The Catalyst Review June 2024 - 16

Movers & Shakers
Dr. Gerwin Wijsman
Catalyst Performance Manager, Borealis, The Netherlands
Gerwin Wijsman received his Ph.D. in Organic Chemistry from the Vrije Universiteit of Amsterdam
in 1994. He then joined DSM as lead for the R&D for Polypropylene catalyst and polymerization,
and later the PP resin development department. In 2004, Gerwin moved to Engelhard
Corporation as Technical Service Manager for polyolefin catalysts. When BASF acquired the
firm in 2006, he assumed responsibility for the global technical service of polyolefin catalysts.
In 2016, Gerwin accepted a position with W.R. Grace, where he transformed the local technical
service into a global organization. Based on his sound background in PO catalysts and PP
resins and his in-depth experience in the implementation of catalysts in polyolefin plants, he
took a position with Borealis in 2023. Currently, Gerwin is responsible for the scale-up, use, and
performance of the polyolefin catalysts used in the assets of Borealis and its joint ventures. He
can be reached at gerwin.wijsman@borealisgroup.com.
The Catalyst Review asked Dr. Wijsman to share his thoughts on catalyst design and use in producing
polyolefins.
It is well known that catalysts used to produce polyolefins dictate the microstructure of the polymer chains and, therefore, influence
the final properties of the resins that are produced. Conventional, heterogeneous catalysts have numerous active sites, which, in turn,
create different polymer chains. The result is a mixture of chains, making the design of the final resin properties a challenging task.
In the mid-1980s, metallocenes, a pure molecular single-site catalyst, emerged as a potential solution to this problem and was
embraced by many polyolefin companies who predicted a bright future for these catalysts. Success depended on implementing
these catalysts cost-effectively in large-scale polymerization processes using classical heterogenous catalysts. However, two
challenges needed to be overcome. First, the heterogenization of the metallocene on supports was adding severe complexity.
Second, the polyolefins produced with these single-site catalysts found only slow entry in the market due to a significant change in
performance that often led to poor processability.
Even though the metallocene catalysts eventually penetrated the polyethylene market, most polyolefin resins are still made using
heterogeneous multisite catalysts. To achieve enhanced resin properties downstream in the value chain, converters often use a
combination of resins and other materials. This combination of many materials (i.e., multi-layer films, resins with fillers, etc.) makes
recycling plastic articles particularly challenging.
In the last decade, development efforts have turned to determine whether advanced mono-material resins can be produced and
recycled. As a result, the polyolefin industry had to re-invent resins and develop applications designed for recycling. One of the
best ways to achieve this is by developing more advanced catalyst systems that give better control of the polymer chains and
using them in multi-reactor processes. Still, a significant area of focus involves improving traditional catalysts by using or changing
internal donors or external components in polymerization. This approach is often driven by increasing operability and complying with
regulation and legislation changes.
However, in order to make a significant step change, newer, more advanced next-generation metallocenes, ones that can give even
more control over the molecular chain and produce resins beyond the product envelope of what is currently possible, are a topic of
continued interest. In addition, although an improved understanding of the supports and how to anchor the metallocenes physically
or chemically has been developed, more know-how is still needed. An additional challenge remains, namely the sensitivity of these
highly sophisticated catalysts to external poisons, which affects the capability to employ them trouble-free in the existing polyolefin
plants.
To address these issues, a multidisciplinary approach is required by continuing to encourage continued cooperation between
academia and industry. In addition, an understanding of how to evaluate these catalysts at a small scale to predict their behavior in
large plants is necessary to speed up implementation timelines. These efforts remain an exciting and challenging feature for both
experienced and new industry specialists.
Polyolefins are unique materials, and the modern world cannot exist without them. Industry participants must ensure these materials
can be recycled at any point in the value chain. However, regulations and infrastructure are needed to make this happen. Most of all,
the awareness and mindset of the population are critical to a sustainable world and to prevent further pollution in nature.
Upcoming Special Features:
* Ethylene and Propylene Markets as a Kind of " Blue Ocean " Strategy for Integrated
Downstream Players
* Integrating Heterogeneous Catalysis & Biorefining Towards Biobased Chemicals:
Biocon Pilot Facility
16
The Catalyst Review
June 2024

The Catalyst Review June 2024

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