In‐Situ and Ex‐Situ Microscopic Study of Gas Phase Propylene Polymerization over a High Activity TiCl4‐MgCl2 Heterogeneous Ziegler‐Natta Catalyst

In‐situ gas phase poly(propylene) (PP) formation over a high activity TiCl₄‐MgCl₂‐supported Ziegler‐Natta catalyst has been studied by video microscopy combined with ex‐situ light microscopy, SEM, high‐resolution TEM, and STEM/PEELS/EDX for the first time. In‐situ observation revealed rapid formation of poly(propylene) beads 9–10 μm in size (< 1/30 s) as well as growth of significant amounts of polymer within local regions. Catalyst particles containing 2–5 nm‐sized MgCl₂ crystalline domains are subjected to transformations during catalysis that form PP/catalyst aggregated structures of 30–50 μm in size.     

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     

Kinetic features of ethylene polymerization over supported catalysts [2,6‐bis(imino)pyridyl iron dichloride/magnesium dichloride] with AlR3 as an activator

The effects of polymerization temperature, polymerization time, ethylene and hydrogen concentration, and effect of comonomers (hexene‐1, propylene) on the activity of supported catalyst of composition LFeCl₂/MgCl₂‐Al(i‐Bu)₃ (L = 2,6‐bis[1‐(2,6‐dimethylphenylimino)ethyl] pyridyl) and polymer characteristics (molecular weight (MW), molecular‐weight distribution (MWD), molecular structure) have been studied. Effective activation energy of ethylene polymerization over LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a value typical of supported Ziegler–Natta catalysts (11.9 kcal/mol). The polymerization reaction is of the first order with respect to monomer at the ethylene concentration >0.2 mol/L. Addition of small amounts of hydrogen (9–17%) significantly increases the activity; however, further increase in hydrogen concentration decreases the activity. The IRS and DSC analysis of PE indicates that catalyst LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a very low copolymerizing ability toward propylene and hexene‐1. MW and MWD of PE produced over these catalysts depend on the polymerization time, ethylene and hexene‐1 concentration. The activation effect of hydrogen and other kinetic features of ethylene polymerization over supported catalysts based on the Fe (II) complexes are discussed. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 5057–5066, 2007     

Of Poisons and Antidotes in Polypropylene Catalysis

Quenched‐flow studies of MgCl₂‐supported Ziegler–Natta catalysts were combined for the first time with ¹³C NMR fingerprinting of the nascent polymer and conclusively proved that, depending on the catalyst formulation, propene polymerization can be slowed down significantly by the occurrence of the few regiodefects (2,1 monomer insertions), changing active sites into dormant sites. Catalysts modified with ethylbenzoate show little dormancy. The more industrially relevant phthalate based catalysts, instead, are highly dormant and require the presence of H₂ to counteract the deleterious effect of this self‐poisoning on productivity and stereoselectivity.     

The discovery and progress of MgCl2‐supported TiCl4 catalysts

Polyolefins represented by polyethylene (PE) and polypropylene (PP) are indispensable materials in our daily lives. TiCl₃ catalysts, established by Ziegler and Natta in the 1950s, led to the births of the polyolefin industries. However, the activities and stereospecificities of the TiCl₃ catalysts were so low that steps for removing catalyst residues and low stereoregular PP were needed in the production of PE and PP. Our discovery of MgCl₂‐supported TiCl₄ catalysts led to more than 100 times higher activities and extremely high stereospecificities, which enabled us to dispense with the steps for the removals, meaning the process innovation. Furthermore, they narrowed the molecular weight and composition distributions of PE and PP, enabling us to control the polymer structures precisely and create such new products as very low density PE or heat‐sealable film at low temperature. The typical example of the product innovations by the combination of the high stereospecificity and the narrowed composition distribution is high‐performance impact copolymer used for an automobile bumper that used to be made of metal. These process and product innovations established these polyolefin industries. The latest MgCl₂‐supported TiCl₄ catalyst is very close to perfect control of isotactic PP structure and is expected to bring about further innovations. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1–8, 2004     

