INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

Case Study # 57

Purpose of this case study: This application illustrates how a

new technology can reduce wastes and emissions by combining

three processes into one.

1. Headline: A polypropylene polymers production process

(CATALLOY process) in gaseous phase reduces environmental

impacts.

2. Background: A 80,000 t/y CATALLOY based polymer production

plant has been in operation since 1990 in Ferrara, Italy.

A second plant is in operation in Bayport Texas, United

States. The process itself was developed in 1984 and came

into full operation in 1990.

3. Cleaner Production Principle: New technology

4. Description of Cleaner Production Application:

The technology in question consists of a multistage

polymerization process carries out in the gaseous hydrogen

phase, using very highly active spherical catalyzers,

Ziegler-Natta type, held by the active magnesium chloride.

Polypropylene and rubber copolymer matrixes can be

obtained at the synthesis step in a single unit operation.

Completed 1992, The CATALLOY process results from

Ziegler-Natta research on catalysts and polymerization and

from studies on properties of structure correlation in

polymeric materials. Features like the use of advanced

catalyzers together with process flexibility, yields

products that can be applied in a wide range of

manufacturing. The new process produces in a single plant

the two components of a polymeric mixture, already

blended, thereby avoiding the need to mechanical blend

them. With conventional technology, the same product is

obtained, only after three separate processes are

performed. By carrying out the overall process in a single

unit of operation, overall costs (investment, operating,

transport and reworking), energy consumption as well as

environmental impact, are greatly reduced. The new

technology is quoted to lower the COD in the liquid waste

by 99%, steam consumption by 68% and electricity by 60%.

It is considered an innovative and successful production

technology resulting in environmental and economic

benefits.

5. Economics: Investments were quoted to be 46% lower

compared to the conventional technology. Operational costs

are quoted to be 19% lower than that of similar

conventional plants.

6. Advantages: In addition to the benefits outlined above and

under economic benefits, a 100,000 t/v CATALLOY based

polymers production plant can substitute a group of plants

producing respectively 70,000 t/y of polypropylene, 30,000

t/y of rubber copolymers and 100,000 t/y of compounds.

7. Constraints: No information.

8. Contacts:

Himont Italia

S.r.l. Via Rosellini 19

I - 20124 MILANO

TEL: 39 2 6996 8070

FAX: 39 2 6996 4548

or

Mr M Loprieno

Foro Bonaparte, 31

I 20121 Milano Italy

TEL: 39 2 6270 5512

FAX: 392 6270 5045

or

Mr G Bardone

ENEA CRE Casaccia

Dip Ambiente

Via Anguillarese 301

00060 - S Maria di Galeria ROME

Italy

TEL: 396 3048 6662

FAX:396 30483220

9. Keywords: Italy, chemical, petrochemical industry,

plastics, new technology, process modification,

polypropylene, catalyst, COD

10. Reviewer's comments: This case study was submitted to UNEP

IE in 1994 by Italy' ENEA. It was reviewed and edited by

UNEP IE in July 1995. It has not undergone a formal

technical review.