Abstract: The invention relates to a continuous flow process for producing polystyrene having discrete particles of rubber included therein. The process utilizes a pre-inversion reactor, in which a solution of styrene, polystyrene and rubber are mixed prior to being introduced into a second stirred tank reactor. The viscosity of the solutions in the pre-inversion reactor and in the second stirred tank reactor are closely controlled to produce desirable HIPS products.

Abstract: A process for the alkylation of aromatic compounds employing silicalite of extremely low sodium content. A feedstock containing an aromatic substrate such as benzene is supplied along with an alkylating agent such as ethylene to a reaction zone containing a silicalite alkylation catalyst having a sodium content of less than 100 ppm Na.sub.2 O. Steam may be cofed to the reaction zone in an amount of at least 1 wt. % based upon the aromatic substrate. The low sodium silicalite has a substantially better aging quality in the alkylation process than does silicalite which normally has a higher sodium content.

Abstract: A process for pretreating a Ziegler-type catalyst for use in olefin polymerization reactions. An olefin monomer is aded to a fluid carrier stream containing a Ziegler-type catalyst. The carrier stream containing the monomer and the catalyst is passed through an elongated tubular reactor at a flow rate sufficient to provide a residence time in the tubular reactor of less than 1 minute and under temperature conditions to prepolymerize the catalyst within the tubular reactor without plugging of the reactor. In a specific embodiment the residence time within the reactor is no more than 10 seconds, and more particularly, no more than 2 seconds.

Abstract: A process for the disproportionation of a toluene feedstock containing ethylbenzene over an aluminum deficient mordenite catalyst. The mordenite catalyst has a silica/alumina mole ratio of at least 30. The feedstock contains at least 5 wt. % ethylbenzene. Hydrogen is supplied to the disproportionation reactor zone along with the toluene feedstock.

Abstract: A process for the disproportionation of a toluene containing feedstock over an aluminum deficient mordenite catalyst having a silica/alumina mole ratio of at least 30. The feedstock and hydrogen co-feed are supplied to a reaction zone containing the mordenite catalyst and which is operated under a temperature and pressure condition to effect the disproportionation of toluene to benzene and xylene. The supply of toluene feedstock to the reaction zone is interrupted while continuing the supply of hydrogen to the reaction zone. By continuing the supply of hydrogen to the reaction zone during periods of interruption of the toluene feedstock, the aging quality of the aluminum-deficient mordenite catalyst is improved.

Abstract: Process for the isomerization of xylene feedstock employing an aluminum-deficient mordenite catalyst. The xylene feedstock is passed into a reaction zone and in contact with a mordenite catalyst having a silica/alumina mole ratio of at least 30. The xylene feedstock may comprise a substantially pure meta-xylene, a mixture of xylene isomers, or in the preferred embodiment, a mixture of xylene isomers and ethylbenzene in which para-xylene is present in less than an equilibrium amount, and ethylbenzene present in an amount greater than the para-xylene content. The reaction zone is operated at a temperature within the range of 350.degree.-600.degree. C. and a hydrogen pressure within the range of 200-1000 psig to effect isomerization of xylene isomers to provide an increased para-xylene content and disproportionation of ethylbenzene to provide a reduced ethylbenzene content in the product.

Abstract: Process for the isomerization of a xylene feedstock employing a silicalite catalyst. A xylene feedstock containing a mixture of xylene isomers and ethylbenzene is passed to a reaction zone containing the silicalite catalyst. Para-xylene is present in the feedstock in less than an equilibrium amount, and ethylbenzene is present in a concentration greater than the para-xylene concentration. Hydrogen and/or water are also supplied to the reaction zone. The reaction zone is operated under conditions to effect isomerization of xylene isomers to provide an increased para-xylene content, and disproportionation of ethylbenzene to provide a decreased ethylbenzene content.

Abstract: Process and apparatus are disclosed for manufacturing foamed articles such as tubes used as pipe insulation, which tubes are of a high impermeability and flexibility and are formed of a polymer, such as polyethylene or polypropylene, containing up to as much as 50% of an elastomer.

