Influence of support friability and concentration of α‐olefins on gas‐phase ethylene polymerization over polymer‐supported metallocene/methylaluminoxane catalysts

The effects of support friability (Φ) and ethylene/comonomer ratios were investigated over supported metallocene/methylaluminoxane catalysts prepared with nine different porous polymeric supports and various comonomer concentrations with a 2‐L reactor operated in the semibatch gas‐phase mode at 80°C and 1.4 MPa. Φ of the supports was measured with a newly devised method. The performance of the supported catalysts depended on support Φ as follows. The average homopolymerization activities varied from less than 6 t of polyethylene (PE) (mol of Zr)^?1 h^?1 for low‐Φ catalysts to 10–20 t of PE (mol of Zr)^?1 h^?1 for moderate‐Φ catalysts and up to 100 t of PE (mol of Zr)^?1 h^?1 for the high‐Φ catalysts. The presence of 1‐hexene and propylene comonomers increased the activity of the low‐Φ catalysts by up to 20‐fold and 50‐fold, respectively; that is, there were very marked comonomer effects. Activity enhancement by 1‐hexene was less than 3‐fold for the moderate‐Φ catalysts, whereas the high‐Φ catalysts showed little activity enhancement. Sometimes, 1‐hexene even resulted in activity reductions. Very different particle morphologies were obtained with the catalysts of different Φ's. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 514–527, 2007     

Gas‐phase olefin polymerization over supported metallocene/MAO catalysts: influence of support on activity and polydispersity

Three catalysts obtained by supporting bis(n‐butylcyclopentadienyl)zirconium dichloride/methylaluminoxane on: (1) porous crosslinked poly(2‐hydroxyethylmethacrylate‐co‐styrene‐co‐divinylbenzene) particles (CAT1); (2) swellable crosslinked poly(styrene‐co‐divinylbenzene) particles (CAT2); and (3) by evaporating the catalyst precursors solution to dry powder, CAT3 were used in gas‐phase polymerization of ethylene, and ethylene/1‐hexene in a 2 L semi‐batch reactor at 80 °C and 1.4 MPa. The average polymerization activities of the three catalysts were 12.3–15.5, 4.2–10.1, and 14.3–62.9 ton PE (mol Zr h)^?1 respectively. CAT1 and CAT3 produced polyethylenes with a polydispersity range of 2.3–2.7, while that of CAT2 was 3.5–6.4. The supported catalysts produced polyolefin particles with bulk density of 0.36–0.43 g ml^?1, and essentially no fines. Ethylene/1‐hexene co‐polymerization (7 mol m^?3 initial 1‐hexene concentration in the reactor) increased polymerization activities and produced lower‐molar‐mass co‐polymers. At 21 mol m^?3 1‐hexene the polymerization activities decreased, but the relative amount of the low‐molar‐mass co‐polymer for CAT2 increased, leading to higher polydispersity. Copyright © 2006 Society of Chemical Industry     

负载茂金属催化剂催化乙烯气相聚合

研究了负载茂金属催化剂(n-BuNeCp)_2ZrCl_2/SiO_2的乙烯气相聚合行为及其催化聚合产品的性能。三乙基铝加入聚合体系后可降低负载茂金属催化剂的初始活性,有利于聚合过程中的温度控制。气相聚合产品聚乙烯的重均分子量为(1 42～2.28)×10~5,相对分子质量分布为2.6～3.1,熔点在135℃以上,结晶度约为60%,聚乙烯产物颗粒形态以球形为主.堆密度大于0.35 g/cm~3。     

Kinetic study of olefin polymerization with a supported metallocene catalyst. II. Ethylene/1‐hexene copolymerization in gas phase

A kinetic study of ethylene/1‐hexene copolymerization is conducted with a supported metallocene catalyst in a gas‐phase reactor. The investigation into the kinetics of ethylene/1‐hexene copolymerization includes the effects of operational parameters such as the reaction temperature, pressure, and comonomer concentration. The large variations in gas‐phase composition using only an initial charge of 1‐hexene are illustrated by experiment. To remedy this, the ability to control the comonomer composition of 1‐hexene online for the entire duration of the reaction is demonstrated. Online perturbation techniques are implemented to determine key kinetic parameters such as the activation energies for propagation and catalyst deactivation. From pressure perturbation results, a reaction rate order close to 1 is obtained for ethylene in the presence of 1‐hexene. Finally, all the parameters obtained from the study are compared to those determined from ethylene–propylene (E–P) copolymerization. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 80: 1096–1119, 2001     

Polymerization of ethylene and ethylene/1‐hexene over Ziegler‐Natta/Metallocene hybrid catalysts supported on SiO2 prepared by a sol‐gel method

A silica support for use in olefin polymerization was prepared by the gelation of a stable, colloidal phase of silica sol using a MgCl₂ solution as the initiator. The Ziegler‐Natta/Metallocene hybrid catalysts prepared using this support exhibited characteristics of both Ziegler‐Natta and metallocene catalysts. The polymers produced by the hybrid catalysts showed a bimodal molecular weight distribution pattern and two different melting points, corresponding to products arising from each catalyst. This suggests that the hybrid catalysts acted as individual active species and produced a blend of polymers. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 78: 2318–2326, 2000     

高分子载体负载Cp2ZrCl2/MAO催化剂及其催化乙烯聚合的研究

苯乙烯、2-乙烯基苯和烯丙基取代的茂金属催化剂进行共聚,合成高分子化的茂金属催化剂。该茂金属催化剂用于乙烯聚合反应活性较高,在聚合工艺条件为75 ℃,压力1.4 MPa,n(Al)∶n(Zr)=400时,活性可达1.95×10⁷ g·（mol·h）^－1,并可控制聚合物的形态。     

