Microstructure of isotactic polypropylene obtained using Ziegler–Natta catalyst at high polymerization temperature

The microstructure of the isotactic polypropylene obtained with various MgCl₂‐supported catalyst systems at high polymerization temperature of 70–100°C is investigated by discussing the intrinsic relation between the different types of active centers and the polymerization temperatures via gel permeation chromatography, temperature rising elution fractionation, and ¹³C NMR. For the MgCl₂/TiCl₄/di‐n‐butyl phathalate‐AlEt₃/external donor and MgCl₂/TiCl₄/2,2‐diisobutyl‐1,3‐dimethoxypropane‐AlEt₃ catalyst systems, the differences in the isotactic productivity of polymers obtained at different polymerization temperatures mainly result from the variation of both the activity of the different isospecific active centers and the stability constants of the complex of catalyst/donor. The reaction rate of high isotactic active centers reaches maximum at 85–90°C, and this effect contributes to both the highest isotacticity and the narrowest molecular weight distribution. For the MgCl₂/TiCl₄/phthalate ester‐AlEt₃ catalyst system, the isotacticity of polypropylene remains approximately constant in the temperature range of experiments, which could be ascribed to elution of phthalate ester after the activation. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42487.     

Hybrid titanium catalyst supported on core‐shell silica/poly(styrene‐co‐acrylic acid) carrier

Hybrid titanium catalysts supported on silica/poly(styrene‐co‐acrylic acid) (SiO₂/PSA) core‐shell carrier were prepared and studied. The resulting catalysts were characterized by Fourier transform infrared (FTIR) spectroscopy, laser scattering particle analyzer and scanning electronic microscope (SEM). The hybrid catalyst (TiCl₃/MgCl₂/THF/SiO₂·TiCl₄/MgCl₂/PSA) showed core‐shell structure and the thickness of the PSA layer in the two different hybrid catalysts was 2.0 μm and 5.0 μm, respectively. The activities of the hybrid catalysts were comparable to the conventional titanium‐based Ziegler‐Natta catalyst (TiCl₃/MgCl₂/THF/SiO₂). The hybrid catalysts showed lower initial polymerization rate and longer polymerization life time compared with TiCl₃/MgCl₂/THF/SiO₂. The activities of the hybrid catalysts were enhanced firstly and then decreased with increasing P/P. Higher molecular weight and broader molecular weight distribution (MWD) of polyethylene produced by the core‐shell hybrid catalysts were obtained. Particularly, the hybrid catalyst with a PSA layer of 5.0 μm obtained the longest polymerization life time with the highest activity (2071 kg PE mol^?1 Ti h^?1) and the resulting polyethylene had the broadest MWD (polydispersity index = 11.5) under our experimental conditions. The morphology of the polyethylene particles produced by the hybrid catalysts was spherical, but with irregular subparticles due to the influence of PSA layer. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

The influence of cocatalysts on 1-hexene polymerization with various supported magnesium – titanium catalysts

Summary The influence of various cocatalysts on the activity and stereospecificity of a supported magnesium–titanium catalyst, generated by in situ reduction of titanium (IV) chloride using a Grignard reagent (MgCl₂/TiCl₃) or prepared by the recrystallization method (MgCl₂/2M2P/ED/TiCl₄, 2M2P= 2-methyl-2-pentanol, ED= dibutyl phthalate or ethyl benzoate), in the 1-hexene polymerization was investigated. The MgCl₂/TiCl₃ catalyst showed the highest activity but the lowest stereospecificity in the 1-hexene polymerization with all investigated cocatalysts. The MgCl₂/2M2P/ED/TiCl₄ catalyst with dibutyl phthalate as an internal electron donor was characterized by the highest stereospecificity and led to the polymers with high molecular weight. All catalysts showed the highest activity and stereospecificity when triisobutylaluminium was used as a cocatalyst. The addition of a small amount of ethyl benzoate as an external electron donor ([Al]/[ED] 10:1) led to considerable improvement of the stereospecificity of the MgCl₂/TiCl₃ catalyst in comparison with the catalysts prepared by the recrystallization method.     

