The Catalyst Review July 2024 - 16

Movers & Shakers
Marco Piccinini, Ph.D.
Catalyst Technology Manager, INEOS Olefins & Polymers Europe, Brussels
After successfully completing his Ph.D. at Cardiff University in heterogeneous catalysis focused on the
use of gold nanoparticles for the direct synthesis of H2
O2, Dr. Piccinini assumed the role of Research
Manager for VCM (Vinyl Chloride Monomer) & OCD (Organic Chlorine Derivatives) at INOVYN,
a subsidiary of INEOS. In this capacity, he oversaw the development and scale-up of catalysts,
progressing from laboratory experimentation to commercial deployment. His responsibilities also
extended to pioneering research in novel catalytic technologies aimed at alternative routes for
ethylene production.
Subsequently, Dr. Piccinini transitioned to the role of Catalyst Technology Manager at INEOS Olefins
& Polymers. In this role, he leads the research and development efforts across a broad spectrum
of Polyethylene and Polypropylene catalysts, encompassing Ziegler-Natta, Chromium, and
Metallocene technologies, from laboratory inception through pilot-scale trials up to commercial
implementation. Additionally, he supports the INEOS Advanced Recycling agenda for converting
plastic waste into virgin polyols. Dr. Piccinini can be reached at marco.piccinini@ineos.com.
The Catalyst Review asked Dr. Piccinini to discuss the challenges and rewards associated with
developing new polyolefin catalysts.
The focus of my research group at INEOS Olefins & Polymers is the development of the next catalyst generation to produce both
polyethylene and polypropylene using different catalytic technologies such as Chromium, Ziegler-Natta, and Metallocene. Though
most of these catalysts were initially developed more than 50 years ago, much work is yet to be done. Notably, the recent shift
towards a more sustainable and circular economy necessitates the redesign of products to meet new recyclability standards and
enhance manufacturing efficiency. In this rapidly evolving landscape, catalysts play a pivotal role in providing efficient solutions and
enabling the production of novel products to meet emerging market needs while improving process efficiency.
A prime example of our endeavors is the recent development of a groundbreaking catalyst capable of producing an outstanding
monomodal resin for HDPE BOPE (Bi-oriented PolyEthylene) production. This accomplishment was the culmination of over three years
of intensive work by our team in Brussels, involving the development and scale-up of a new catalyst from laboratory bench reactors
to demo up to commercial-scale production. Notably, INEOS was among the pioneers in introducing this innovative solution to the
market. The challenge was multifaceted: delivering a monomodal resin to reduce energy consumption during extrusion, offering an
economically attractive solution, and having a product design that can withstand significant stretching of the polyethylene film in
both the machine and transverse directions. The resulting BOPE product promises to transform current hard-to-recycle packaging
solutions, such as multi-material stand-up pouches, into mono-material designs that are significantly more recyclable.
Another key focus of our research involves developing more efficient catalysts to reduce the carbon footprint of manufacturing
processes. Our latest Ziegler-Natta catalyst generation, INcat™ S, features higher activity, enabling reduced catalyst usage.
Additionally, this new catalyst generation exhibits a 70% lower ethanation rate compared to standard catalysts, minimizing the
formation of unwanted ethane through side-reaction hydrogenation. The reduction of ethane is important as it is often flared, leading
to CO2
The transition towards more sustainable polyolefin production and a circular economy will be paramount in the next decade. I
firmly believe that catalysts will serve as enablers in this journey. Significant effort is still required to support polyolefin converters
in developing and manufacturing the recyclable products of tomorrow. Collaboration and innovation across the industry will be
essential in driving meaningful change and addressing the challenges posed by an evolving market landscape.
Upcoming Special Features:
Integrating Heterogeneous Catalysis & Biorefining Towards Biobased Chemicals: Biocon Pilot Facility
Ethylene and Propylene Markets as a Kind of " Blue Ocean " Strategy for Integrated Downstream Players
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The Catalyst Review
July 2024
emissions. For a plant with a capacity of 300 kta, the carbon footprint improvement is estimated to reach up to 800 tons of
CO2. Moreover, INcat™ S possesses the unique ability to reduce the production of undesired wax.

The Catalyst Review July 2024

Table of Contents for the Digital Edition of The Catalyst Review July 2024