Synthesis and Application of FI Catalyst for Ethylene Polymerization

A FI (phenoxy-imine) Zr-based catalyst of bis[1-[(2,6-diisopropylphenyl)imino]methyl-3,6-ditertbutyl-2-naphtholato]zirconium(IV) dichloride was prepared by changing the ligand from salicylaldehyde imine ligand which is used for well known FI catalysts to 2-hydroxynaphthalene-1-carbaldehyde imine ligand and used for polymerization of ethylene. Replacement of the phenoxy-group by naphtholato-group does not provide any spatial difficulties in the ortho-position to oxygen, but introduction of the bulky alkyl substitution groups at the ortho position of the naphthoxy-oxygen and on phenyl ring on the N dramatically enhanced the activity of the catalyst, as well as viscosity average molecular weight (M_v) of the obtained polymer. The prepared catalyst could produce a high molecular weight polyethylene under the polymerization conditions used. The optimum activity of the catalyst was obtained at the reaction temperature of 40°C. Activity of the catalyst was continuously increased with increasing MAO concentration and monomer pressure and no optimum activity was observed in the range studied. Crystallinity and melting point of the obtained polymer were between 55–65% and 125–135°C, respectively. A molecular weight distribution of 1.55–2.75 was obtained under the polymerization condition used and the polydispersity was broadened with the time. The activity of the catalyst was not sensitive to the hydrogen concentration. However, higher amount of hydrogen could slightly increase the activity of the catalyst.