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.