Polyolefins (POs) are the largest polymer product in the world. The innovation in converting commodity olefin monomers to highly value added high‐performance POs has been and will continue to be a major theme in both academic research and industry practice. The excellent properties of POs can be achieved through precise engineering of their chain architectures, which largely involves control of the chain branching structures. Long‐chain branching is one of the most important parameters in the aspect of various chain branching structures. A huge amount of literatures have been reported to achieve better control of long‐chain branched structures over the last two decades. Recently, good effort has been made in reviewing all the major literatures and summarizing the catalytic systems and synthetic strategies for the controlled synthesis of long‐chain branched POs. This paper represents the first of the series, that is, controlled synthesis of long‐chain branched POs via single catalyst systems.
Chain‐shuttling polymerization with dual catalysts has introduced a new class of polyolefins called olefin block copolymers (OBCs). A dynamic Monte Carlo model to describe the kinetics of chain‐shuttling copolymerization in a semi‐batch reactor is developed, and used it to study how the microstructure of OBCs with different numbers of blocks per chain evolves during polymerization. The model also describes how chain‐shuttling rate constants and concentration of chain‐shuttling agent affect populations of OBCs with different numbers of blocks per chain. These model predictions are useful to make OBCs with precisely designed microstructures.
Reversible‐deactivation radical polymerization (RDRP) techniques have received lots of interest for the past 20 years, not only owing to their simple, mild reaction conditions and broad applicability, but also their accessibility to produce polymeric materials with well‐defined structures. Modeling is widely applied to optimize the polymerization conditions and processes. In addition, there are numerous literatures on the kinetic and reactor models for RDRP processes, which show the accessibility on polymerization kinetics insight, process optimization, and controlling over chain microstructure with predetermined molecular weight and low dispersity, copolymer composition distribution, and sequence distribution. This review highlights the facility of the method of moments in the modeling field and presents a summary of the present state‐of‐the‐art and future perspectives focusing on the model‐based RDRP processes based on the method of moments. Summary on the current status and challenges is discussed briefly.
Polymer microgels with sizes of some tens to hundreds of micrometers can be formed with exquisite control by droplet‐based microfluidic templating. This study presents a systematic assessment of the effect of the premicrogel droplet size on the ability of production of such microgels. The focus is on two popular acrylamide‐derivatives at a fixed monomer concentration and external polymerization temperature. An exponential dependence of the success of droplet gelation on the droplet size is found, which can be rationalized in view of the balance between production and transfer of heat within and from the droplets on basis of a simple Arrhenius argument.
This article proposes a method to quantify the polymerization kinetics of ethylene and α‐olefins with commercial TiCl4/MgCl2 Ziegler–Natta catalysts. The method determines the leading apparent polymerization kinetic constants for each active site in a Ziegler–Natta catalyst by simultaneously fitting the instantaneous polymerization rate, cumulative polymer yield, and polymer molecular weight distribution measured at different times during a series of semi‐batch polymerization experiments. This approach quantifies the behavior of olefin polymerization with multisite catalysts using the least number of adjustable parameters needed to consistently model polymerization kinetics and polymer microstructural data.
Computational fluid dynamics (CFD) is used to study the gas–particle heat transfer in gas‐phase olefin polymerizations. Particularly, the effects of particle rotation on the gas–particle heat transfer coefficient and internal particle temperatures are evaluated, showing that particle rotation can exert a significant impact on observed temperature profiles, so that this effect should not be neglected during detailed CFD process simulations. As a consequence, particle rotation can lead to particle cooling and development of spherical gradient symmetry, validating the use of simpler modeling schemes that are based on reaction–diffusion in symmetrical spherical geometry.
The effect of prepolymerization on ethylene homopolymerization and ethylene/1‐hexene copolymerization with a commercial TiCl4/MgCl2 catalyst was investigated and the apparent homo‐ and copolymerization rate constants were estimated by varying polymerization temperature, pressure, time, and 1‐hexene/ethylene molar ratio during the prepolymerization. The apparent rate constants for activation, propagation, and deactivation depend on the prepolymerization conditions, showing that the prepolymerization stage strongly regulates the behavior of the catalyst in the main polymerization. Interestingly, the surface morphology of the prepolymer particles correlates to and explains these changes in polymerization kinetics behavior.
Various MgCl2‐supported Ziegler–Natta (ZN) catalysts are synthesized with the intention to influence polymerization performance and 1‐butene incorporation in an ethylene copolymer. Modifications are introduced during different steps in the synthesis process, namely support preparation, titanation, and catalyst workup. While multiple different effects are observed upon modification, heat treatment during titanation shows the greatest impact. Increasing the heat‐treatment temperature increases polymerization activity. More importantly, the 1‐butene distribution can be shifted toward a more homogeneous profile. The amount of 1‐butene incorporated is similar to both for short‐ and for very long‐chain molecules. This behavior has so far been known only from metallocene‐based polyethylene and suggests that active sites are distributed more homogeneously in the ZN catalyst.
