{"id":1016,"date":"2026-06-28T14:22:37","date_gmt":"2026-06-28T06:22:37","guid":{"rendered":"https:\/\/bastone-petrochem.com\/?p=1016"},"modified":"2026-08-13T09:27:20","modified_gmt":"2026-08-13T01:27:20","slug":"copolymer-polypropylene-manufacturing-process","status":"publish","type":"post","link":"https:\/\/bastone-petrochem.com\/ru\/copolymer-polypropylene-manufacturing-process\/","title":{"rendered":"\u041a\u0430\u043a \u043f\u0440\u043e\u0438\u0437\u0432\u043e\u0434\u0438\u0442\u0441\u044f \u0441\u043e\u043f\u043e\u043b\u0438\u043c\u0435\u0440\u043d\u044b\u0439 \u043f\u043e\u043b\u0438\u043f\u0440\u043e\u043f\u0438\u043b\u0435\u043d"},"content":{"rendered":"

Random and impact copolymer polypropylene run the same reactor train up to one decision. Either ethylene gets co-fed into the main loop, or a second gas-phase reactor is added downstream to grow a rubber phase inside the finished homopolymer.
.<\/p>\n\n\n\n

That one fork is the difference between a clear pipe resin and a sub-zero-tough automotive grade. Everything before it is shared chemistry; everything after it is the same finishing line.
.<\/p>\n\n\n\n

The sequence below runs from the propylene feed onward, naming the resin property and grade slot each step delivers. Knowing where a property is set lets you sanity-check a COA instead of trusting the spec sheet blindly.
.<\/p>\n\n\n\n

Step 1 \u2014 The Propylene Feed and the Ziegler-Natta Catalyst System
<\/h2>\n\n\n\n

Copolymer PP
<\/a> production starts with polymer-grade propylene (typically \u226599.5% purity) and a supported Ziegler-Natta catalyst. The catalyst sets stereochemistry before a single chain has grown \u2014 it decides isotacticity, which is what makes commercial PP rigid at all.
.<\/p>\n\n\n\n

The modern industrial system is TiCl\u2084 supported on MgCl\u2082, activated by triethylaluminum cocatalyst. Two donors do the fine-tuning: an internal donor (diisobutyl phthalate) and an external alkoxysilane such as cyclohexylmethyldimethoxysilane.
.<\/p>\n\n\n\n

The donors are not optional dressing. They control how cleanly the chain stays isotactic and how evenly ethylene incorporates on a copolymer route.
.<\/p>\n\n\n\n

Commercial isotactic PP lands at an isotactic index of 85-95%, a direct output of the donor package. A metallocene single-site catalyst is the narrower-distribution alternative, but sees little commodity use.
.<\/p>\n\n\n\n

Feed purity is the quiet constraint. Ziegler-Natta sites are poisoned by trace moisture, oxygen, and sulfur, so the propylene is dried and guard-bed treated before the reactor.
.<\/p>\n\n\n\n

Step 2 \u2014 Primary Polymerization in the Bulk Loop Reactor
<\/h2>\n\n\n\n

Primary polymerization happens in a liquid-pool loop reactor running liquid propylene as its own solvent at roughly 60-80 \u00b0C and 30-40 atm. This is where the isotactic homopolymer matrix that every copolymer route shares gets built.
.<\/p>\n\n\n\n

Chains grow off the active TiCl\u2084 sites as the mixture circulates. Hydrogen is dosed in as the chain-transfer agent: more hydrogen means shorter chains, which means higher melt flow.
.<\/p>\n\n\n\n

That hydrogen dose is the single lever setting the grade\u2019s
melt flow index
<\/a> target, dialed in right here in the loop.
.<\/p>\n\n\n\n

Commercial trains run two loops in series. The bulk-phase route caps ethylene at roughly 5 wt%, so any grade needing more comonomer or a rubber phase moves downstream \u2014 where the fork begins.
.<\/p>\n\n\n\n

Run propylene alone through these loops and the output is
homopolymer polypropylene<\/a>, the rigid baseline that melts at 160-171 \u00b0C. Both copolymer routes branch from this same loop output; what changes is whether ethylene enters, and when.
.<\/p>\n\n\n\n

Step 3 \u2014 The Random-vs-Impact Fork
<\/h2>\n\n\n\n

The random-vs-impact decision is one physical choice on the train. Co-feed ethylene into the loops for a random copolymer, or hold the loop matrix and add a second gas-phase reactor to grow a rubber phase for an impact copolymer.
.<\/p>\n\n\n\n

