Effect of prepolymerization on propylene polymerization

Polymerization of propylene was performed using MgCl₂. EtOH.TiCl₄.ID.TEA.ED catalyst system in hexane, where internal donor (ID) was an organic diester and external donor (ED) was a silane compound and also triethyl aluminum (TEA) as activator. A new method called isothermal/nonisothermal method (INM), a combination of isothermal and nonisothermal methods, was applied to produce the spherical polymer particles. The effects of the INM method and prepolymerization temperature on the final polymer morphology, M_w, and catalyst activity were also investigated. The morphology of the polymers was evaluated through scanning electron microscopy (SEM) images. GPC results were used for molecular weight (M_w) evaluation. It was found that the polymers had a better morphology when they were prepared using INM method. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Preparation of bimodal polypropylene in two‐step polymerization

Polymerization of propylene was carried out by using MgCl₂.EtOH.TiCl₄.DIBP.TEA.cHMDMS catalyst system in n‐heptane, where MgCl₂, EtOH, TiCl₄, DIBP (diisobutyl phthalate), TEA (triethyl aluminum), and cHMDMS (cyclohexyl methyl dimethoxy silane) were support, ethanol for alcoholation, catalyst, external donor, cocatalyst (activator), and internal donor, respectively. The catalyst activity and polymer isotacticity were studied by measuring the produced polymer and its solubility in boiling n‐heptane, respectively. The molecular weight and molecular weight distribution of the polymers were evaluated by gel permeation chromatography. Hydrogen was used for controlling the molecular weight. For producing the bimodal polypropylene, the polymerization was carried out in two steps (i.e., in the presence and absence of hydrogen). It was found that the catalyst showed high activity and stereoselectivity, on the other hand, bimodal polymer could simply be produced in two‐step polymerization by using MgCl₂.EtOH.TiCl₄.DIBP.TEA.cHMDMS catalyst system. Meanwhile, the effect of the step of the hydrogen adding on propylene polymerization was investigated. It was shown that the addition of hydrogen in the second step was more suitable. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1456–1462, 2006     

Comparative study of propylene polymerization using monosupported and bisupported titanium‐based Ziegler–Natta catalysts

Heterogeneous Ziegler–Natta systems—MgCl₂ (ethoxide type)/TiCl₄/di‐n‐butyl phthalate (DNBP)/triethylaluminum (TEA)/dimethoxymethylcyclohexylsilane (DMMCHS) and SiO₂/MgCl₂ (ethoxide type)/TiCl₄/DNBP/TEA/DMMCHS—were studied for the polymerization of propylene. The slurry polymerization of propylene was carried out with the catalyst systems in n‐heptane. Both systems performed with optimum activity at a particular [Al]/[DMMCHS]/[Ti] molar ratio. The ratio to reach the highest activity was much lower for the bisupported catalyst system. The productivity of the bisupported catalyst was higher than that of the monosupported one. Polypropylene of a high isotacticity index (II; >96%) was obtained with both systems and did not significantly change with an increasing [Al]/[DMMCHS]/[Ti] molar ratio. The addition of hydrogen as a chain‐transfer agent reduced II of the polymers obtained with both systems. The effect of the polymerization temperature (40–75°C) on the viscosity‐average molecular weight (M_v) and II showed a decrease in both cases. The bisupported catalyst system produced a polymer with higher M_v. The effect of temperature on II was similar for both the monosupported and bisupported systems. A monomer pressure of 2.02 × 10⁵ to 0.8 × 10⁶ Pa increased M_v of the obtained polymer. II of the polymer slightly decreased with increasing monomer pressure. The titanium content of the catalyst was 1.70 and 3.55% for the monosupported and bisupported systems, respectively. The surface area of the bisupported catalyst was higher than that of the monosupported catalyst. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 2220–2226, 2006     

Polymerization of propylene using the high‐activity Ziegler–Natta catalyst system SiO2/MgCl2 (ethoxide type)/TiCl4/Di‐n‐butyl phthalate/triethylaluminum/dimethoxy methyl cyclohexyl silane

