Polypropylene is one of the most widely used thermoplastics, accounting for one sixth of total consumption of polymeric materials. Many automobiles, textiles, appliances, and other everyday items contain substantial amounts of these polymers. The ability to manufacture a broad variety of polypropylenes having properties tailored for specific applications is the primary factor in its widespread use. Polypropylene is a polymer whose stereoregularity can be controlled, and it exhibits a spectrum of structural variations, because of the ability to control the manner in which the asymmetrum monomer is incorporated into the growing chain, and through the use of comonomers, usually ethylene, which is often used to provide impact‐modified or lower melting polymers. The types of polymers produced, chain‐structural parameters which can be varied and means to characterize them, morophology, thermodynamic properties, processing methods, end use properties, and applications are discussed.
Highly stereoselective Ziegler–Natta catalyst are primarily used to produce polypropylene and are the basis for most modern propylene polymerization processes. The historical development of these catalysts, from the early TiCl
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systems to the modern, high yield MgCl
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‐supported systems, including proposed polymerization mechanisms, are discussed. These catalysts enabled the evolution of these polymerization processes from the early slurry process to the current liquid monomer or gas‐phase processes. Metallocene catalysts have increasingly been an area of emphasis and have provided further commerical advances recently. Most major polymerization process in use today are discussed, with the most notable being the Spheripol and Unipol process. Key input into these polypropylene technologies and economics are the technology and infrastructure associated with propylene monomer. The large expansion in polypropylene production in the late 1980s was facilitated by the availability of this newer, less costly polymerization technology. This expansion, well in excess of growth in consumption, caused a dramatic reduction in polypropylene prices in the 1990s, most dramatically in the Far East, where few polypropylene plants existed outside Japan before 1985. Current economic prospects and associated industry trends are discussed.