The preparation of forced gradient polymers has received considerable attention using batch reactors, while the preparation of usable quantities of forced gradient copolymers using continuous flow reactors has been hampered by the need to vary the composition of the monomer feedstock continuously during the reaction. A reactor that allows for addition of a monomer feedstock continuously at all points along the length of the reactor tubing allows for the preparation of forced gradient copolymers in continuous flow reactors, allowing for the scale‐up and bulk preparation of these polymers. This study reports here the initial investigation of preparing forced gradient copolymers using the reversible addition–fragmentation chain transfer methodology in tube‐in‐tube continuous flow reactors.
A new way to fabricate monodisperse polymer particles in a microfluidic device without UV‐light and without the need for high temperatures is described in this article. By applying an activator regeneration by electron transfer ‐ atom transfer radical polymerization (ARGET‐ATRP) initiator system in a co‐capillary microfluidic setup and by separating the monomer mixture in an initiator and a catalyst phase, a fast polymerization of the droplets at low temperature without premature curing and thus clogging of the capillaries can be achieved. The influence of the flow rates on the particle sizes and their polydispersity as well as the controlled character of the polymerization are investigated. The particle size is well adjustable, but the reaction is not controlled due to the high radical concentration needed for rapid polymerization. In addition, particles with incorporated UV‐dyes are produced as a proof of concept at low temperature.
In this article a systematic method is proposed to deconvolute the time‐dependent molecular weight distributions (MWD) and average comonomer fraction profiles of ethylene/1‐olefin copolymers made with heterogeneous Ziegler–Natta catalysts. These distributions with a high‐temperature gel permeation chromatography equipped with an infrared detector at four different polymerization times have been measured and used this information to infer how the fractions of polymer made on each site type varied with polymerization time. The model estimates here the minimum number of active site types needed to describe these copolymers, the MWD of polymer populations made on each site type, and their average comonomer fractions. This method is useful to quantify the microstructure of olefin copolymers made with multiple site type catalysts using the least number of adjustable parameters.
This work aims at deriving analytical solutions for the molecular architecture of multi‐block polymer synthesized in a dual‐catalyst single CSTR. While the relevant equations are developed for homopolymerization, they can easily be extended to copolymerization. Special emphasis is placed on the quantities associated with each catalyst rather than the overall ones. However, if all rate parameters are available, the expressions can be used to calculate the properties of the material made by each catalyst as well as the overall ones under various process conditions. Given the reasonable assumption of large residence time, the solutions are simplified to elucidate the kinetics of chain‐shuttling involving two catalysts. It is shown that systems with low chain‐shuttling ability, if DPPn,0 ≠ DPQn,0, may exhibit significant deviation from Flory's most probable distribution. Furthermore, systems with high chain‐shuttling ability produce macromolecules with more uniform architecture and polydispersity index close to 2.
The present article reveals important roles of metal alkyl activators in tuning the performance of the Phillips catalyst in ethylene polymerization. The addition of aluminum alkyl aids the activation of the catalyst, while excess addition leads to the loss of the activity. The balance between the activation and deactivation depends on the type of employed aluminum alkyl, and tri‐n‐octylaluminum offers the most efficient catalyst usage by preferentially suppressing the deactivation. The passivation of aluminum trialkyl with a hindered phenol mildens not only the deactivation but also chain transfer reactions, leading to an increment of high molecular weight fractions.
Two artificial neural network models (forward and inverse) are developed to describe ethylene/1‐olefin copolymerization with a catalyst having two site types using training and testing datasets obtained from a polymerization kinetic model. The forward model is applied to predict the molecular weight and chemical composition distributions of the polymer from a set of polymerization conditions, such as ethylene concentration, 1‐olefin concentration, cocatalyst concentration, hydrogen concentration, and polymerization temperature. The results of the forward model agree well with those from the kinetic model. The inverse model is applied to determine the polymerization conditions to produce polymers with desired microstructures. Although the inverse model generates multiple solutions for the general case, unique solutions are obtained when one of the three key process parameters (ethylene concentration, 1‐olefin concentration, and polymerization temperature) is kept constant. The proposed model can be used as an efficient tool to design materials from a set of polymerization conditions.
