Norner Advance® M: Pioneering Sustainable Metallocene PE Technology

Norner Advance® M represents a significant leap forward in Metallocene PE technology. By employing unsupported metallocene catalysts in solution form, this technology not only reduces environmental impact but also lowers production costs, making it a more sustainable and economically viable option for the industry.

Authors: Albrecht Dix and Lars Henry Evensen, Norner.

Market Growth and Potential

In the second decade of the 21st century, the growth of metallocene polyethylene (PE) has been remarkable, driven by its superior properties and versatility. This period saw a notable shift in market dynamics, with metallocene resins experiencing high single-digit growth rates, outpacing traditional PE resins. In particular, Metallocene linear low-density polyethylene (mLLDPE) has gained significant traction, mainly in the flexible packaging sector, due to its ability to produce stronger, thinner films with enhanced performance characteristics. However, most of this growth was fueled by gas-phase polymerisation plants, leading to a commoditisation of mLLDPE while leaving the product opportunities in MDPE and HDPE from slurry-type polymerisation processes unexplored.

Technological Advancements & Benefits

Generally, the polyolefin industry prefers heterogeneous catalysts for polyethylene polymerisation processes. Ziegler-Natta catalysts, in particular, are effective in slurry-phase polymerisation, which is widely used for producing polyethylene, giving high productivity and reliable process stability. Heterogenous metallocene catalysts, on the other hand, have proven to be costly due to manufacturing cost and low activity, thereby limiting access to advanced MDPE and HDPE products.

The Norner Advance® M PE technology addresses this issue by demonstrating high polymerisation activity, resulting in lower production costs and reduced catalyst consumption (Figure 1). The technology also ensures higher purity and lower catalyst residues in the final polymer, contributing to a cleaner and more sustainable production process.

Figure 1: Polymerisation Activity

One of the standout features of Norner Advance® M is its adaptability to slurry processes, such as Mitsui CX, Hostalen, MarTECH, and Innovene-S. The technology is particularly beneficial for multimodal PE production, which benefits polymer processability and product performance in film, roto blow moulding and pipe applications. Furthermore, the technology can be applied to a wide range of metallocene complexes and activators, allowing free choice for the implementation of license-free or proprietary solutions.

Process Validation and Operability

The technology has been validated in a continuous bimodal process on a mini-pilot scale, showcasing excellent operability and stable conditions. The validation process involved comparing the behavior of unsupported metallocene catalysts with silica-supported catalysts, with the former demonstrating superior performance in terms of process stability and product quality. It was demonstrated that while achieving higher productivity, similar particle size and distribution are achieved in a 2-reactor process (Figure 2).

Application Potential

Norner Advance® M supports an advanced metallocene PE product portfolio, catering to various applications such as roto moulding and blown film. The technology has been tested and validated in these applications, with the prototypes matching or surpassing commercial benchmarks. We are also confident that the high Mw capability of Norner Advance® M combined with excellent comonomer distribution will provide well-performing products for blow moulding and pressure pipes.

Conclusion

Norner Advance® M is a testament to Norner's commitment to innovation and sustainability. By leveraging unsupported metallocene catalysts, the technology offers significant benefits in terms of process operability, cost efficiency, and environmental impact. As the Metallocene PE market continues to grow, Norner Advance® M is well-positioned to lead the change towards a more sustainable future in polymer technology.

The technology has demonstrated a TRL 6, and Norner is now welcoming partners that are interested in evaluating the benefits of entering the market with high-value-added metallocene PE products by revamping their CSTR plants.

About Norner Advance® M

Norner Advance® M provides metallocene PE from slurry technologies with significant advantages, like:

• Substantially reduced catalyst costs

• A broader molecular weight window

• Enhanced purity

• Improved comonomer distribution compared to Ziegler-Natta catalysts

• A reduced carbon footprint