Synthesis mechanisms of poly[styrene‐co‐(acrylic acid)]‐supported TiCl4 catalysts modified by magnesium compounds

Soluble poly[styrene‐co‐(acrylic acid)] (PSA) modified by magnesium compounds was used to support TiCl₄. For ethylene polymerization, four catalysts were synthesized, namely PSA/TiCl₄, PSA/MgCl₂/TiCl₄, PSA/(n‐Bu)MgCl/TiCl₄, and PSA/(n‐Bu)₂Mg/TiCl₄. The catalysts were characterized by a set of complementary techniques including X‐ray photoelectron spectroscopy, Fourier‐transform infrared spectroscopy, X‐ray diffraction, thermogravimetric analysis, scanning electron microscopy, and element analysis. Synthesis mechanisms of polymer‐supported TiCl₄ catalysts were proposed according to their chemical environments and physical structures. The binding energy of Ti 2p in PSA/TiCl₄ was extremely low as TiCl₄ attracted excessive electrons from ? COOH groups. Furthermore, the chain structure of PSA was destroyed because of intensive reactions taking place in PSA/TiCl₄. With addition of (n‐Bu)MgCl or (n‐Bu)₂Mg, ? COOH became ? COOMg‐ which then reacted with TiCl₄ in synthesis of PSA/(n‐Bu)MgCl/TiCl₄ and PSA/(n‐Bu)₂Mg/TiCl₄. Although MgCl₂ coordinated with ? COOH first, TiCl₄ would substitute MgCl₂ to coordinate with ? COOH in PSA/MgCl₂/TiCl₄. Due to the different synthesis mechanisms, the four polymer‐supported catalysts correspondingly showed various particle morphologies. Furthermore, the polymer‐supported catalyst activity was enhanced by magnesium compounds in the following order: MgCl₂ > (n‐Bu)MgCl > (n‐Bu)₂Mg > no modifier. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

The roles of Grignard reagent in the Ziegler–Natta catalyst for propylene polymerization

Grignard reagent PhMgCl was added during the preparation of the catalyst system MgCl₂/di-n-butyl phthalate (DNBP)/TiCl₄—AlEt₃/diphenyl dimethoxyl silane (DPDMS) to improve its performance. It was found that PhMgCl could enhance both the activity of the catalyst and the isotacticity of the products, but decreased the Ti content of the catalysts under the same preparation conditions. The polymerization kinetics showed that PhMgCl accelerates the decay in the same time that it increased the initial and final polymerization rates. By means of UV-vis spectroscopy, electron spin resonance (ESR) spectroscopy, and the Ti content determination of the catalysts, the multiple roles of PhMgCl were disclosed: reduction of Ti⁴⁺ to Ti³⁺, association with MgCl₂ to replace part of TiCl₄ in aspecific active sites, and complexing with the original active sites to form new active sites. © 1997 John Wiley & Sons, Inc. J Appl Polm Sci 65:925–930, 1997     

Novel binary chlorides containing TiCl3 as components of coordination catalysts for ethylene polymerization. II. Behavior of the resulting catalyst systems

Binary chlorides described in part I yielded very active catalyst systems for HDPE synthesis when they were associated with (i-C₄H₉)₃Al. Very high initial polymerization rates were observed for systems bases on MnCl₂·TiCl₃, MnCl₂·2TiCl₃, or FeCl₂·2TiCl₃ (III), but high yields, i.e., above 30 kg polymer/g Ti, could be reached only using moderate pressure of ethylene. Hydrogen consumption during ethylene polymerization was observed in the case of catalysts based on AlCl₃·3TiCl₃, CrCl₃·3TiCl₃, and other binary chlorides containing elements of the VIII group. Relevant amounts of ethane were found in the case of systems III, V, and VIII. All the mixed chlorides studied were able to reduce cyclohexene in the presence of H₂ and (i-C₄H₉)₃Al, even though with different kinetic courses. Compounds II, III, V, and VIII and (MgCl₂)_1.5·TiCl₃ and AlCl₃·3TiCl₃ were very active. The results have been explained on the basis of solubilization processes involving the heterogeneous catalysts which actually were experimentally verified during cyclohexene reduction. Analogous processes may occur also during HDPE synthesis.     

