Influence of the particle size of the MgCl2 support on the performance of Ziegler catalysts in the polymerization of ethylene to ultra‐high molecular weight polyethylene and the resulting polymer properties

A highly systematic size series of Ziegler catalysts with similar porosities and surface textures are synthesized by varying the stirring speed during the MgCl₂ support synthesis. Besides the mean particle size, the only substantial difference observed between the various catalysts is the size and number of nodules per particle. Varying the mean diameter of the catalyst particles between 1.5 and 11.9 µm, leads to a pronounced impact on the activity in ultra‐high molecular weight polyethylene (UHMWPE) polymerization, while the M_w capabilities are only affected to a limited extend. In addition, it is observed that both the M_ws as the polymer bulk density (BD) increases during the course of the polymerization. This particularity allows to optimize the M_w and/or BD at a set polymer size, by tuning the catalyst particle size. This is particularly interesting in UHMWPE production, as control of the morphological and structural properties of the UHMWPE reactor powders are critical for efficient processing as well as the performance of the final product. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2679–2690     

Preparation of Polyethylene/Graphene Nanocomposites with Octadecylamine‐Modified Graphene Oxide‐MgCl‐Supported Ziegler–Natta Catalyst

In this work, an octadecylamine‐modified graphene oxide (ODA‐GO)‐MgCl‐supported Ziegler–Natta catalyst was synthesized by reacting ODA‐GO with a Grignard reagent, followed by anchoring TiCl₄ to the structure. The effect of the ODA‐GO on the catalyst morphology and ethylene polymerization behavior was examined. The resultant polyethylene (PE)/ODA‐GO nanocomposites directly mirrored the catalyst morphology by forming a layered morphology, and the ODA‐GO fillers were well dispersed in the PE matrix and showed strong interfacial adhesion with it. The resultant PE/ODA‐GO nanocomposites exhibited better thermal stability and mechanical properties than neat PE, even with a small amount of ODA‐GO added. Thus, this work provides a facile approach to the production of high‐performance PE. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 855–860     

Syndiospecific polymerization of styrene with Cp*TiCl((OCH(R)CH2)2NAr)/MMAO

A series of titanium complexes Cp*TiCl((OCH(R)CH₂)₂NAr) (Cp* = C₅Me₅, R = H, Ar = Phenyl ( 2a) ; R = H, Ar = 2,6‐dimethylphenyl ( 2b ); R = Me, Ar = Phenyl ( 2c )) was prepared by the reaction of corresponding N,N‐diethoxylaniline derivatives, with Cp*TiCl₃ in the presence of excessive triethylamine. All the titanium complexes display higher catalytic activities towards the syndiospecific polymerization of styrene in the presence of modified methylaluminoxane (MMAO) as a cocatalyst, and produce higher molecular weight polystyrenes with higher syndiotacticity and melting temperature than their mother complex Cp*TiCl₃. The catalyst activities and polymer yields as well as polymer properties are considerably affected by the steric and electronic effect of the tridentate ligands. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 1562–1568, 2005     

Novel spherical Ziegler–Natta catalyst for polymerization and copolymerization. I. Spherical MgCl2 support

Spherical MgCl₂ adducts used as supports for a Ziegler–Natta catalyst for olefin polymerization were prepared by the general precipitation method. The influence of MgCl₂/EtOH (mol/mol) and the dispersion speeds on the particle size (PS) and particle size distribution (PSD) were investigated. It was found that the former played a trivial role in controlling the PS and PSD, and the latter was the key factor. In particular, the influence of ethanol on the crystal structure was further examined, with consideration given to the performance of the supported Ziegler–Natta catalyst. It was believed that the reactions between MgCl₂ and ethanol had a controlling effect on the destruction of the original anhydrous MgCl₂, which was the key point in the preparation of suitable supports for the latest generation Ziegler–Natta catalyst. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3112–3119, 2002     

Microgels based on isotactic poly(styrene): Synthesis and characterization

Poly(styrene) microgels are known, but the influence of tacticity on particle formation and behavior has not been investigated yet. Isotactic poly(styrene) (iPS) with M_n = 15–120 kg/mol is synthesized by coordinate polymerization and cross‐linked by Friedel–Crafts alkylation in a miniemulsion. Nuclear magnetic resonance (NMR) spectroscopy, light microscopy, cryogenic transmission electron microscopy, and wide‐angle powder diffraction are applied to understand the structure of microgels obtained. Typically, spherical microgels with overall diameter of 40–500 nm are found. Isotacticity of the polymer is retained during microgel formation. Increase of cross‐linker content leads to partial crystallinity inside the microgel. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 175–180     