\"\u0420\u0430\u0437\u0432\u0435\u0442\u0432\u043b\u0435\u043d\u0438\u0435<\/figure>\n\n\n\n

Same upstream loops, two different resins. The taxonomy of
what copolymer polypropylene is
<\/a> sits in the definitional companion; the focus here is where the routes diverge.
.<\/p>\n\n\n\n

Property outcome
<\/th>		Random route
<\/th>		Impact route
<\/th><\/tr><\/thead>
Ethylene entry
<\/td>		Loops, 2.7-8 wt%
<\/td>		Second reactor as rubber
<\/td><\/tr>
Reactors used
<\/td>		Two loops only
<\/td>		Loops + gas-phase reactor
<\/td><\/tr>
Melting point
<\/td>		~135-150 \u00b0C
<\/td>		Matrix Tm retained
<\/td><\/tr>
Clarity
<\/td>		High (clear)
<\/td>		Set by domain size
<\/td><\/tr>
Cold-impact toughness
<\/td>		Modest
<\/td>		Several-fold higher
<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

Random Route \u2014 Ethylene Co-Fed Into the Loops
<\/h3>\n\n\n\n

Feeding ethylene into the loops at 2.7-8 wt% inserts ethylene units randomly along the chain. That disrupts the isotactic sequence, so crystallinity \u2014 and the melting point \u2014 drops, trading stiffness for clarity.
.<\/p>\n\n\n\n

A measured Spheripol random grade at 2.7-3.0 wt% ethylene sits at Tm 144.6 \u00b0C, well below homopolymer\u2019s 160-171 \u00b0C, with 4.8 wt% xylene-soluble fraction. It is made in two loops only, with no gas-phase reactor.
.<\/p>\n\n\n\n

PetroChina Dushanzi T4401 is the real-world output of this loop-reactor random route. The PP-R pipe grade runs MFR 0.25 g\/10 min (230 \u00b0C\/2.16 kg, ASTM D1238\/ISO 1133), density 0.90 g\/cm\u00b3, rated to 95 \u00b0C hot-water service.
.<\/p>\n\n\n\n

One spec-sheet sanity-check: some vendor pages list T4401 at 164-170 \u00b0C, which is homopolymer range. A genuine random copolymer cannot melt that high \u2014 random ethylene insertion physically prevents it. Expect ~135-150 \u00b0C.
.<\/p>\n\n\n\n

Impact Route \u2014 A Rubber Phase Grown in a Second Reactor
<\/h3>\n\n\n\n

The impact route keeps the loop output as a rigid homopolymer matrix. It routes that matrix into a second gas-phase fluidized-bed reactor (70-80 \u00b0C, 25-35 bar), where ethylene-propylene rubber (EPR) grows in-situ as a dispersed phase at 5-15 wt%, sometimes up to ~25%. Those domains absorb impact energy the rigid matrix cannot.
.<\/p>\n\n\n\n

\u201cBlock copolymer\u201d is the common trade name, but it is a misnomer. The impact route makes no chain with covalently joined blocks \u2014 it makes a heterophasic alloy: discrete EPR rubber domains dispersed in an isotactic homopolymer matrix. That is why impact and stiffness tune almost independently, by rubber fraction rather than chain architecture.
.<\/p>\n\n\n\n

Rubber-domain size is the clarity-versus-impact lever, set by EPR molecular weight relative to the matrix. Coarse ~1 \u03bcm domains scatter light to 98.8% haze (opaque) at 14.5 kJ\/m\u00b2 impact. Fine ~100 nm domains drop haze to 13.5% (nearly clear) while raising impact to 25.1 kJ\/m\u00b2.
.<\/p>\n\n\n\n

\"\u0421\u0440\u0430\u0432\u043d\u0435\u043d\u0438\u0435<\/figure>\n\n\n\n

Lower-MW EPR disperses into smaller domains \u2014 better clarity and toughness from the same process. This output lands in the
impact copolymer (ICP) grade slot
<\/a> for sub-zero and drop-test applications.
.<\/p>\n\n\n\n