Amphiphilic block copolymers of 2,3,4,5,6‐pentafluorostyrene (PFS) and methacrylic acid (MAA) are synthesized via nitroxide‐mediated polymerization (NMP). It is established that to obtain a controlled copolymerization a minimum of 40 mol% of PFS is required, which is significantly greater than other copolymerization systems such as using 4.5–8 mol% styrene or 1 mol% of 9‐(4‐vinylbenzyl)‐9H‐carbazole to control the copolymerization of methacrylates. It is surmised that this lack of control is due to the reactivity ratios that favor the addition of MAA rather than PFS (rPFS = 0.14, rMAA = 6.97). However this reactivity ratio pair suggests that a one‐shot delayed injection approach can be utilized to synthesize almost pure block copolymers in one pot. Therefore, poly(PFS)‐b‐(PFS‐ran‐MAA) block copolymers are synthesized by a one‐shot delayed addition of MAA. While the concentration of irreversibly terminated chains is evident these results suggest a promising route to the synthesis of fluorinated amphiphilic block copolymers by NMP.
SiO2‐supported Cr–V bimetallic catalyst can be used for producing bimodal polyethylene which can be applied for high‐performance pipe material. Alkyl aluminum are used to prereduce the bimetallic catalysts, and the effects of alkyl aluminum for the bimetallic catalyst are fully studied by catalyst characterization, polymerization kinetics, and the properties of polymer product by the comparison with the catalyst without prereduction. The result shows that the optimum polymerization activity is almost double after the catalyst is prereduced by triisobutylaluminum (TIBA), and the needed dosage of alkyl aluminum also is decreased significantly. The alkyl aluminum of the prereduced catalyst can also act as a chain transfer agent, significantly reducing the molecular weight of the polymer. The diethylaluminum chloride (DEAC) is mostly deactivating the Cr species during the ethylene polymerization. The synthesized catalysts, prereduced by TIBA, triethylaluminum (TEA), and DEAC, all exhibited good hydrogen response and comonomer interposition ability, which will be favorable for the further application of the bimetallic catalyst in the industrial field.
The present work describes a kinetic approach which is able to predict how the internal surface area of polymer particles evolve during suspension copolymerization in the presence of porogen. For such a purpose, the concept of elementary gel structures has been introduced by modeling their surface area through the numerical fractionation technique. Thus, variables such as diluents composition, divinyl monomer concentration, and dilution degree could be assessed in the simulations. The present mathematical model is validated by using different experimental data from literature and a fair agreement is reached. Furthermore, the developed model is also capable of predicting the most significant copolymerization variables, e.g., conversion rate, concentration of species, and average molecular weights.
A novel vanadium‐modified (SiO2/MgO/MgCl2)·TiClx Ziegler–Natta ethylene polymerization catalyst with much better catalytic performance is successfully developed. The catalyst is prepared by co‐impregnation of aqueous solution of water‐soluble magnesium and vanadium compounds on SiO2, and a supported thin layer of magnesium and vanadium oxides is formed over the surface of SiO2 after high temperature calcination in dry air, followed by further reaction with titanium tetrachloride to synthesize the magnesium dichloride carrier in situ and to support the titanium species simultaneously. By characterization of the catalysts and the polymers and investigation of the polymerization behaviors, it is found that compared with the original (SiO2/MgO/MgCl2)·TiClx ZN catalyst, the introduction of vanadium species induce improved catalytic performance with 27% higher activity, 48% higher hydrogen response, and 60% higher 1‐hexene incorporation ability with better short chain branch distribution.
A kinetic model for the radical homopolymerization of acrylamide in aqueous solution is developed, incorporating propagation and termination rate coefficients as functions of monomer concentration and including the formation and reaction of midchain radicals based on the insights and measured rate coefficients from recent pulsed‐laser studies. The model successfully represents the batch conversion profiles measured using an in situ NMR technique between 40 and 70 °C with initial monomer concentrations of 5 to 40 wt%, as well as the associated polymer molar mass distributions. In particular, the model captures the decreased rate that occurs at lowered monomer concentrations as a result of the formation of less‐active midchain radicals by backbiting. Previous literature data are also well represented by the model.
The photopolymerization of acrylated oligomers dispersed in an aqueous medium is successfully demonstrated using a simple continuous photoreactor designed with flexible tubing, which presents straightforward up‐scaling and maintenance features. The performance of the continuous photoreactor is assessed by varying the length of the tube exposed to ultraviolet light as well as the flow rate of the aqueous dispersion thr ough the reactor. The insoluble nature of the dispersed particles after in‐situ photo‐crosslinking is particularly suitable for the estimation of the actual number of polymerized particles from static and dynamic light scattering data. The procedure is discussed in detail. Along with the overall acrylate double bond conversion of the particles determined by infrared spectroscopy, an estimation of the average conversion per polymerized particle is provided as a function of the exposure time to ultraviolet light. The sub‐microscopic characterization by peak‐force tapping atomic force microscopy of the particles after photopolymerization is also presented.
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