Morphological study of spherical MgCl2.nEtOH supported TiCl4 Ziegler‐Natta catalyst for polymerization of ethylene

Spherical MgCl₂·nEtOH was prepared by adducting ethanol to MgCl₂ using melt quenching method. Effect of molar ratio of [EtOH]/[MgCl₂] = 2.8–3.05 on the morphology and particle size of the MgCl₂·nEtOH were studied. The best adduct of spherical morphology was obtained when 2.9 mol ethanol to 1 mol MgCl₂ was used. An emulsion of dissolved MgCl₂ in ethanol was prepared in a reactor containing silicon oil. Stirrer speed of the emulsion and its transfer rate to quenching section that work at ?10 to ?40°C are affected by the particle size of the adduct particle. The adducted ethanol was partially removed with controlled heat primary to catalyst preparation (support). Treatment of the support with excess TiCl₄ increased its surface area from 13.1 to 184.4 m²/g. Heterogeneous Ziegler‐Natta catalyst system of MgCl₂ (spherical)/TiCl₄ was prepared using the spherical support. Scanning electron microscopy studies of adduct, support, and catalyst obtained shown spherical particles, however, the polyethylene particles obtained have no regular morphology. The behavior indicates harsh conditions used for catalyst preparation, prepolymerization, and polymerization method used. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 3829–3834, 2006     

TiCl4 immobilized on a composite support SiO2/MgCl2·x(1,4-butanediol)/poly[styrene-co-(acrylic acid)] for ethylene polymerization: The barrier effect of poly[styrene-co-(acrylic acid)]

By immobilizing titanium-based Ziegler–Natta catalyst on composite support, SiO₂/MgCl₂·x(1,4-butanediol)/poly[styrene-co-(acrylic acid)] (SiO₂/MgCl₂·xBD/PSA) and SiO₂/MgCl₂·xBD/PSA/TiCl₄ (SMPT) were synthesized for ethylene polymerization. SiO₂/MgCl₂·xBD/TiCl₄ without PSA was also prepared for comparison. The results of energy-dispersive X-ray analysis, SEM, and thermogravimetric analysis demonstrated that SMPT had a unique core-mantle-shell structure. The PSA layer can be considered as a barrier for the mass-transfer of reactants based on the results of self-diffusion measurement by pulsed field gradient NMR and ethylene polymerization. The polyethylene produced by SMPT showed high molecular weight (MW) and broad molecular weight distribution (MWD). The influences of PSA content, hydrogen, and comonomer on the ethylene polymerization behavior were also investigated. The results further demonstrated that the PSA layer in the composite support had different diffusion capabilities to the reactants. The physical properties of the produced polyethylene implied the possibility to control the MW and MWD of polyethylene by the manipulation of PSA layer. The catalyst fragmentation during ethylene polymerization was also affected by the PSA shell due to its barrier effect. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Surface science studies of Ziegler-Natta olefin polymerization system: Correlations between polymerization kinetics, polymer structures, and active site structures on model catalysts