Step 4 \u2014 Degassing, Compounding, and Pelletizing
<\/h2>\n\n\n\n

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\u041e\u0441\u0432\u0435\u0442\u043b\u0438\u0442\u0435\u043b\u044c \u043e\u0442\u043d\u043e\u0441\u0438\u0442\u0441\u044f \u0441\u044e\u0434\u0430, \u0430 \u043d\u0435 \u0432 \u0440\u0435\u0430\u043a\u0442\u043e\u0440 \u2014 \u043f\u043e\u043c\u0443\u0442\u043d\u0435\u043d\u0438\u0435 12,51% \u043d\u0430 \u0442\u043e\u0439 \u0441\u0442\u0430\u0442\u0438\u0441\u0442\u0438\u0447\u0435\u0441\u043a\u043e\u0439 \u0441\u043e\u043f\u043e\u043b\u0438\u043c\u0435\u0440\u043d\u043e\u0439 \u043c\u0430\u0440\u043a\u0435 \u0431\u044b\u043b\u043e \u0432\u044b\u0437\u0432\u0430\u043d\u043e 3000 ppm \u0441\u043e\u0440\u0431\u0438\u0442\u043e\u043b\u043e\u0432\u043e\u0433\u043e \u043e\u0441\u0432\u0435\u0442\u043b\u0438\u0442\u0435\u043b\u044f \u043d\u0430 \u043a\u043e\u043c\u043f\u0430\u0443\u043d\u0434\u0435\u0440\u0435, \u0430 \u043d\u0435 \u043f\u043e\u043b\u0438\u043c\u0435\u0440\u0438\u0437\u0430\u0446\u0438\u0435\u0439.<\/p>\n\n\n\n

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\u041f\u043e\u043b\u043d\u0430\u044f \u043a\u0430\u0440\u0442\u0438\u043d\u0430, \u043e\u0442 \u043d\u0430\u0447\u0430\u043b\u0430 \u0434\u043e \u043a\u043e\u043d\u0446\u0430.<\/h2>\n\n\n\n

\u0420\u044b\u0447\u0430\u0433, \u043a\u043e\u0442\u043e\u0440\u044b\u0439 \u0440\u0435\u0448\u0430\u0435\u0442 \u0432\u0441\u0451, \u043c\u0430\u043b \u0438 \u043d\u0430\u0445\u043e\u0434\u0438\u0442\u0441\u044f \u043d\u0430 \u0440\u0430\u043d\u043d\u0435\u0439 \u0441\u0442\u0430\u0434\u0438\u0438: \u0432\u0432\u043e\u0434\u0438\u0442\u0441\u044f \u043b\u0438 \u044d\u0442\u0438\u043b\u0435\u043d \u0432 \u043f\u0435\u0442\u043b\u0435\u0432\u044b\u0445 \u0440\u0435\u0430\u043a\u0442\u043e\u0440\u0430\u0445 \u0438\u043b\u0438 \u0432 \u0432\u0438\u0434\u0435 \u043e\u0442\u0434\u0435\u043b\u044c\u043d\u043e\u0439 \u043a\u0430\u0443\u0447\u0443\u043a\u043e\u0432\u043e\u0439 \u0444\u0430\u0437\u044b \u043d\u0438\u0436\u0435 \u043f\u043e \u043f\u043e\u0442\u043e\u043a\u0443. \u041e\u0434\u043d\u0430 \u0441\u043e\u0432\u043c\u0435\u0441\u0442\u043d\u0430\u044f \u043f\u043e\u0434\u0430\u0447\u0430 \u0434\u0430\u0435\u0442 \u043f\u0440\u043e\u0437\u0440\u0430\u0447\u043d\u0443\u044e \u0441\u0442\u0430\u0442\u0438\u0441\u0442\u0438\u0447\u0435\u0441\u043a\u0443\u044e \u0441\u043e\u043f\u043e\u043b\u0438\u043c\u0435\u0440\u043d\u0443\u044e \u0441\u043c\u043e\u043b\u0443 \u0441 \u0431\u043e\u043b\u0435\u0435 \u043d\u0438\u0437\u043a\u043e\u0439 Tm; \u043e\u0434\u0438\u043d \u0434\u043e\u043f\u043e\u043b\u043d\u0438\u0442\u0435\u043b\u044c\u043d\u044b\u0439 \u0440\u0435\u0430\u043a\u0442\u043e\u0440 \u0434\u0430\u0435\u0442 \u0445\u043b\u0430\u0434\u043e\u0441\u0442\u043e\u0439\u043a\u0438\u0439 \u0433\u0435\u0442\u0435\u0440\u043e\u0444\u0430\u0437\u043d\u044b\u0439 \u0441\u043f\u043b\u0430\u0432.<\/p>\n\n\n\n

