Technology: driving force behind innovation and growth of polyolefins

Abstract The scientific and industrial significance of Ziegler–Natta catalysis for the development of polyolefin polymerisation processes and the improvement of product properties has been proven by the explosive growth of their worldwide consumption. The key of this huge evolution, still in progress, has been the revolutionary developments of the catalytic system, which can be considered as the true ‘engine’ for the technological innovation. A long and systematic research effort resulted in the truly scientific understanding of the complex catalysis mechanisms. This has allowed a great process simplification, which has culminated in the polymer particles themselves working as microreactors. This catalysis and process breakthrough, the reactor granule technology (RGT) has made multimonomer polymerisations possible, enhancing enormously the degree of freedom in achieving new materials. In order to continue the guaranteeing of the achievement of novel properties, a continuous development in the catalyst performance is needed. In recent years, a lot of attention has been focused on metallocene catalysts and polymeric materials they have generated. In spite of the huge expenditure from companies for research and development, metallocene polymers have acquired only niche positions in the marketplace due to their poor processability and catalyst costs. The possibility to combine Ziegler–Natta and metallocene (singe site, more in general) catalysts has been explored. Polymerisations synergistically coupling with the advantages of the two catalytic systems will allow the improvement and enlarging of the property envelope of today's polyolefins. The full exploitation of this potentiality will make the future for the revitalised Ziegler–Natta catalysis brighter still.