The bisupported Ziegler–Natta catalyst system SiO₂/MgCl₂ (ethoxide type)/TiCl₄/di‐n‐butyl phthalate/triethylaluminum (TEA)/dimethoxy methyl cyclohexyl silane (DMMCHS) was prepared. TEA and di‐n‐butyl phthalate were used as a cocatalyst and an internal donor, respectively. DMMCHS was used as an external donor. The slurry polymerization of propylene was studied with the catalyst system in n‐heptane from 45 to 70°C. The effects of the TEA and H₂ concentrations, temperature, and monomer pressure on the polymerization were investigated. The optimum productivity was obtained at [Al]/[DMMCHS]/[Ti] = 61.7:6.2:1 (mol/mol/mol). The highest activity of the catalyst was obtained at 60°C. Increasing the H₂ concentration to 100 mL/L increased the productivity of the catalyst, but a further increase in H₂ reduced the activity of the catalyst. Increasing the propylene pressure from 1 to 7 bar significantly increased the polymer yield. The isotacticity index (II) decreased with increasing TEA, but the H₂ concentration, temperature, and monomer pressure did not have a significant effect on the II value. The viscosity‐average molecular weight decreased with increasing temperature and with the addition of H₂. Three catalysts with different Mg/Si molar ratios were studied under the optimum conditions. The catalyst with a Mg/Si molar ratio of approximately 0.93 showed the highest activity. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 1177–1181, 2003     

Polymerization of propylene using MgCl2 (ethoxide type)/TiCl4/diether heterogeneous Ziegler–Natta catalyst

Heterogeneous Ziegler–Natta catalyst of MgCl₂ (ethoxide type)/TiCl₄/diether was prepared. 2,2‐Diisobutyl‐1,3‐dimethoxy propane (DiBDMP), diether, was used as internal donor. Slurry polymerization of propylene was carried out using the catalyst in dry heptane while triethylaluminium (TEA) was used as co‐catalyst. The co‐catalyst effects, such as catalyst molar ratio, polymerization temperature, H₂ pressure, external donor, triisobutylaluminium (TiBA) and monomer pressure, on the activity of the catalyst and isotacticity index (II) of the polymers obtained were studied. Rate of polymerization versus polymerization time is of a decay type with no acceleration period. There are an optimum Al/Ti molar ratio and temperature to obtain the highest activity of the catalyst. The maximum activity was obtained at 60 °C. Increasing the monomer pressure to 1 010 000 Pa linearly increased the activity of the catalyst. Addition of hydrogen to 151 500 Pa pressure increased activity of the catalyst from 2.25 to 5.45 kg polypropylene (PP) (g cat)^?1 h^?1 using 505 000 Pa pressure of monomer. The II decreased with increasing Al/Ti ratio, monomer pressure, hydrogen pressure and increased with increasing temperature to 60 °C, following with decrease as the temperature increases. Productivity of 11.55 kg (PP) (g cat)^?1 h^?1 was obtained at 1 010 000 Pa pressure of monomer and temperature of 60 °C. Addition of methyl p‐toluate (MPT) and dimethoxymethyl cyclohexyl silane (DMMCHS) as external donors decreased the activity of the catalyst sharply, while the II slightly increased. Some studies of the catalyst structure and morphology of the polymer were carried out using FTIR, X‐ray fluorescence, scanning electron microscopy and Brunauer–Emmett–Teller techniques. Copyright © 2005 Society of Chemical Industry     

Effects of the type and concentration of alkylaluminum cocatalysts on the molar mass of polypropylene made with in situ supported metallocene catalysts

Propylene homopolymerizations were carried out with rac‐dimethylsilylenebis(indenyl)zirconium dichloride, methylaluminoxane‐modified silica, and common alkylaluminum cocatalysts. Supported catalysts were prepared by the in situ immobilization technique. The effects of the type and concentration (Al/Zr = 40–1000) of alkylaluminum on the propylene polymerization were evaluated with triethylaluminum (TEA), isoprenylaluminum (IPRA), and triisobutylaluminum (TIBA) as cocatalysts. The polymers were analyzed by gel permeation chromatography, differential scanning calorimetry, and ¹³C‐NMR. The polypropylene molar mass varied according to the nature of the alkylaluminum in the following order: TIBA > IPRA > TEA > no alkylaluminum. The polymers made with an in situ supported catalyst had lower crystallinities and melting points than the ones produced by homogeneous polymerization. The isotacticity was not affected by the polymerization conditions examined in this investigation. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 1050–1055, 2005     

Preparation of porous spherical MgCl2/SiO2 complex support as precursor for catalytic propylene polymerization

The MgCl₂/SiO₂ complex support was prepared by spray drying using alcoholic suspension, which contained MgCl₂ and SiO₂. The complex support reacted with TiCl₄ and di‐n‐butyl phthalate, giving a catalyst for propylene polymerization. The catalyst was spherical and porous with high specific surface area. TEA was used as a cocatalyst, and four kinds of alkoxysilane were used as external donors. The bulk polymerization of propylene was studied with the catalyst system. The effect of the reaction conditions and external donor on the polymerization were investigated. The results showed that the catalyst had high activity, high stereospecificity, and sensitive hydrogen responsibility. Polypropylene has good grain morphology because of duplicating the morphology of the catalyst. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 1296–1299, 2005     