Abstract: Disclosed is a process and apparatus for the continuous mass polymerization of styrenic and alkenylnitrile monomers. The process comprises the steps of continuously introducing a feed comprising a predetermined ratio of styrenic and alkenylnitrile monomers into a reaction vessel to produce a reaction mixture; subjecting the reaction mixture to conditions of temperature and pressure under which said monomers copolymerize to produce a styrenic/alkenylnitrile copolymer; subjecting the reaction mixture to agitation; continuously withdrawing styrenic/alkenylnitrile copolymer from the reaction vessel; and by withdrawing vapour phase from the reaction vessel in a controlled amount by varying the amount of cooled surface available for condensing the vapors, condensing the vapors by contact with the cooled surface and returning the condensate to the reaction vessel. The process and apparatus also include a novel means for devolatilizing the product copolymer.

Abstract: The apparatus for making plastic containers having decreased gas permeability includes a chamber, an ionizing source located in the chamber for ionizing a material to be deposited on the containers, and a screen located between the ionizing source and the containers for preventing damage to the containers by heat generated by the ionizing source. The method includes the step of locating a screen between the ionization source and the container whereby heat generated by the ionization source will not damage the container.

Abstract: Apparatus for producing open ended plastic containers having decreased gas permeability that includes a vacuum chamber and a pump for regulating the pressure therein, an ionization source mounted in the chamber proximate the container's open end and a container holder located in the chamber. The container holder has a hole aligned with the open end and may include a shield that encompasses the exterior of the container and may include a magnet setting up a magnetic field on the exterior of the shield. In the method, a container is placed on the container holder in the chamber with the open end and hole aligned and with the shield and magnet located as described above. The coating material is vaporized and ionized so that the ionized material is deposited on the interior wall of the container.

Abstract: Apparatus for forming deep containers from a thermoplastic material including a first mold portion having a cavity therein defining the side and bottom configuration of the container and a second mold portion having a plunger provided for reciprocation therein and arranged so that the plunger moves into the cavity. The first mold portion is provided with a first passageway that terminates adjacent to the cavity and in the parting surface of the mold portion and a second passageway that extends therethrough into the cavity adjacent to the bottom of the container. A control apparatus is provided that directs a vacuum through the first passageway securely holding the thermoplastic against the parting surface of the first mold portion.

Abstract: Process for the disproportionation of toluene employing an aluminum deficient mordenite catalyst. A toluene containing feedstock is supplied to a reaction zone containing a mordenite catalyst having a silica/alumina mole ratio of at least 30. The toluene WHSV is more than one. A hydrogen cofeed is supplied at a hydrogen/toluene mole ratio of 3-6, and the reaction zone is operated at a temperature within the range of 370.degree.-500.degree. C. and a hydrogen pressure of at least 500 psig. The toluene feedstock can have a moisture content in excess of 25 ppm and typically will have a water content ranging from about 50 ppm up to about the saturation point, about 250 ppm. A start-up procedure employs passing a hot preflush gas over the catalyst to dehydrate water from the catalyst prior to passing the toluene feedstock to the catalyst.

Abstract: A process for forming hollow articles from a thermoplastic polymer sheet material. Polymer sheet material is heated to a forming temperature and clamp between a ported mold plug and a jacketed mold cavity. The mold plug is moved into the mold cavity to stretch the material into the cavity. The clamping is released during the moving of the plug and a substantial portion of the air trapped between the material and mold cavity is evacuated. Pressurized forming gas is injected through flow means around the mold plug to further expand the material into the mold cavity. Thereafter, the injecting of forming gas is discontinued and coolant is flowed through the jacketed mold cavity and a cooling fluid is injected through the ported mold plug against the material while the pressurized forming gas is simultaneously purged from the area between the mold plug and expanded material through the flow means.

Abstract: A process for the distillation of readily polymerizable vinyl aromatic compounds which comprises subjecting said compounds to distillation conditions in the presence of an effective amount of a pretreated polymerization inhibitor selected from the group consisting of asphalts, asphaltenes and any combination thereof. The inhibitor is pretreated by subjecting the inhibitor to a process for substantially increasing the free radical content therein.

Abstract: A process for the distillation of readily polymerizable vinyl aromatic compounds which comprises subjecting said compounds to distillation conditions in the presence of oxygen and an effective amount of asphaltene as a polymerization inhibitor.