Abstract: This invention relates to a process for forming polymer including: polymerizing a monomer dissolved in a solvent in the presence of a catalyst system under conditions to obtain a first effluent stream including a solution of the polymer and the solvent; heating the first effluent stream in at least one spiral heat exchanger to produce a second effluent stream, where the first effluent stream flows through the spiral heat exchanger in a cross-flow direction relative to spirals of the spiral heat exchanger and performing a separation on the second effluent stream to produce: a third effluent stream including polymer substantially free of the solvent; and a recycle stream including the solvent and unreacted monomer. Processes for devolatilizing a polymer stream are also provided herein.

Abstract: Disclosed is a solution polymerization process, or, alternatively, a method of delivering powder catalysts to a solution polymerization reactor, comprising combining a homogeneous single-site catalyst precursor with ?-olefin monomers to form a polyolefin, wherein the homogeneous single-site catalyst precursor is in the form of (i) a dry powder, (ii) suspended in a aliphatic hydrocarbon solvent, or (iii) suspended in an oil or wax, wherein the homogeneous single-site catalyst precursor is at a concentration greater than 0.8 mmole/liter when suspended in the aliphatic hydrocarbon solvent prior to entering the solution polymerization reactor.

Abstract: This disclosure describes polymerization processes and processes for quenching polymerization reactions using high molecular weight polyhydric quenching agents.

Abstract: Described herein are methods for continuous solution polymerization. The method may comprise polymerizing one or more monomers and comonomers in the presence of a solvent in a polymerization reactor to produce a polymer solution; determining the composition of the polymer solution exiting the polymerization reactor in an on-line fashion; determining at least one of the critical pressure or critical temperature; comparing the critical pressure and/or critical temperature to the actual temperature of the polymer solution and the actual pressure of the polymer solution; heating or cooling the polymer solution to a temperature within 50° C. of the critical temperature; and passing the polymer solution through a pressure letdown valve into a liquid-liquid separator, where the pressure of the polymer solution is reduced or raised to a pressure within 50 psig of the critical pressure to induce a separation of the polymer solution into two liquid phases.

Abstract: This disclosure describes processes for producing polymer using non-polar and condensable stripping agents to remove volatile components, such as solvent and unreacted monomer, from the produced polymer. Systems for performing these processes are also disclosed.

Abstract: This invention relates to a polymerization process for forming polymer comprising: contacting (typically in a solution or slurry phase), a monomer and a catalyst system in a reaction zone comprising at least one spiral heat exchanger and recovering polymer, wherein the monomer, the catalyst system and the polymer flow through the at least one spiral heat exchanger in a cross-flow direction relative to spirals of the at least one spiral heat exchanger.

Abstract: This invention relates to a polymerization process for forming polymer comprising: contacting (typically in a solution or slurry phase), a monomer and a catalyst system in a reaction zone comprising at least one spiral heat exchanger and recovering polymer, wherein the monomer, the catalyst system and the polymer flow through the at least one spiral heat exchanger in a cross-flow direction relative to spirals of the at least one spiral heat exchanger.

Abstract: Described herein are methods for continuous solution polymerization. The method may comprise polymerizing one or more monomers and comonomers in the presence of a solvent in a polymerization reactor to produce a polymer solution; determining the composition of the polymer solution exiting the polymerization reactor in an on-line fashion; determining at least one of the critical pressure or critical temperature; comparing the critical pressure and/or critical temperature to the actual temperature of the polymer solution and the actual pressure of the polymer solution; heating or cooling the polymer solution to a temperature within 50° C. of the critical temperature; and passing the polymer solution through a pressure letdown valve into a liquid-liquid separator, where the pressure of the polymer solution is reduced or raised to a pressure within 50 psig of the critical pressure to induce a separation of the polymer solution into two liquid phases.

Abstract: This invention relates to a method for the determination of the average particle size or particle size distribution of a material in a gas phase reactor comprising: 1) analyzing the average particle size and particle size distribution of a baseline composition using the method described in ASTM D1921; 2) analyzing the average particle size and particle size distribution of said baseline composition using an FT-NIR analysis technique; 3) preparing a calibration matrix by comparing results from said reference analytical technique to the results from said FT-NIR analysis technique; 4) analyzing the material using an FT-NIR technique; and 5) identifying and quantifying the type and content of particles present in the material by comparing spectral data obtained from said FT-NIR technique of the material to said calibration matrix. This invention also relates to a process for determining polymer properties in a polymerization reactor system using such techniques.

Abstract: This invention relates to a process to produce a functionalized polymer comprising: a) contacting an iodine modified aromatic polymer with an oxidizing agent to obtain an iodonium salt of the aromatic polymer; b) contacting the iodonium salt of the aromatic polymer with a polymer having internal or terminal unsaturation(s); and c) obtaining a functionalized polymer from the polymer having internal or terminal unsaturation(s) wherein the functionalized polymer has an Mn less than the Mn of the polymer having internal or terminal unsaturation(s) and the functionalized polymer has an acid number higher than the acid number of the polymer having internal or terminal unsaturation(s).