The influence of combined external donor and combined cocatalyst on propylene polymerization with a MgCl2‐supported Ziegler–Natta catalyst in the presence of hydrogen

The influence of combined external donor (ED) (diphenyldimethoxysilane/dicyclopentyldimethoxysilane) and combined cocatalyst (triethylaluminum/triisobutylaluminum) on propylene polymerization with MgCl₂‐supported Ziegler–Natta catalyst in the presence of hydrogen was investigated. By deconvolution analysis of the molecular weight distribution (MWD) into multiple Flory components, the influence of ED and cocatalyst on the active center distribution of the catalyst was demonstrated, and the mechanism was discussed. Using combined cocatalyst and combined donor, iPP with high molecular weight, high isotacticity index, and broad MWD can be obtained. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41689.     

MgCl2‐supported Ziegler–Natta catalyst containing dibenzoyl sulfide donor for propylene polymerization

Polypropylene (PP) was synthesized in the presence of Ziegler–Natta catalysts composed of MgCl₂‐TiCl₄‐internal donor/AlR₃‐external donor. Diisobutyl phthalate is a well‐known internal donor in current PP production. Nevertheless, phthalates are often blamed as endocrine disruptors. The objective is to find an ecofriendly internal donor producing PP with maintaining its physical properties. When using dibenzoyl sulfide, synthesized PP shows the superiority to diisobutyl phthalate in the activity of catalyst (40 vs. 22 kg PP/g catalyst), the isotacticity of polymer (99.5 vs. 98.0 wt % of heptane insolubles), and the molecular weight distribution of PP product (M_w/M_n = 4.8 vs. 4). © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40743.     

Copolymerization of ethylene–propylene using high‐activity bi‐supported Ziegler–Natta TiCl4 catalyst

Heterogeneous Ziegler–Natta TiCl₄ catalyst using MgCl₂ and SiO₂ as supports was prepared under controlled conditions. Mg(OEt)₂ was used as a starting material and was expected to convert to active MgCl₂ during catalyst preparation. Due to the high surface area and good morphological control, SiO₂ was chosen as well. Slurry copolymerization of ethylene and propylene (EPM) was carried out in dry n‐heptane by using the catalyst system SiO₂/MgCl₂/TiCl₄/EB/TiBA or TEA/MPT/H₂ at temperatures of 40–70°C, different molar ratios of alkyl aluminum : MPT : Ti, hydrogen concentrations, and relative and total monomers pressure. Titanium content of the catalyst was 2.96% and surface area of the catalyst was 78 m²/g. Triisobutyl aluminum (TiBA) and triethyl aluminum (TEA) were used as cocatalysts, while ethyl benzoate (EB) and methyl p‐toluate (MPT) were used as internal and external donors, respectively. H₂ was used as a chain‐transfer agent. Good‐quality ethylene propylene rubber (EPR) of rubber was obtained at the ratio of [TiBA] : [MPT] : [Ti] = 320 : 16 : 1 and polymerization temperature was 60°C. When TiBA was used as a cocatalyst, a higher and more rubberlike copolymer was obtained. For both of the cocatalysts, an optimum ratio of Al/Ti was obtained relative to the catalyst productivity. Ethylene content of the copolymer obtained increased with increasing TiBA concentration, while inverse results were obtained by using TEA. Addition of H₂ increased the reactivity of the catalyst. The highest product was obtained when 150 mL H₂/L solvent was used. Increasing temperature from 40 to 70°C decreased the productivity of the catalyst, while irregular behavior was observed on ethylene content. Relative pressure of P_P/P_E = 1.4 : 1 and total pressure of 1 atm was the best condition for the copolymerization. Polymers with ethylene contents of 25–84% were obtained. Increasing ethylene content of EPR decreased T_g of the polymer obtained to a limiting value. Viscosity‐average molecular weight (M_v) decreased with increasing temperature and TiBA and H₂ concentration. However, increasing the polymerization time increased the M_v. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 2597–2605, 2004     

Preparation of high isotactic polybutene‐1

Polymerization of butene‐1 (B‐1) was carried out with a PP‐TiCl₃/Et₂AlCl/methyl methacrylate (MMA) catalyst system in n‐heptane. The influence of temperature, pressure, time and H₂ on molecular weight, isotacticity, and catalytic activity were studied by viscometry, solubility in boiling diethyl ether, and measuring the polymer produced, respectively. The structural properties of the isotactic polybutene‐1 (IPB‐1) were characterized by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), and melt flow index (MFI). The molecular weight of the products can be controlled by H₂. It was found that the catalyst showed high isotacticity and activity. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 78: 2533–2539, 2000     