The surface composition and structure of model Ziegler-Natta catalysts, polymerizing α-olefins to produce polyolefins, have been studied using modern surface science techniques and compared with their polymerization behaviors. Two types of thin films — TiCl_x/MgCl₂ and TiCl_y/Au — were fabricated on an inert gold substrate, using chemical vapor deposition methods, to model the high-yield catalysts of MgCl₂-supported TiCl₄ and TiCl₃-based catalysts, respectively. The model catalysts could be activated by exposure to triethylaluminum (AlFt₃) vapor. Once activated, both catalysts were active for polymerization of ethylene and propylene in the absence of excess AlEt₃ during polymerization. The model catalysts had polymerization activities comparable to the high-surface-area industrial catalysts. Though both catalysts were terminated with chlorine at the surface, each catalyst assumed different surface structures. The TiCl_x/MgCl₂ film surface was composed of two structures: the (001) basal plane of these halide crystallites and a non-basal plane structure. The TiCl_y/Au film surface assumed only the non-basal plane structure. These structural differences resulted in different tacticity of the polypropylene produced with these catalysts. The TiCl_x/MgCl₂ catalyst produced both atactic and isotactic polypropylene, while the TiCl_y/Au catalyst without the MgCl₂ support produced exclusively isotactic polypropylene. The titanium oxidation state distribution did not have a critical role in determining the tacticity of the polypropylene.     

Immobilization of Titanium Tetrachloride on Mixed Support of MgCl2 · xEB/Poly(methyl acrylate-co-1-octene): Catalyst for Synthesis of Broad MWD Polyethylene

TiCl₄ immobilization on different compositions of mixed support of MgCl₂ · xEB and poly(methyl acrylate-co-1-octene) (PMO; synthesized through ARGET ATRP) resulted in the formation of solid catalysts having variation in incorporation of titanium. The effect of mixed support composition onto the titanium immobilization, catalyst morphology and performance for ethylene polymerizations has been evaluated. The polyethylenes synthesized showed broad to bimodal MWD in GPC and DSC where the broadness was found to be dependent upon the ratio of mixed support MgCl₂ · xEB/PMO. The morphological features of PE as elucidated using SEM lead to postulation of polymer formation mechanism.     

Copolymerization of propylene with 1‐octene catalyzed by MgCl2/TiCl4/diether catalyst

MgCl₂/TiCl₄/diether is a fifth‐generation Ziegler–Natta catalyst for the commercial polymerization of propylene. The outstanding features of this catalyst are the high activity and high isotacticity for propylene polymerization without using an external electron donor. In this study, we explored the copolymerization of propylene and 1‐octene with MgCl₂/TiCl₄/diether catalyst. It was found that MgCl₂/TiCl₄/diether catalyst showed higher polymerization activity and led to greater 1‐octene content incorporation, compared with a fourth‐generation Ziegler–Natta catalyst (MgCl₂/TiCl₄/diester). With an increase in 1‐octene incorporation in polypropylene chains, the melting temperature, glass transition temperature and crystallinity of the copolymers decreased distinctly. The microstructures of the copolymers were characterized using ¹³C NMR spectroscopy, and the copolymer compositions and number‐average sequence lengths were calculated from the dyad concentration and distribution. This result is very important for the in‐reactor polyolefin alloying process, especially for the case of a single catalyst and two‐step (or two‐reactor) process. Copyright © 2011 Society of Chemical Industry     

Ethylene polymerization with heterogeneous Ziegler-Natta catalysts

Summary TiCl₄/SiO₂, Ti(OC₄H₉)₄/SiO₂, MgCl₂/TiCl₄/SiO₂ and MgCl₂/Ti(OC₄H₉)₄/SiO₂ catalysts were prepared by treating silica gel with TiCl₄, Ti(OC₄H₉)₄, MgCl₂/TiCl₄ or MgCl₂/Ti(OC₄H₉)₄ in tetrahydrofuran (THF) solution. Ethylene polymerization was performed with these catalysts activated by common alkylaluminum compounds. The influence of magnesium dichloride on catalyst performance was investigated. MgCl₂ has enhanced the catalyst activity for both titanium compounds. In addition, all catalyst systems were only active when they were washed with AlCl(C₂H₅)₂ (DEAC).     