\u0421\u0435\u0440\u0442\u0438\u0444\u0438\u043a\u0430\u0442 \u0430\u043d\u0430\u043b\u0438\u0437\u0430 \u0442\u0430\u043a\u0436\u0435 \u0447\u0438\u0442\u0430\u0435\u0442\u0441\u044f \u0438\u043d\u0430\u0447\u0435, \u043a\u043e\u0433\u0434\u0430 \u0432\u044b \u0437\u043d\u0430\u0435\u0442\u0435 \u0442\u0435\u0445\u043d\u043e\u043b\u043e\u0433\u0438\u0447\u0435\u0441\u043a\u0443\u044e \u043b\u0438\u043d\u0438\u044e. Tm, \u043c\u0443\u0442\u043d\u043e\u0441\u0442\u044c, \u0443\u0434\u0430\u0440\u043d\u0430\u044f \u0432\u044f\u0437\u043a\u043e\u0441\u0442\u044c \u0438 \u041f\u0422\u0420 \u043a\u0430\u0436\u0434\u044b\u0439 \u0432\u043e\u0441\u0445\u043e\u0434\u044f\u0442 \u043a \u043e\u043f\u0440\u0435\u0434\u0435\u043b\u0435\u043d\u043d\u043e\u0439 \u0441\u0442\u0430\u0434\u0438\u0438 \u2014 \u0441\u043e\u043c\u043e\u043d\u043e\u043c\u0435\u0440 \u0432 \u043f\u0435\u0442\u043b\u0435\u0432\u043e\u043c \u0440\u0435\u0430\u043a\u0442\u043e\u0440\u0435, \u0440\u0430\u0437\u043c\u0435\u0440 \u043a\u0430\u0443\u0447\u0443\u043a\u043e\u0432\u044b\u0445 \u0434\u043e\u043c\u0435\u043d\u043e\u0432 \u0432\u043e \u0432\u0442\u043e\u0440\u043e\u043c \u0440\u0435\u0430\u043a\u0442\u043e\u0440\u0435, \u043e\u0441\u0432\u0435\u0442\u043b\u0438\u0442\u0435\u043b\u044c \u0438 \u0434\u043e\u0437\u0438\u0440\u043e\u0432\u043a\u0430 \u0432\u043e\u0434\u043e\u0440\u043e\u0434\u0430 \u043d\u0430 \u0444\u0438\u043d\u0438\u0448\u0435. \u0427\u0438\u0442\u0430\u0439\u0442\u0435 \u0438\u0445 \u043a\u0430\u043a \u0432\u044b\u0445\u043e\u0434\u043d\u044b\u0435 \u043f\u0430\u0440\u0430\u043c\u0435\u0442\u0440\u044b \u043f\u0440\u043e\u0446\u0435\u0441\u0441\u0430, \u0438 \u043d\u0435\u043d\u0430\u0434\u0435\u0436\u043d\u043e\u0435 \u0437\u043d\u0430\u0447\u0435\u043d\u0438\u0435, \u0442\u0430\u043a\u043e\u0435 \u043a\u0430\u043a Tm \u0441\u0442\u0430\u0442\u0438\u0441\u0442\u0438\u0447\u0435\u0441\u043a\u043e\u0433\u043e \u0441\u043e\u043f\u043e\u043b\u0438\u043c\u0435\u0440\u0430 168 \u00b0C, \u0432\u044b\u0434\u0430\u0441\u0442 \u0441\u0435\u0431\u044f.<\/p>","protected":false},"excerpt":{"rendered":"

Random and impact copolymer polypropylene run the same reactor train up to one decision. Either ethylene gets co-fed into the main loop, or a second gas-phase reactor is added downstream to grow a rubber phase inside the finished homopolymer. That one fork is the difference between a clear pipe resin and a sub-zero-tough automotive grade. […]<\/p>\n","protected":false},"author":4,"featured_media":1014,"comment_status":"closed","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[1],"tags":[],"class_list":["post-1016","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"blocksy_meta":[],"acf":[],"yoast_head":"\nHow Copolymer Polypropylene Is Manufactured - BASTONE<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/bastone-petrochem.com\/ru\/copolymer-polypropylene-manufacturing-process\/\" \/>\n<meta property=\"og:locale\" content=\"ru_RU\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How Copolymer Polypropylene Is Manufactured - BASTONE\" \/>\n<meta property=\"og:description\" content=\"Random and impact copolymer polypropylene run the same reactor train up to one decision. 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