New clay‐supported Ziegler–Natta catalyst for preparation of PE/Clay nanocomposites via in situ polymerization

Polyethylene/clay (PE/Clay) nanocomposites were prepared by the in situ polymerization of ethylene using the new Clay/butyl octyl magnesium (BOM)/Chloroform/EtOH/TiCl₄/tri ethyl aluminum (TEA) catalyst system in heptane where BOM and TEA were the support for the clay modification and cocatalyst, respectively. The influence of the modified clay using BOM on the catalyst and polymerization was investigated. Also, the effect of temperature, pressure, hydrogen, and the molar ratios of TEA/Ti on the catalyst yield and ethylene consumption (polymerization rate) were studied. It was found that the above clay‐supported catalyst was an efficient Ziegler–Natta type catalyst due to its suitable yield for the polymerization of ethylene toward the production of the PE/Clay nanocomposites. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Effects of chemical structure of phenolic antioxidants on Ziegler–Natta catalyst performance during propylene polymerization

Present work studied the synthesis of in-reactor stabilization of polypropylene via introducing antioxidant into polymerization media. Special attention was dedicated to assess the efficiency of antioxidant in catalyst deactivation. Three different types of antioxidants (Irganox 1076, Irganox 1010 and Irganox 1330) which contain ester and/or phenolic OH functional groups were chosen to investigate their impact on Ziegler–Natta catalyst performance during slurry propylene polymerization. Our Results indicated that not only phenolic OH groups but also esteric bond of antioxidants are capable of interacting with active center of catalyst and consequently decreasing the catalyst activity. Our propylene polymerization results showed that determining factors such as antioxidant chemical structures and its steric hindrance effect and the number of functional groups (phenolic and esteric groups) affected on the Ziegler–Natta catalyst performance. Therefore, effects of these three types of antioxidants on polymer characteristics such as particle size distribution, morphology, T _m , T _c , X _c , and isotacticity were evaluated. Morphological analysis using scanning electron microscopy (SEM) showed that introducing antioxidant during propylene polymerization did not destroy the spherical morphology of the polypropylene particles. Conclusively, due to the negative effect of esteric bond of antioxidant on Ziegler–Natta catalyst performance, the use of antioxidant without ester groups (Irganox 1330) is more recommended during propylene polymerization.     

Butyl chloride as promoter in ethylene polymerization by magnesium ethoxide‐supported catalyst

The effects of butyl chloride as a promoter in the ethylene polymerization were studied using a Mg(OEt)₂/TiCl₄/triethyl aluminum (TEA) Ziegler–Natta catalyst system, where Mg(OEt)₂, TiCl₄, TEA were used as support, catalyst, and activator, respectively. The influence of BC on the catalyst performance, polymerization rate, and polymer properties were investigated. This study strongly indicates that BC could act as a promoter with high performance in the ethylene polymerization. There was a remarkable increase in the catalyst yield and polymerization rate, in particularly, in the presence of hydrogen which was used for controlling the molecular weight. A reduction in the polymer molecular weight was observed in the presence of BC and hydrogen. The morphology of the polymers was evaluated through scanning electron microscopy and particle size distribution. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40189.     

A stacked neural network approach for yield prediction of propylene polymerization

Prediction of reaction yield as the most important characteristic process of a slurry polymerization industrial process of propylene has been carried out. Stacked neural network as an effective method for modeling of inherently complex and nonlinear systems–especially a system with a limited number of experimental data points–was chosen for yield prediction. Also, effect of operational parameters on propylene polymerization yield was modeled by the use of this method. The catalyst system was Mg(OEt)₂/DIBP/TiCl₄/PTES/AlEt₃, where Mg(OEt)₂, DIBP (diisobutyl phthalate), TiCl₄, PTES (phenyl triethoxy silane), and triethyl aluminum (AlEt₃) (TEAl) were employed as support, internal electron donor (ID), catalyst precursor, external electron donor (ED), and co‐catalyst, respectively. The experimental results confirmed the validity of the proposed model. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Preparation and properties of isotactic polypropylene obtained from MgCl2-supported TiCl4 catalyst bearing bifunctional internal donor

In this research, a novel MgCl₂-supported TiCl₄ catalyst in conjunction with bifunctional internal donor was synthesized. The effects of internal donor on propylene polymerization behaviors and polymer properties (morphology, M _w and MWD) were investigated. It was found that the activity of novel catalyst was higher than that of the traditional DIBP-based Ziegler–Natta catalyst, while the catalyst activity was less influenced by the ether group length of the bifunctional internal donor. It was also observed that the MWD of PP obtained by bifunctional internal donor-based catalyst was broader than that of PP made by DIBP-based Ziegler–Natta catalyst.     