Propylene polymerization reactions with supported Ziegler–Natta catalysts: Observing polymer material produced by a single active center

Medium‐ and high‐resolution SEM analysis of several Ti‐based MgCl₂‐supported Ziegler–Natta catalysts and isotactic polypropylene produced with them is carried out. Each catalyst particle, 35–55 μ in size, produces one polymer particle with an average size of 1.5–2 mm, which replicates the shape of the catalyst particle. Polymer particles contain two distinct morphological features. The larger of them are globules with D_av ～400 nm; from 1 to 2 × 10¹¹ globules per particle. Each globule represents the combined polymer output of a single active center. The globules consist of ～2500 microglobules with an average size of ～20 nm. The microglobules contain several folded polymer molecules; they are the smallest thermodynamically stable macromolecular ensembles in propylene polymerization reactions. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 3832–3841     

Superactive and stereospecific catalysts. III. Definitive identification of active sites by electron paramagnetic resonance

Superactive Ziegler–Natta catalysts have been prepared from a soluble MgCl₂·2-ethyl hexanol adduct in the presence of organic esters through reactions with TiCl₄ and activated with AlEt₃/phenyltriethoxy-silane. Electron paramagnetic spectra (EPR) were used to elucidate the nature and amount of those Ti⁺³ ions not bridged to another Ti⁺³ ion; the chlorine bridged Ti⁺³ ions are EPR silent. The EPR spectra were attributed to two rhombic Ti⁺³ sites with principal values for the g-tensors (1.967, 1.949, 1.915; and 1.979, 1.935, 1.887). The total amount of the EPR species, obtained by double integration of the EPR spectra, is in close agreement with the concentration of isospecific catalytic sites determined by radiotagging. This suggests that the nonspecific sites are EPR silent. When o-phthalic ester was present during the catalyst synthesis, there appears an EPR signal at the free electron g-value. This signal was attributed to a Ti⁺³ phthalate species with resonance stabilization and spin delocalization; it is absent in the catalysts made in the presence of monoesters such as ethyl benzoate. The effects of monomer, O₂, H₂O, and I₂ on the EPR spectra were investigated. The changes in the EPR spectral intensity and the total Ti⁺³ ions, the latter determined by redox titrations during a polymerization or catalyst aging, are described. The results were extensively compared with those observed for supported Ziegler–Natta catalyst prepared with crystalline MgCl₂.     

Study of the compositional heterogeneity of ethylene–hexene-1 copolymers by thermal fractionation technique by means of differential scanning calorimetry

The successive self-nucleation/annealing technique (SSA) by differential scanning calorimetry has been applied to study the heterogeneity of ethylene–hexene-1 copolymers produced with supported catalytic systems of different compositions: highly active supported Ziegler–Natta (Z–N) catalysts—a titanium–magnesium catalyst TiCl₄/MgCl₂ (TMC) and a vanadium–magnesium catalyst VCl₄/MgCl₂ (VMC), a supported zirconocene catalyst Me₂Si(Ind)₂ZrCl₂/SiO₂ (MAO), and a chromium-oxide catalyst CrO₃/SiO₂. Comparative data by SSA technique with the same temperature program were obtained for copolymers differed by MWD from narrow to very broad (Mw/Mn = 2.4–54) and short chain branching distribution from narrow (zirconocene catalyst) to very broad (TMC and chromium oxide catalysts). It is demonstrated that copolymers produced with the zirconocene catalyst have the narrowest melting range and do not contain thick lamellae. The widest lamella thickness distribution has been found for a copolymer produced with the chromium-oxide catalyst. Copolymers produced with the supported Z–N catalysts are ranked in the middle with a more narrow lamella thickness distribution for copolymer prepared with VMC as compared with the one produced with TMC. The SSA results are compared with the data on copolymer fractionation by TREF. It is shown that these methods give a good correlation for copolymers with narrow short-chain branching distribution produced with the supported zirconocene catalyst. In the case of copolymers produced with TMC, TREF yields a higher content of the high-branched fractions.     

