Process Development for a Novel Class of Polymer

Project Objectives

Provide process development/compound preparation services to support commercial development of a new class of polymers.

Client Profile/Project Background

Our client, a multibillion dollar diversified chemical producer, had developed a new class of polymers exhibiting unique, commercially useful properties. While our client has internal pilot plant facilities, none met the processing requirements needed for the new system. Ricerca became involved early in the project and was selected to conduct process studies and supply test quantities of polymer.

Results/Status

Working closely with our client's development engineers, Ricerca conducted a statistically-designed process variable study at the 10-gallon scale. Processing involved operation at high pressure and utilized a proprietary catalyst developed by our client. Results of that work were used to scale the process to 100 gallons. Several polymer isolation/recovery strategies were conceptualized and tested. The end result of this effort was the installation and operation of a dedicated pilot plant capable of preparing several thousand pounds per month of specification polymer solution. We later added polymer processing equipment which allowed preparation of polymer in pellet form. We ultimately scaled up the polymerization process to our 500-gallon high pressure reactor and produced precommercial quantities of the polymer. We then helped transition the technology to our client's manufacturing site.