Effect of the structure of titanium–magnesium catalysts on the morphology of polyethylene produced

The structure and formation of polyethylene (PE) particles on supported titanium–magnesium catalysts having different structural characteristics (sizes of microcrystallites, mesopores, and subparticles) were studied for the first time. Scanning electron microscopy was used to identify structural elements of the polymer particles formed over such catalysts and to reveal morphological changes in the growing polymer particles when the yield was increased from approximately 0.2 g PE/g catalyst to approximately 13 kg PE/g catalyst. A relationship was found between structural characteristics of the porous catalyst particles, morphology of the nascent polymer particles, and bulk density of the polymer powder. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2298–2308     

Increased rubber content in high impact polypropylene via a sirius ziegler‐natta catalyst containing nanoparticles

High impact polypropylene was produced in a two‐reactor polymerization process operating in series using two different Ziegler‐Natta catalysts (referred to as catalysts A and B) that had been prepared by Sirius emulsion technology in the absence and presence of SiO₂ nanoparticles, respectively. The homo polypropylene matrix was produced in liquid bulk and the ethylene/propylene rubber in gas phase under industrial conditions. Catalyst B was prepared with the same emulsion technology as catalyst A, except that SiO₂ nanoparticles (average particles size 80 nm) were added during catalyst preparation. Scanning electron microscopy studies showed that the nanoparticles were fairly evenly distributed within catalyst B particles, although there was some agglomeration. It was shown that the nanoparticles in catalyst B increased the internal porosity in the homo polypropylene matrix particles and this enabled a significant increase in the rubber content. Maximum rubber content, before running into stickiness problems, was approximately 25 wt % for catalyst A without nanoparticles, whereas the maximum rubber content for catalyst B was almost doubled to 45 wt % due to the beneficial transformation of the internal catalyst morphology by the nanoparticles. In addition, it was also found that the reaction was not mass transfer limited during the ethylene/propylene rubber polymerization stage, even at very high rubber contents where all pores and cavities were filled with rubber. © 2013 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Active center determinations on MgCl2‐supported fourth‐ and fifth‐generation Ziegler–Natta catalysts for propylene polymerization

Active center determinations on different Ziegler–Natta polypropylene catalysts, comprising MgCl₂, TiCl₄, and either a diether or a phthalate ester as internal donor, have been carried out by quenching propylene polymerization with tritiated ethanol, followed by radiochemical analysis of the resulting polymers. The purpose of this study was to determine the factors contributing to the high activities of the catalyst system MgCl₂/TiCl₄/diether—AlEt₃. Active center contents (C*) in the range 2–8% (of total Ti present) were measured and a strong correlation between catalyst activity and active center content was found, indicating that the high activity of the diether‐containing catalysts is due to an increased proportion of active centers rather than to a difference in propagation rate coefficients. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1635–1647, 2006     

AlR2Cl/MgR2 combinations as universal cocatalysts for Ziegler–Natta,metallocene, and post‐metallocene catalysts

Combinations of dialkylaluminum chlorides and dialkylmagnesium compounds, when used at molar [AlR₂Cl]:[MgR₂] ratios ≥ 2, act as universal cocatalysts for all three presently known types of alkene polymerization catalysts—Ziegler–Natta, metallocene, and post‐metallocene. When these cocatalysts are used with supported Ti‐based Ziegler–Natta catalysts, they produce catalyst systems which are 1.5–2 times more active than the systems utilizing AlR₃ compounds as cocatalysts. Combinations of AlR₂Cl/MgR₂ cocatalysts and various metallocene complexes produce single‐center catalyst systems similar to those formed in the presence of MAO. The same cocatalysts activate numerous post‐metallocene Ti complexes containing bidentate ligands of a different nature and produce multicenter systems of very high activity. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3271–3285, 2009     

Investigation of the microstructure of polypropylene prepared with ansa and fluxional metallocene catalysts with an extended Coleman–Fox model

Temperature (T) effects on the microstructure of polypropylene made with metallocene catalysts have been investigated with the theoretical framework originally developed by Coleman and Fox and extended to the stereospecific polymerization of propylene with two‐state ansa and fluxional metallocene catalysts. T effects on the polymer microstructure are mainly due to factors other than changes in the intrinsic stereoselectivity of the two states. The model has been applied to the stereosequence distributions of polypropylene prepared with the C₁‐symmetric Me₂Si(Ind)(Flu)ZrCl₂ complex, activated with methyl aluminoxane, over a range of T and monomer concentration ([M]) values. The use of these two variables, in combination with the Coleman–Fox model (or a kinetic model), allows more reliable estimates of fundamental parameters, especially when the microstructure is a weak function of one of these variables at a constant value of T (e.g., [M]). © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 1797–1810, 2005     