Novel Preparation of Polyethylene from Nano‐extrusion Polymerization Inside the Nanochannels of MCM‐41/MgCl2/TiCl4 Catalysts

The MCM‐41 and SiO₂ supported TiCl₄ and TiCl₄/MgCl₂ catalysts with different molar ratios of Mg/Ti were synthesized and used for ethylene polymerization under atmospheric pressure. The nanochannels of MCM‐41 serve as nanoscale polymerization reactor and the polyethylene nanofibers were extruded during the reaction. The nanofibers were observed in SEM micrographs of resulting polyethylene. The effect of MgCl₂ on catalytic activity and thermal properties of resulting polyethylene is investigated too. In the presence of MgCl₂, the catalytic activity increased and more crystalline polyethylene with higher melting points were formed. However, no fibers could be observed in the polyethylene prepared by SiO₂ supported catalysts.     

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     

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     

Supported titanium-magnesium catalysts for propylene polymerization

The results of studies of the synthesis and properties of supported titanium-magnesium catalysts for propylene polymerization performed at the Boreskov Institute of Catalysis, Siberian Branch, Russian Academy of Sciences, are considered. The composition of the catalysts is TiCl₄/D₁/MgCl₂-AlEt₃/D₂, where D₁ and D₂ are stereoregulating donors. With the use of the procedure proposed for the synthesis of titanium-magnesium catalysts, the morphology of catalyst particles depends on the stage of the preparation of a Mg-containing support. The titanium-magnesium catalysts developed afforded polypropylene (PP) in a high yield; this PP was characterized by high isotacticity and excellent morphology. The controllable fragmentation of the catalyst by the polymer is of crucial importance for the retention of the morphology of titanium-magnesium catalyst particles in PP. The fragmentation of catalyst particles to microparticles occurred in the formation of more than 100 g of PP per gram of the catalyst. The surface complexes were studied by DRIFT and MAS NMR spectroscopy and chemical analysis. It was shown that the role of internal donors is to regulate the distribution of TiCl₄ on different MgCl₂ faces and, thereby, to influence the properties of PP. It was found that chlorine-containing complexes of aluminum compounds were formed on the catalyst surface by the interaction of the catalyst with AlEt₃; these complexes can block the major portion of titanium chloride. Data on the number of active sites and the rate constants of polymer chain propagation (k _p) at various sites indicate that donor D₁ increases the stereospecificity of the catalyst because of an increase in the fraction of highly stereospecific active sites, at which k _p is much higher than that at low-stereospecificity active sites. Donor D₂ enhances the role of D₁. Similar values of k _p at sites with the same stereospecificity in titanium-magnesium catalysts and TiCl₃ suggest that the role of the support mainly consists in an increase in the dispersity of titanium chloride.     

Highly active MgCl2‐supported CpMCl3 (M = Ti,Zr) catalysts for ethylene polymerization

Monocyclopentadienyl compounds, CpMCl₃ (M = Ti, Zr) supported on activated MgCl₂ were used for the polymerizations of ethylene in the presence of methylaluminoxane (MAO) or a common alkylaluminium as a cocatalyst. By supporting CpMCl₃ on MgCl₂, the catalyst activity was increased drastically to show high activity similar to MgCl₂‐supported TiCl₄ catalysts. The activity of the CpZrCl₃ /MgCl₂ catalyst was higher than that of the CpTiCl₃/MgCl₂ one. Both catalysts gave polymers with high molecular weight (M_w) and broad molecular weight distribution (M_w/M_n) in comparison with the corresponding soluble half‐metallocene catalysts.     