Modification of Ziegler-Natta catalysts by cyclopentiadienyl-type ligands: Activation of titanium-based catalysts

Conventional Ziegler-Natta catalysts, based on TiCl₄ supported on MgCl₂, were modified by substituting a part of the chlorides by cyclopentadienyl (and derivatives) ligands. Although these catalysts are very active (activities up to 10⁵ g PE/g catalyst/h) they exhibit a conventional Ziegler-Natta behavior (methylaluminoxane is not necessary, polyethylene produced with a rather broad molar weight distribution, low sensitivity to hydrogen). It was attributed to cluster effects: an increase of the number of conventional TiCl₄ active sites by adding cyclopentadienyl ligands on titanium neighbors. © 1997 John Wiley & Sons, Inc. J Appl Polym Sci 65: 2281–2288, 1997     

Polymerization of olefins through heterogeneous catalysis. XII. The influence of hydrogen in the solution copolymerization of ethylene

The copolymerization of ethylene with highly active TiCl₄/MgCl₂-supported catalysts in solution reactors at 185°C and 400 Psig pressure is presented. The performance of these supported catalysts at these conditions is characterized by a high initial rate that decays rapidly within the 10 min polymerization period. In the presence of hydrogen and a comonomer, catalyst yields up to about 300 kg/g (Ti) are achieved. The kinetic data indicate rate enhancement when hydrogen is added in moderate concentrations. However, a high concentration of hydrogen results in a decreasing rate of ethylene consumption. Increasing the H₂/C₂ molar ratio in the range 0–10.66 ? 10^?3 leads to a reduction in the M_n values from 31,600 to 17,400. © 1993 John Wiley & Sons, Inc.     

Modification of a Ziegler-Natta catalyst with a metallocene catalyst and its olefin polymerization behavior

A Ziegler-Natta catalyst was modified with a metallocene catalyst and its polymerization behavior was examined. In the modification of the TiCl₄ catalyst supported on MgCl₂ (MgCl₂-Ti) with a rac-ethylenebis(indenyl)zirconium dichloride (rac-Et(Ind)₂ZrCl₂, EIZ) catalyst, the obtained catalyst showed relatively low activity but produced high isotactic polypropylene. These results suggest that the EIZ catalyst might block a non-isospecific site and modify a Ti-active site to form highly isospecific sites. To combine two catalysts in olefin polymerization by catalyst transitioning methods, the sequential addition of catalysts and a co-catalyst was tried. It was found that an alkylaluminum like triethylaluminum (TEA) can act as a deactivation agent for a metallocene catalyst. In ethylene polymerization, catalyst transitioning was accomplished with the sequential addition of bis(cyclopentadienyl)zirconium dichloride (Cp₂ZrCl₂)/methylaluminoxane (MAO), TEA, and a titanium tetrachloride/vanadium oxytrichloride (TiCl₄/VOCl₃, Ti-V) catalyst. Using this method, it was possible to control the molecular weight distribution (MWD) of polyethylene in a bimodal pattern. In the presence of hydrogen, polyethylene with a very broad MWD was obtained due to a different hydrogen effect on the Cp₂ZrCl₂ and Ti-V catalyst. The obtained polyethylene with a broader MWD exhibited more apparent shear thinning.     

Study of the MgCl2 recrystallization conditions on Ziegler-Natta catalyst properties

Summary Magnesium dichloride supported titanium catalysts were prepared by dissolving anhydrous MgCl₂ in 1-hexanol/isooctane. Then recrystallization took place through different techniques such as evaporation of the solvent, quick cooling, precipitation with silicon tetrachloride and precipitation with titanium tetrachloride. The FT-IR analysis showed that several degrees of dealcoholation took place as a result of the adducts of MgCl₂· XROH. Moreover, it was found that the most active catalysts in the polymerization of ethylene were those obtained recrystallizing MgCl₂ by precipitation with SiCl₄. On the other hand, those directly recrystallized with TiCl₄ were the least reactive and the ones that produced polyethylenes with the highest molecular weights and the lowest degrees of crystallinity. Received: 14 December 1998/Revised version: 17 August 1999/Accepted: 17 August 1999     

