to the extruder and adjusting throughput and/or gear suction pressure keep SEI less than 300 kW.h/ton, and forming an article.

Abstract: Disclosed is a bimodal Ziegler-Natta catalyzed polyethylene, having a density of from 0.930 g/cc to 0.960 g/cc, and a molecular weight distribution of from 10 to 25, wherein an article formed therefrom has a PENT of at least 1500. Also disclosed is a method of preparing a tubular article including obtaining a bimodal polyethylene having a density of from 0.930 g/cc to 0.960 g/cc and a molecular weight distribution of from 10 to 25, and processing the polyethylene under conditions where a specific energy input (SEI) is less than 300 kW·h/ton, and wherein the article has a PENT of at least 1500. Further disclosed is a method for controlling the degradation of polyethylene including polymerizing ethylene monomer, recovering polyethylene, extruding the polyethylene, and controlling the degradation of polyethylene by measuring the SEI to the extruder and adjusting throughput and/or gear suction pressure keep SEI less than 300 kW·h/ton, and forming an article.

Abstract: The present invention includes an apparatus and method for narrowing the residence time distribution of a continuous stirred-tank reactor, or CSTR, which includes the optional procedures of: decreasing the vertical cross-sectional area of the reactor's agitator blades; decreasing the RPM of the agitator blades; and increasing the reactor's L/D ratio. The CSTR can be used in the production of monovinylidene aromatic polymers, such as high impact polystyrene.

Abstract: A method of preparing a polystyrene blend that includes combining a first polystyrene composition having a first melt flow index with a second polystyrene composition having a second melt flow index and forming a polystyrene blend, the second melt flow index being at least 2 dg/min higher that the first melt flow index. The polystyrene blend has an observed tensile strength value greater than 3% above the expected tensile strength value. The second polystyrene composition can include a recycled polystyrene material, which can include expanded polystyrene. An alternate method of preparing the polystyrene blend includes combining a polystyrene composition with a styrene monomer to form a reaction mixture, polymerizing the reaction mixture and obtaining a polystyrene blend, where the polystyrene containing composition has a melt flow index at least 2 dg/min higher than the melt flow index of the styrene monomer after it has been polymerized.

Abstract: Disclosed is a bimodal Ziegler-Natta catalyzed polyethylene, having a density of from 0.930 g/cc to 0.960 g/cc, and a molecular weight distribution of from 10 to 25, wherein an article formed therefrom has a PENT of at least 1500. Also disclosed is a method of preparing a tubular article including obtaining a bimodal polyethylene having a density of from 0.930 g/cc to 0.960 g/cc and a molecular weight distribution of from 10 to 25, and processing the polyethylene under conditions where a specific energy input (SEI) is less than 300 kW·h/ton, and wherein the article has a PENT of at least 1500. Further disclosed is a method for controlling the degradation of polyethylene including polymerizing ethylene monomer, recovering polyethylene, extruding the polyethylene, and controlling the degradation of polyethylene by measuring the SEI to the extruder and adjusting throughput and/or gear suction pressure keep SEI less than 300 kW·h/ton, and forming an article.

Abstract: Process for the preparation of a hydroperoxide functionalized olefinic compound in an oxidation reactor containing a particulate catalyst bed comprising a light induced photosensitized catalyst component supported on a particulate substrate material forming a permeable catalyst bed. The photoenergized catalyst component is a photoreductant material which is effective for the conversion of triplet oxygen to singlet oxygen under illumination with ultraviolet or visible light. An oxygen containing feed stream containing triplet oxygen is supplied to the catalyst bed. The catalyst bed is irradiated at an intensity to convert triplet oxygen to singlet oxygen to produce a singlet oxygen enriched gas stream.

Abstract: Disclosed is a bimodal Ziegler-Natta catalyzed polyethylene, having a density of from 0.930 g/cc to 0.960 g/cc, and a molecular weight distribution of from 10 to 25, wherein an article formed therefrom has a PENT of at least 1500. Also disclosed is a method of preparing a tubular article including obtaining a bimodal polyethylene having a density of from 0.930 g/cc to 0.960 g/cc and a molecular weight distribution of from 10 to 25, and processing the polyethylene under conditions where a specific energy input (SEI) is less than 300 kW.h/ton, and wherein the article has a PENT of at least 1500. Further disclosed is a method for controlling the degradation of polyethylene including polymerizing ethylene monomer, recovering polyethylene, extruding the polyethylene, and controlling the degradation of polyethylene by measuring the SEI to the extruder and adjusting throughput and/or gear suction pressure keep SEI less than 300 kW.h/ton, and forming an article.

Abstract: A devolatilizer nozzle comprising at least one perforated flow tube having a non-circular cross-section. In an embodiment, the non-circular cross-section has equal to or greater than 3 sides. The non-circular cross-section of said nozzle may be a triangle, diamond, pentagon, hexagon, heptagon, or octagon. A majority of the perforations in the flow tube of said nozzle may have a maximum strand angle of equal to or less than 45 degrees. The nozzle may further comprise tapered holes, which may be formed by a water jet. The nozzle may further comprise a plurality of parallel flow tubes. The nozzle may comprise 304 stainless steel, AL-6XN stainless steel, or LDX 2101 stainless steel.

Abstract: An accelerated method of determining the failure time of a polyethylene resin by determining the minimum displacement rate, or the time at minimum displacement rate, using ASTM F 1473-01, then following one of these routes: (1) If failure has not yet occurred, cryogenically fracturing the resin specimen and examining it for slow crack growth to determine whether the anticipated, or desired, failure time is generally before or after the predicted failure time; or (2) Applying the minimum displacement rate, or the time at minimum displacement rate, in the appropriate mathematical formula to predict the failure time for the resin. The mathematical formula is derived from the discovery of a power law relationship between the failure time and minimum displacement rate, or between failure time and the time at minimum displacement rate.

Abstract: An accelerated method of determining the failure time of a polyethylene resin by determining the minimum displacement rate, or the time at minimum displacement rate, using ASTM F 1473-01, then following one of these routes: (1) If failure has not yet occurred, cryogenically fracturing the resin specimen and examining it for slow crack growth to determine whether the anticipated, or desired, failure time is generally before or after the predicted failure time; or (2) Applying the minimum displacement rate, or the time at minimum displacement rate, in the appropriate mathematical formula to predict the failure time for the resin. The mathematical formula is derived from the discovery of a power law relationship between the failure time and minimum displacement rate, or between failure time and the time at minimum displacement rate.

Abstract: A method is provided for perforating a steel plate, forming a devolatilizer nozzle from the steel plate, and heat treating the devolatilizer nozzle. The devolatilizer nozzle may have a yield strength of at least about 110 ksi, and a tensile strength of at least about 140 ksi. The perforations in the steel plate are holes in the nozzle and may be no more than about 0.05 inches in diameter. The thickness of the steel plate may be from about 0 to about 0.75 inches. The nozzle may include at least about 500,000 perforations where the center-to-center hole distance may be at least about 0.08 inches. The capacity of the devolatilizer nozzle may be from about 0 to about 75,000 pounds per hour.