Optimization of the Preparation Temperature for the Novel (SiO2/MgO/MgCl2)⋅TiClx Ziegler–Natta Polyethylene Catalyst

A series of (SiO₂/MgO/MgCl₂)?TiCl_x Ziegler‐Natta polyethylene catalysts have been synthesized using water‐soluble Mg‐compounds such as magnesium acetate as Mg‐source at different TiCl₄ treating temperatures. The catalyst shows the highest activity of homopolymerization when preparation temperature is 120 °C with only 1.25 of optimal Al/Ti molar ratio, which is much lower than industrial value, resulting in much lower catalyst preparation and poly­ethylene production cost. The operation condition is relatively moderate and the synthesized catalysts exhibit rather high activity, good hydrogen response, and copolymerization ability with high 1‐hexene incorporation. The polymers obtained from these catalysts have high molecular weight and medium molecular weight distribution. Compared with the conventional industrial Ti/Mg Ziegler‐Natta catalysts using the relatively expensive, anhydrous and moisture‐sensitive Mg‐sources, the most unique feature of our novel catalysts is the capability of utilization of any soluble Mg‐compounds under mild conditions and can achieve rather high activity with only a small amount of cocatalyst, hence show great potential for application in polyethylene industry.

     

Gas-phase polymerization of ethylene over Ti-based Ziegler–Natta catalysts prepared from different magnesium sources

This study focuses on gas-phase polymerization of ethylene using the titanium-based Ziegler–Natta catalysts prepared from different magnesium sources including MgCl₂ (Cat A), magnesium powder (Cat B), and Mg(OEt)₂ (Cat C). During polymerization, different cocatalysts were also used. It was found that Cat C with triethylaluminum as a cocatalyst exhibited the highest activity. This was likely attributed to optimal distribution of active sites on the catalyst surface. It can be observed by increased temperature in the reactor due to highly exothermic reaction during polymerization. By the way, the morphologies of the polymer obtained from this catalyst were spherical, which is more preferable. Besides the catalytic activity, crystallinity and morphology were also affected by the different magnesium sources used to prepare the catalysts.     

Morphology Evolution in the Early Stages of Olefin Polymerization

The olefin polymerizations were carried out by using silica supported metallocene/MAO catalysts and MgCl₂ supported Ziegler-Natta catalysts under mild reaction conditions and stopped at very low yield. The surface and cross sectional morphology of the polymer particles were characterized by using scanning electron microscopy (SEM). A homogeneous distribution of (co)catalyst on the support material is a prerequisite condition to get a homogeneous fragmentation and uniform polymer particle morphology. In the present work the catalysts show two different fragmentation behaviors. They can gradually fragment from the outer to the inner surface of the catalyst particle, or instantaneously break up into a large amount of small sub-particles at the beginning of the polymerization. The incorporation of comonomer does not change the general catalyst fragmentation scheme but delays the catalysts break-up progress.     

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     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. II. Mechanism of the chain‐transfer reaction

Hydrogen is a very effective chain‐transfer agent in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts. However, measurements of the hydrogen concentration effect on the molecular weight of polypropylene prepared with a supported TiCl₄/dibutyl phthalate/MgCl₂ catalyst show a peculiar effect: hydrogen efficiency in the chain transfer significantly decreases with concentration, and at very high concentrations, hydrogen no longer affects the molecular weight of polypropylene. A detailed analysis of kinetic features of chain‐transfer reactions for different types of active centers in the catalyst suggests that chain transfer with hydrogen is not merely the hydrogenolysis reaction of the Ti? C bond in an active center but proceeds with the participation of a coordinated propylene molecule. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1899–1911, 2002     

A Preparation Method for Well‐Defined Crystallites of Mgcl2‐Supported Ziegler‐Natta Catalysts and their Observation by AFM and SEM

A method for the preparation of well‐defined crystallites of MgCl₂‐supported Ziegler‐Natta catalysts on Si wafers has been developed. This has been achieved by the spin‐coating of a MgCl₂ solution onto a flat Si wafer, followed by controlled crystal growth to give well‐defined MgCl₂ · nEtOH crystallites. The growth of the crystallites on the flat silica facilitates their characterization using electron and scanning probe microscopy. The relative proportions of 120° and 90° edge angles indicate the preference for the formation of a particular crystallite face for the MgCl₂. Polyethylene has been identified to be formed on the lateral faces of the crystallite.

     

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