High pressure LDPE production was first started in the 1950s and, while this technology has been overshadowed in recent years by its LLDPE rival, processors still appreciate LDPE's good optical and processing qualities.
Two basic processes are available for the production of low density polyethylene: stirred autoclave or tubular routes. The tubular reactor has been gaining preference over the autoclave route due to its higher ethylene conversion rates. The reaction is carried out using a free radical initiator consisting of one or two peroxides with or without oxygen. The processes can generally be used to make copolymers with polar comonomers, such as EVA polymer.
Recent developments have seen the scale of tubular plants rising sharply, to around 300,000 tonnes/year and above, giving lower production costs while ethylene conversion rates have also improved. Capital costs are claimed to be competitive while the higher utility costs for LDPE are offset by no need for comonomers. New operating techniques prevent polymer build-up on the inside wall of the reactor tubes, which decreases downtime and increases reactor efficiency.
However, the development of metallocene catalysts could further help the penetration of LLDPE into low density markets. The latest metallocenes are claimed to produce high pressure type resins with comparable processing qualities to LDPE.
Webinar - Understanding Polyethylene Margins
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Polyethylene low density
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Polyethylene low density
Uses and Outlook
Low density polyethylene (LDPE) is used mainly in film applications for both packaging and non-packaging uses. Other markets include extrusion coatings, sheathing in cables and injection moulding applications.
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