Synthesis of polypropylene-co-p-methylstyrene copolymers by metallocene and Ziegler–Natta catalysts

This paper discusses the copolymerization reaction of propylene and p-methylstyrene (p-MS) via four of the best-known isospecific catalysts, including two homogeneous metallocene catalysts, namely, {SiMe₂[2-Me-4-Ph(Ind)]₂}ZrCl₂ and Et(Ind)₂ZrCl₂, and two heterogeneous Ziegler–Natta catalysts, namely, MgCl₂/TiCl₄/electron donor (ED)/AlEt₃ and TiCl₃. AA/Et₂AlCl. By comparing the experimental results, metallocene catalysts show no advantage over Ziegler–Natta catalysts. The combination of steric jamming during the consective insertion of 2,1-inserted p-MS and 1,2-inserted propylene (k₂₁ reaction) and the lack of p-MS homopolymerization (k₂₂ reaction) in the metallocene coordination mechanism drastically reduces catalyst activity and polymer molecular weight. On the other hand, the Ziegler–Natta heterogeneous catalyst proceeding with 1,2-specific insertion manner for both monomers shows no retardation because of the p-MS comonomer. Specifically, the supported MgCl₂/TiCl₄/ED/AlEt₃ catalyst, which contains an internal ED, produces copolymers with high molecular weight, high melting point, and no p-MS homopolymer. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2795–2802, 1999     

Copolymerization of ethylene with styrene catalyzed by a linked bis(phenolato) titanium catalyst

Copolymerization of ethylene with styrene, catalyzed by 1,4‐dithiabutanediyl‐linked bis(phenolato) titanium complex and methylaluminoxane, produced exclusively ethylene–styrene copolymers with high activity. Copolymerization parameters were calculated to be r_E = 1.2 for ethylene and r_S = 0.031 for styrene, with r_E r_S = 0.037 indicating preference for alternating copolymerization. The copolymer microstructure can be varied by changing the ratio between the monomers in the copolymerization feed, affording copolymers with styrene content up to 68%. The copolymer microstructure was fully elucidated by ¹³C NMR spectroscopy revealing, in the copolymers with styrene content higher than 50%, the presence of long styrene–styrene homosequences, occasionally interrupted by isolated ethylene units. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1908–1913, 2006     

Ethylene polymerization with FI complexes having novel phenoxy‐imine ligands: Effect of metal type and complex immobilization

A series of bis(phenoxy‐imine) vanadium and zirconium complexes with different types of R³ substituents at the nitrogen atom, where R³ = phenyl, naphthyl, or anthryl, was synthesized and investigated in ethylene polymerization. Moreover, the catalytic performance was verified for three supported catalysts, which had been obtained by immobilization of bis[N‐(salicylidene)‐1‐naphthylaminato]M(IV) dichloride complexes (M = V, Zr, or Ti) on the magnesium carrier MgCl₂(THF)₂/Et₂AlCl. Catalytic performance of both supported and homogeneous catalysts was verified in conjunction with methylaluminoxane (MAO) or with alkylaluminium compounds (Et_nAlCl_3?n, n = 1–3). The activity of FI vanadium and zirconium complexes was observed to decline for the growing size of R³, whereas the average molecular weight (MW) of the polymers was growing for larger substituent. Moreover, vanadium complexes exhibited the highest activity with EtAlCl₂, whereas zirconium ones showed the best activity with MAO. All immobilized systems were most active in conjunction with MAO, and their activities were higher than those for their homogeneous counterparts, and they gave polymers with higher average MWs. That effect was in particular evident for the titanium catalyst. The vanadium complex 3 was also a good precursor for ethylene/1‐octene copolymerization; however, its immobilization reduced its potential for incorporation of a comonomer into a polyethylene chain. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011     

Preparation and application of a novel core–shell‐particle‐supported zirconocene catalyst