Abstract: This invention relates to a method for the determination of the average particle size or particle size distribution of a material in a gas phase reactor comprising: 1) analyzing the average particle size and particle size distribution of a baseline composition using the method described in ASTM D1921; 2) analyzing the average particle size and particle size distribution of said baseline composition using an FT-NIR analysis technique; 3) preparing a calibration matrix by comparing results from said reference analytical technique to the results from said FT-NIR analysis technique; 4) analyzing the material using an FT-NIR technique; and 5) identifying and quantifying the type and content of particles present in the material by comparing spectral data obtained from said FT-NIR technique of the material to said calibration matrix. This invention also relates to a process for determining polymer properties in a polymerization reactor system using such techniques.

Abstract: This invention relates to inventive ethylene-based copolymers comprising 75.0 wt % to 99.5 wt % of ethylene-derived units and 0.5 wt % to 25.0 wt % of C3 to C20 olefin derived units; the inventive ethylene-based copolymer having: a density in the range of from 0.900 to less than 0.940 g/cm3; a g?(vis) of less than 0.80; a melt index, I2, of from 0.25 to 1.5 g/10 min.; a Mw/Mn within a range from 3.0 to 6.0, and Mz/Mn greater than 8.0; and an absence of a local minimum loss angle at a complex modulus, G*, of 1.00×104 to 3.00×104 Pa.

Abstract: This invention relates to a process to produce a functionalized polymer comprising: a) contacting an iodine modified aromatic polymer with an oxidizing agent to obtain an iodonium salt of the aromatic polymer; b) contacting the iodonium salt of the aromatic polymer with a polymer having internal or terminal unsaturation(s); and c) obtaining a functionalized polymer from the polymer having internal or terminal unsaturation(s) wherein the functionalized polymer has an Mn less than the Mn of the polymer having internal or terminal unsaturation(s) and the functionalized polymer has an acid number higher than the acid number of the polymer having internal or terminal unsaturation(s).

Abstract: This invention relates to inventive ethylene-based copolymers comprising 75.0 wt % to 99.5 wt % of ethylene-derived units and 0.5 wt % to 25.0 wt % of C3 to C20 olefin derived units; the inventive ethylene-based copolymer having: a density in the range of from 0.900 to less than 0.940 g/cm3; a g?(vis) of less than 0.80; a melt index, I2, of from 0.25 to 1.5 g/10 min.; a Mw/Mn within a range from 3.0 to 6.0, and Mz/Mn greater than 8.0; and an absence of a local minimum loss angle at a complex modulus, G*, of 1.00×104 to 3.00×104 Pa.

Abstract: The present invention relates to a method for preparing olefin comonomers from ethylene. The comonomer generated can be used in a subsequent process, such as a polyethylene polymerization reactor. The comonomer generated can be transported, optionally without isolation or storage, to a polyethylene polymerization reactor. One method includes the steps of: feeding ethylene and a catalyst in a solvent/diluent to one or more comonomer synthesis reactors; reacting the ethylene and the catalyst under reaction conditions sufficient to produce an effluent comprising a desired comonomer; forming a gas stream comprising unreacted ethylene, and a liquid/bottoms stream comprising the comonomer, optionally by passing the effluent to one or more downstream gas/liquid phase separators; and purifying at least a portion of said liquid/bottoms stream by removing at least one of solid polymer, catalyst, and undesirable olefins therefrom.

Abstract: A plug flow reactor having an inner shell 27 surrounded by outer shell 21 and having at least one annular flow passage 35 therebetween can be used to prepare compositions, including polymers. The plug flow reactor also includes inlet port 36, an outlet port 37 and a plurality of exchanger tubes 26 wherein the exchanger tubes are in fluid communication to the at least one annular flow passage. Polystyrene and high impact polystyrene can be prepared using the reactor.

Abstract: A plug flow reactor having an inner shell 27 surrounded by outer shell 21 and having at least one annular flow passage 35 therebetween can be used to prepare compositions, including polymers. The plug flow reactor also includes inlet port 36, an outlet port 37 and a plurality of exchanger tubes 26 wherein the exchanger tubes are in fluid communication to the at least one annular flow passage. Polystyrene and high impact polystyrene can be prepared using the reactor.

Abstract: A method and apparatus are described in which a polymer feed is pelletized by introducing the polymer feed to an extruder, removing heat from the polymer feed in the extruder, and extruding the polymer feed through a pelletizing die.

Abstract: Disclosed are novel non-linear vinyl polymers comprised of a multifunctional peroxide, and a cross-linking agent and/or a chain transfer agent, and methods of making such polymers having: at least 0.03 branches/1000 backbone carbons; linear portions with a molecular weight (Mw) of 350,000 or less; 0.2 to 3.0 branches/molecule; or, a Mz/Mw of from 1.7 to 5.7. Methods of quantifying branching are disclosed using a linear reference having 0.0 to 0.06 branches/1000 backbone carbons along with SEC techniques and measurements of molecular weight, molecular size, and concentration. Also discovered is a vinyl polymer resin comprised of from 0.1 to 50 weight percent of non-linear polymers having at least 0.06 branches/1000 backbone carbons, where branching is measured using a heat polymerized polystyrene having from 0.0 to 0.06 branches/1000 backbone carbons as a linear reference.

Abstract: A plug flow reactor having an inner shell 27 surrounded by outer shell 21 and having at least one annular flow passage 35 therebetween can be used to prepare compositions, including polymers. The plug flow reactor also includes inlet port 36, an outlet port 37 and a plurality of exchanger tubes 26 wherein the exchanger tubes are in fluid communication to the at least one annular flow passage. Polystyrene and high impact polystyrene can be prepared using the reactor.