Polyketone (POK): A new highlight in the family of engineering plastics

Thread Content

Polyketones (POK), also known as aliphatic polyketones, are novel semi-crystalline engineering plastics formed by the alternating copolymerization of carbon monoxide and olefins (mainly ethylene and propylene). Thanks to its unique molecular structure, POK combines high strength, exceptional wear resistance, high toughness, low water absorption, as well as excellent resistance to chemical corrosion and gas permeation. It is gradually overcoming the performance limitations of traditional engineering plastics such as PA and POM, and is becoming a highly promising alternative for use in high-end manufacturing sectors such as automotive, electronics, and packaging. I. Product Characteristics: The performance advantages of POK stem from its regular linear crystalline structure, in which the main chain is formed by a strict alternation of carbon monoxide and olefins. This structure endows it with a range of excellent comprehensive properties: 1. Wear resistance: Its wear resistance is 14 times that of polyoxymethylene (POM), and its notched impact strength is more than twice that of PA66; it combines stiffness with toughness. 2. Chemical resistance and low water absorption: The water absorption rate is extremely low (about 0.5%), far lower than that of nylon, with good dimensional stability ； It exhibits excellent resistance to a variety of chemical solvents, oils, and automotive fuels, aside from strong acids and strong bases. 3. Temperature resistance and environmental friendliness: The heat deformation temperature is as high as 200–215°C, and the temperature for long-term use can reach 120°C℃ ； The synthesis process consumes carbon monoxide, giving it green and environmentally friendly properties. II. Production Process and Technology Origin The core technology for the industrial production of POK lies in achieving a strictly alternating copolymerization of carbon monoxide and olefins, which heavily depends on a specific catalytic system. 1. Mainstream process: Currently, commercial POK production worldwide relies on the solution polymerization method, whose core involves using a palladium-phosphine ligand catalyst system to catalyze the reaction in the presence of strong acids. This technology was developed by Shell in the 1980s, and later the Hyosung Group of South Korea acquired the patents and brought it to commercial use. The key process challenges lie in the preparation and recovery of highly active and selective palladium catalysts, the effective removal of reaction heat, and the precise control of monomer ratios. These high technical barriers are the main reasons why POK has long been under the monopoly of a few companies in terms of production. 2. Sources of technology and global competitive landscape: The technological development and industrialization of POK have followed a tortuous path, and the global market is currently highly concentrated. (1) Development history and overseas monopolies: The true technological breakthrough was the palladium catalytic system developed by Shell in the 1980s. Hyosung Group of South Korea acquired the relevant patents and, following research and development, launched a commercial product in 2013. In 2015, it built the world’s first 10,000-ton production line in Ulsan, thereby coming to dominate the global POK market. Currently, Hyosung remains the world’s largest POK producer, essentially monopolizing the market. (2) Domestic technology status: As of now, Chinese domestic enterprises do not yet possess the capacity to produce POK resin on a large scale, so the domestic market relies on imports. Domestic companies have already made arrangements in the areas of modification and product processing; for example, companies such as Suzhou Warduf New Materials Technology Co., Ltd. provide modified POK materials reinforced with glass fibers.