The use of functional groups bearing silica/poly(styrene‐co‐4‐vinylpyridine) core–shell particles as a support for a zirconocene catalyst in ethylene polymerization was studied. Several factors affecting the behavior of the supported catalyst and the properties of the resulting polymer, such as time, temperature, Al/N (molar ratio), and Al/Zr (molar ratio), were examined. The conditions of the supported catalyst preparation were more important than those of the ethylene polymerization. The state of the supported catalyst itself played a decisive role in both the catalytic behavior of the supported catalyst and the properties of polyethylene (PE). IR and X‐ray photoelectron spectroscopy were used to follow the formation of the supports. The formation of cationic active species is hypothesized, and the performance of the core–shell‐particle‐supported zirconocene catalyst is discussed as well. The bulk density of the PE formed was higher than that of the polymer obtained from homogeneous and polymer‐supported Cp₂ZrCl₂/methylaluminoxane catalyst systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2085–2092, 2001     

Synthesis of poly(p‐methoxyphenylacetylene) with the vanadium acetylacetonate‐aluminum triethyl Ziegler–Natta catalyst system: Cyclotrimers/polymer ratio analysis

Poly(p‐methoxyphenylacetylene) was obtained by the reaction of p‐methoxyphenylacetylene (MOPA) with the vanadium acetylacetonate‐aluminum triethyl V(acac)₃‐AlEt₃ homogeneous catalyst system. The crude product was always a mixture of 1,2,4‐ and 1,3,5‐tris(p‐methoxyphenyl)benzene and poly(MOPA) of low averaged molecular weight. The 1,2,4‐ and 1,3,5‐cyclotrimers versus poly(MOPA) ratio was analyzed. The poly(MOPA) obtained under different conditions, on the basis of the spectroscopic data, always shows a cis–transoidal stereo‐regular structure. Molecular mass of poly(MOPA) was determined by vapor pressure osmometry, high pressure liquid chromatography (HPLC), and gel permeation chromatography (GPC) techniques. The kinetics of the reaction has been also analyzed. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 5987–5997, 2005     

Alternating,gradient, block,and block–gradient copolymers of ethylene and norbornene by Pd–Diimine‐Catalyzed “living” copolymerization

We demonstrate, in this article, the facile synthesis of a broad class of low‐polydispersity ethylene–norbornene (E–NB) copolymers having various controllable comonomer composition distributions, including gradient, alternating, diblock, triblock, and block–gradient, through “living”/quasiliving E–NB copolymerization facilitated with a single Pd – diimine catalyst ( 1 ). This synthesis benefits from two remarkable features of catalyst 1 , its high capability in NB incorporation and high versatility in rendering E–NB “living” copolymerization at various NB feed concentrations ([NB]₀) while under an ethylene pressure of 1 atm and at 15 °C. At higher [NB]₀ values between 0.42 and 0.64 M, E–NB copolymerization with 1 renders nearly perfect alternating copolymers. At lower [NB]₀ values (0.11–0.22 M), gradient copolymers yield due to gradual reduction in NB concentration, with the starting chain end containing primarily alternating segments and the finishing end being hyperbranched polyethylene segments. Through two‐stage or three‐stage “living” copolymerization with sequential NB feeding, diblock or triblock copolymers containing gradient block(s) have been designed. This work thus greatly expands the family of E–NB copolymers. All the copolymers have controllable molecular weight and relatively low polydispersity (with polydispersity index below 1.20). Most notably, some of the gradient and block–gradient copolymers have been found to exhibit the characteristic broad glass transitions as a result of their possession of broad composition distribution. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

An experimental and computational evaluation of ethylene/styrene copolymerization with a homogeneous single‐site titanium(IV)‐constrained geometry catalyst

Styrene was copolymerized with ethylene using the geometry constrained Me₂Si(Me₄Cp)(N‐tert‐butyl)TiCl₂ Dow catalyst activated with methylaluminoxane. Increasing the styrene/ethylene ratio in the reactor feed had the effects of reducing both the activity of the catalyst and the molecular weight of the copolymers produced. However, the higher the styrene/ethylene ratio used, the greater the amount of styrene that became incorporated in the copolymer. We discuss these experimental findings within the framework of a computational analysis of ethylene/styrene copolymerization performed through hybrid density functional theory (B3LYP). In general, there was good agreement between the experimental and theoretical results. Our findings point to the suitability of combining experimental and theoretical data for clarifying the copolymerization mechanisms that take place in α‐olefin‐organometallic systems. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 711–725, 2005     

1‐Hexene Polymerization over Supported Titanium–Magnesium Catalyst: The Effect of Composition of the Catalytic System and Polymerization Conditions on Temperature Dependence of the Polymerization Rate

