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The effects of condensed-mode operation on the polymerization, morphology and properties of high-impact ethylene–propylene copolymers
János Molnár, Pavel Shutov, Renate Eckmayr, Jingbo Wang, Vasileios Touloupidis, Markus Gahleitner
Vol. 20., No.9., Pages 939-954, 2026
DOI: 10.3144/expresspolymlett.2026.69
Corresponding author: János Molnár

GRAPHICAL ABSTRACT

ABSTRACT

Elastomeric ethylene–propylene copolymer (EPC) content is a decisive factor in the impact performance of multiphase polypropylene (PP) impact copolymers (ICPs). However, producing PP ICPs with high EPC content remains challenging because increasing EPC content raises powder stickiness, potentially leading to production problems such as fouling or sheeting. Condensed mode operation with an induced condensing agent (ICA) has recently been proposed to reduce stickiness and improve flowability. In this study, we performed bench-scale PP ICP polymerizations with n-pentane (C5) or n-heptane (C7) as ICAs to assess this approach. Both ICAs enhanced monomer solubility and the polymerization rate through co-solubility. At high EPC content, C7 improved powder flowability, whereas C5 gave stickiness comparable to or greater than that of the reference. Atomic force microscopy revealed that C7 shifted the dispersed EPC phase toward the particle core, explaining the improved flowability. In contrast to literature reports, ethylene response and EPC comonomer distribution remained unchanged. Consequently, mechanical and thermal properties were unaffected. Condensed-mode operation may therefore offer benefits only when specific ICAs, such as C7, are used in substantial amounts, limiting practical applicability because of additional purification costs.


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Published by:

Budapest University of Technology and Economics,
Faculty of Mechanical Engineering, Department of Polymer Engineering