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.