The effect of temperature on the rate of 1‐hexene polymerization over supported titanium–magnesium catalyst of composition TiCl₄/D₁/MgCl₂ + AlR₃/D₂ (D₁ is dibutyl phthalate, D₂ is propyltrimethoxysilane, and AlR₃ is an organoaluminum cocatalyst) is studied. The unusual data that the polymer rate decreases when temperature is increased from 30 to 70 °C are obtained. The 1‐hexene polymerization rate and the pattern of changes in polymerization rate with temperature depend on a combination of factors such as cocatalyst (AlEt₃ or Al(i‐Bu)₃) and presence/absence of hydrogen and an external donor in the reaction mixture. These factors differ in their effects on catalytic activity at different polymerization temperatures, so the temperature coefficient (E_eff) values calculated using the Arrhenius dependence of the polymerization rate on polymerization temperature vary greatly. The “normal” Arrhenius plot where polymerization rate increases with temperature is observed only for polymerization with the Al(i‐Bu)₃ cocatalyst in the presence of hydrogen and without an external donor. Formation of high‐molecular‐weight polyhexene at low polymerization temperatures results in catalyst particle fragmentation, which may additionally contribute to the increase in polymerization rate as polymerization temperature is reduced.     

Polymerizations of olefins and diolefins catalyzed by monocyclopentadienyltitanium complexes containing a (dimethylamino)ethyl substituent and comparison with ansa-zirconocene systems

{[2-(dimethylamino)ethyl]cyclopentadienyl}titanium trichloride (Cp^NTiCl₃, 1 ) was activated with methylaluminoxane (MAO) to catalyze polymerizations of ethylene (E), propylene (P), ethylidene norbornene (ENB), vinylcyclohexene (VCH), and 1,4-hexadiene (HD). The dependence of homopolymerization activity ( A ) of 1 /MAO on olefin concentration ([M]ⁿ) is n = 2.0 ± 0.5 for E and n = 1.8 ± 0.2 for P. The value of n is 2.4 ± 0.2 for CpTiCl₃/MAO catalysis of ethylene polymerization; this system does not polymerize propylene. 1 /MAO catalyzes HD polymerization at one-tenth of A _H for 1-hexene, probably because of chelation effects in the HD case. The copolymerization of E and P has reactivity ratios of r_E = 6.4 and r_P = 0.29 at 20°C, and r_Er_P = 1.9, which suggests 1 /MAO may be a multisite catalyst. The copolymerization activity of CpTiCl₃/MAO is 50 times smaller than that of Cp^NTiCl₃/MAO. Terpolymerization of E/P/ENB has A of 10⁵ g of polymer/(mol of Ti h), incorporates up to 14 mol % (∼ 40 wt %) of ENB, and high MW's of 1 to 3 × 10⁵. All of these parameters are surprisingly insensitive to the ENB concentration. The E/P/VCH terpolymerization has comparable A value of (1.3 ± 0.3) × 10⁵ g/(mol of Ti h). The incorporation of VCH in terpolymer increases with increasing [VCH]. Terpolymerization with HD occurs at about one-third of the A of either ENB or VCH; the product HD–EPDM is low in molecular weight and contains less than 4% of HD. These terpolymerization results are compared with those obtained previously for three zirconocene precursors: rac-ethylenebis(1-η⁵-indenyl)dichlorozirconium ( 6 ), rac-(dimethylsilylene)bis(1-η⁵-indenyl)dichlorozirconium ( 7 ), and ethylenebis(9-η⁵-fluorenyl)dichlorozirconium ( 8 ). The last compound is a particularly poor terpolymerization catalyst; it incorporates very little VCH or HD and no ENB at all. 7 /MAO is a better catalyst for E/P/VCH terpolymerization, while 6 /MAO is superior in E/P/HD terpolymerization. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 319–328, 1998     

New Quenching Procedure for Preservation of Initial Polymer/Catalyst Particle Morphology in Ziegler–Natta Olefin Polymerization

Preservation of initial polymer/catalyst particle morphology under air, was examined using stopped‐flow Ziegler–Natta polymerization with various quenching conditions and post‐chemical treatments. The exposure of the initial particles to air caused the fast formation of cracks on the surface, finally leading to significant reformation of the particle shape, when polymerizing particles were washed with heptane at ?65 °C under N₂ or under CO₂. On the other hand, when the particles were washed with heptane containing an appropriate amount of tetrahydrofuran under CO₂, the particle morphology under air was almost completely maintained even after 1 h exposure. The present results are useful for various ex situ characterizations of unstable initial polymer/catalyst particles.