Propylene polymerization using MgCl2/ethylbenzoate/TiCl4 catalyst: Determination of titanium oxidation states

The chemical interaction of the catalyst MgCl₂/ethylbenzoate/TiCl₄ with the cocatalysts triethylaluminum and trisobutylaluminum was investigated to establish a relationship between the titanium oxidation states and the catalytic activity, polymer isotacticity, and polymer molecular weight in propylene polymerizations. This interaction was studied using different Al : Ti molar ratios by measuring the changes of the titanium oxidation states at different polymerization times. Both hydrogen and alkyl aluminum caused a reduction of Ti⁴⁺ species to lower oxidation states species Ti³⁺ and Ti²⁺. However, the Ti⁴⁺ species reduction appeared to be incomplete. It was found that the Ti⁴⁺ species undergoes a severe reduction as the Al : Ti molar ratio increases from 50 to 230 as overreduction takes place. This change of the Ti³⁺ species percentage with time was found to correlate with the rate–time profiles of propylene polymerization. From this observation, it would be fair to conclude that the trivalent titanium species is more likely to be the active titanium species for propylene polymerization than the aforementioned catalyst system. On the other hand, hydrogen addition was found to cause an increase in Ti³⁺ species. The increases in both hydrogen amount and/or Al : Ti molar ratio were found to cause a decrease in both molecular weight and polypropylene isotactic index. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 56–62, 2004     

Influence of cocatalyst on the structure and properties of polypropylene/poly (ethylene‐co‐propylene) in‐reactor alloys prepared by MgCl2/TiCl4/diester type Ziegler‐Natta catalyst

In this work, a series of polypropylene/poly(ethylene‐co‐propylene) (iPP/EPR) in‐reactor alloys were prepared by MgCl₂/TiCl₄/diester type Ziegler‐Natta catalyst with triethylaluminium/triisobutylaluminium (TEA/TIBA) mixture as cocatalyst. The influence of cocatalyst and external electron donor, e.g., diphenyldimethoxysilane (DDS) or dicyclopentyldimethoxysilane (D ‐donor), on the structure and mechanical properties of iPP/EPR in‐reactor alloys were studied and discussed. According to the characterization results, PP/EPR was mainly composed of random poly(ethylene‐co‐propylene), segmented poly(ethylene‐co‐propylene), and high isotactic PP. Using TEA/TIBA mixture as cocatalyst and DDS as external electron donor, as TEA/TIBA ratio increased, the impact strength of iPP/EPR in‐reactor alloys had an increasing trend. Using TEA/TIBA mixture as cocatalyst and D ‐donor as external electron donor, the impact strength of iPP/EPR in‐reactor alloy were dramatically improved. In this case, the iPP/EPR in‐reactor alloy prepared at TEA: TIBA = 4 : 1 was the toughest. The influence of cocatalyst and external electron donor on the flexural modulus and flexural strength could be ignored. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

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     

Synthesis of highly isotactic poly 1-hexene using Fe-doped Mg(OEt)2/TiCl4/ED Ziegler–Natta catalytic system

In this article, polymerization of 1-hexene with FeCl_3-doped Mg(OET)₂/TiCl₄/electron donor (ED) catalytic system is presented. For this purpose, first a number of TiCl₄ catalysts supported on Mg(OEt)₂ and Fe-doped Mg(OEt)₂ supports were prepared with ethylbenzoate or dibutylphthalate as the internal EDs. After successive catalysts synthesis, they were employed in 1-hexene polymerization using cyclohexyl methyl dimethoxysilane as external ED as well as without it. The catalysts activity and molecular weight distribution (MWD) of poly 1-hexenes (PHs) were influenced strongly by both FeCl₃ doping and donor presence so that a remarkable increase in the catalyst activity was seen in doped catalysts. Deconvolution of MWD curves revealed that increase in the type of active centers by introducing FeCl₃ into the support should be responsible for the broadening of MWD of PHs. ¹³CNMR analysis indicated that while isotacticity does not change considerably by Fe doping, EDs increase its amount as high as 8–21%. Second, the stereoselective behavior of active Ti species in doped and undoped catalysts was fully explored by molecular modeling using density functional theory (DFT) method. Finally, with the aid of rheological measurements, the processability of polymers were evaluated and then the gel permeation chromatography (GPC) results were approved through the values obtained from model fitting as well as changes in moduli crossover modulus.