Description

The Polypropylene Pilot Plant is a continuous polymerization unit designed for research and process development. The process begins with purification of propylene, ethylene, hydrogen, and nitrogen feeds. Purified monomers are fed to a pre-polymerization reactor operating at low temperature and pressure. Catalyst, co-catalyst, and donor are injected to initiate controlled polymer formation. The pre-polymer slurry is transferred to a sequence of stirred reactors. Reactor configurations allow operation in slurry, bulk, or gas-phase polymerization modes. Liquid propylene, hexane, or iso-butane may be used as the continuous phase in slurry operation. Polymerization temperature and pressure are precisely controlled in each reactor. Hydrogen and comonomer feeds regulate molecular weight and polymer properties. Reaction heat is removed using a tempered water circulation system. Polymer slurry or powder is continuously discharged from the reactors. Gas-phase operation includes recycle compression and condensation of unreacted monomer. Unreacted propylene is recovered and recycled back to the reactor system. Polymer samples can be withdrawn as slurry or powder during operation. The process enables flexible evaluation of catalysts, operating conditions, and polymer grades.