Preparation and properties of polyethylene/montmorillonite nanocomposites by in situ polymerization

Polyethylene (PE)/montmorillonite (MMT) nanocomposites were prepared by in situ coordination polymerization using a MMT/MgCl₂/TiCl₄ catalyst activated by Al(Et)₃. The catalyst was prepared by first diffusing MgCl₂ into the swollen MMT layers, followed by loading TiCl₄ on the inner/outer layer surfaces of MMT where MgCl₂ was already deposited. The intercalation of MMT layers by MgCl₂ and TiCl₄ was demonstrated by the enlarged interlayer spacing determined by WAXD. The nanoscale dispersion of MMT layers in the polyethylene matrix was characterized by WAXD and TEM. As a consequence, the crystallinity of the nanocomposite decreased sharply, whereas the tensile strength was significantly improved compared to that of virgin polyethylene of comparable molecular weight. The confinement of the nanodispersed MMT layers to molecular chain and the strong interaction between the nanoscale MMT layers and the resin matrix were thought to account for the decrease of crystallinity and the remarkable enhancement of strength. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 3680–3684, 2003     

Studies on highly active coordination catalysts for polymerization of α-olefins: 3. Polymerization of propylene with MgCl2/TiCl4/AlEt3 or MgCl2/PhCOOC2H5/TiCl4/AlEt3 systems

Activity and stereospecificity of the $\text{MgCl}{}_2\text{TiCl}{}_4$ catalyst in the polymerization of propylene follow curves showing maxima with grinding time of the MgCl₂ support. Using MgCl₂/PhCOOC₂H₅/TiCl₄ catalysts, no decrease in activity and stereospecificity was observed presumably because of complex formation between MgCl₂ support and ethyl benzoate.     

Ethylene-propylene copolymers by a supported Ziegler-Natta catalyst based on TiCl4/MgCl2

Ethylene-propylene copolymers have been prepared by using Ziegler-Natta catalysts based on TiCl₄, MgCl₂, PCl₃ and (n-Bu)₃PO₄. The catalysts TiCl₄/MgCl₂/PCl₃ and TiCl₄/MgCl₂/(n-Bu)₃PO₄ were prepared by reacting TiCl₄ with pretreated MgCl₂. The support was prepared by ball milling of MgCl₂ with varied amounts of PCl₃ or (n-Bu)₃PO₄. The addition of PCl₃ has remarkably increased the MgCl₂ surface area in comparison with (n-Bu)₃PO₄. The effects of PCl₃ and (n-Bu)₃PO₄ on ethylene homopolymerization, ethylene-propylene copolymerization and on copolymer properties were evaluated. The catalyst system containing PCl₃ permitted to synthesize propylene-ethylene copolymers with up to 75% (w/w) of propylene and provided control of copolymer crystallinity. The reduction of the copolymer molecular weight distribution suggested that PCl₃ acted as an internal donor, poisoning some active catalytic sites. Received: 2 April 1997/Revised: 6 June 1997/Accepted: 18 June 1997     

Copolymerization of propylene with a small amount of ethylene using a MgCl2/TiCl4 and a TiCl3 catalyst system

Summary Copolymerization of propylene with a small amount of ethylene and homopolymerization of propylene were performed using a highly active MgCl₂/TiCl₄-Et₃Al/ethyl benzoate(EB) and a conventional TiCl₃-Et₂AlCl catalyst systems. The obtained polymers were fractionated into n-decane (C₁₀) soluble and insoluble portions. In all homopolymer fractions with the investigated catalyst systems and copolymer fractions with TiCl₃ catalyst system, the inversion of the direction of arrangement of the propylene unit was not observed by ¹³C-NMR analysis. On the other hand, in C₁₀ soluble fractions of copolymer using MgCl₂/TiCl₄ catalyst system, regardless of the presence of EB, a significant amount of the inversion unit was detected.