The influence of aluminum alkyls on the polymerization of ethylene with SiO2/MgCl2-supported TiCl4 catalysts

The influence of different aluminum alkyls (diethylaluminum chloride, triethylaluminum, triisobutylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum and isoprenylaluminum) on the ethylene polymerization activity of a laboratory prepared high-activity SiO₂/MgCl₂-supported TiCl₄ catalyst has been investigated. A slurry reactor (decane diluent) was used for measuring rates of polymerization. The average molar mass, the breadth of the molar mass distribution, the polymerization activity, and the shapes of the activity-time profiles, were strongly dependent on the nature of the aluminum alkyl. For several of the cocatalysts used, the catalytic activity approached a constant value after a certain amount of time under reaction conditions. In this constant activity region, a first-order dependence of the polymerization rate on the monomer concentration was found for all of the systems examined. However, the activation energy of the polymerization reaction was found to depend strongly on the type of cocatalyst which was used.     

Study on copolymerization of ethylene/1‐hexene catalyzed by a novel polystyrene‐supported metallocene catalyst

Ethylene/1‐hexene copolymerization was carried out with polystyrene‐supported metallocene catalyst. It was found that the kinetic of the copolymerization was strongly influenced by the steric hindrance of carrier. The influences of 1‐hexene concentration in the feed on catalyst productivity and comonomer reactivity were investigated. The microstructure of resultant copolymer was analyzed by ¹³C NMR. It was found that the different carriers have slight effect on the composite of copolymer. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 1574–1577, 2006     

Experimental proof of the existence of mass‐transfer resistance during early stages of ethylene polymerization with silica supported metallocene/MAO catalysts

The size of a silica supported metallocene/MAO (methylaluminoxane) catalyst plays an important role in determining its productivity during ethylene polymerization. From a chemical engineering point of view, this size dependency of catalytic activity of supported metallocenes is mathematically connected with the different levels of mass‐transfer resistance in big and small catalyst particles but no experimental evidence has been provided to date. The results of this systematic experimental study clearly demonstrate that the intraparticle monomer diffusion resistance is high in bigger catalyst particles during initial instants of ethylene polymerization and diminishes with the polymer particle growth. Two different silica supported metallocene/MAO catalysts provided the same results while highlighting the fact that catalyst chemistry should be carefully considered while studying complex chemical engineering problems. © 2017 American Institute of Chemical Engineers AIChE J, 63: 4476–4490, 2017     

气相法mPE的性能剖析

茂金属聚乙烯（mPE)具有优越的力学性能和光学性能，这与茂金属催化剂的催化性能及其聚合物特殊的链结构形式密切相关。对国内开发的mPE进行了结构表征，结果表明：mPE薄膜的力学性能和光学性能明显优于线型低密度聚乙烯产品，其耐穿刺性能明显好于其他聚乙烯产品。     

Nanosized silica‐supported metallocene/MAO catalyst for propylene polymerization

A nanosized silica particle was used as the support to prepare an Et[Ind]₂ZrCl₂/MAO catalyst for propylene polymerization of polypropylene. The catalyst and the polymer produced were characterized with nitrogen adsorption, ICP, DSC, SEM, TEM, XRD, solution viscometer, ¹³C NMR and optical microscopy. The effects of polymerization temperature and [Al]/[Zr] ratio on catalyst activity and polymer melting point were investigated. Under identical reaction conditions, nanosized catalyst exhibited better polymerization activity than the microsized catalyst (e.g., the former had 64% higher activity than the latter at the optimum polymerization temperature (50°C) and [Al]/[Zr] = 570). DSC results indicated that polymer melting point increased with the increase of [Al]/[Zr] ratio and with the decrease of polymerization temperature. XRD results showed that the percentage of γ crystals increased with decreasing [Al]/[Zr] ratio. Electron microscopic results showed that the polymer particle size increased with increasing polymerization temperature. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2573–2580, 2006     

Nano‐sized silica supported Me2Si(Ind)2ZrCl2/MAO catalyst for ethylene polymerization

Nano‐sized and micro‐sized silica particles were used to support a zirconocene catalyst [racemic‐dimethylsilbis(1‐indenyl)zirconium dichloride], with methylaluminoxane as a cocatalyst. The resulting catalyst was used to catalyze the polymerization of ethylene in the temperature range of 40–70°C. Polyethylene samples produced were characterized with scanning electron microscopy (SEM), X‐ray diffraction (XRD), differential scanning calorimetry (DSC), and gel permeation chromatography (GPC). Nano‐sized catalyst exhibited better ethylene polymerization activity than micro‐sized catalyst. At the optimum temperature of 60°C, nano‐sized catalyst's activity was two times the micro‐sized catalyst's activity. Polymers obtained with nano‐sized catalyst had higher molecular weight (based on GPC measurements) and higher crystallinity (based on XRD and DSC measurements) than those obtained with micro‐sized catalyst. The better performances of nano‐sized catalyst were attributed to its large external surface area and its absence of internal diffusion resistance. SEM indicated that polymer morphology contained discrete tiny particles with thin long fiberous interlamellar links. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Ethylene polymerization by alkylidene‐bridged asymmetric dinuclear titanocene/MAO systems

Two asymmetric alkylidene‐bridged dinuclear titanocenium complexes (CpTiCl₂)₂(η⁵‐η⁵‐C₉H₆(CH₂)_nC₅H₄), 1 (n = 3) and 2 (n = 4) have been prepared by treating two equivalents of CpTiCl₃ with the corresponding dilithium salts of the ligands C₉H₇(CH₂)_nC₅H₅ (n = 3, 4). Additionally, Ti(η⁵:η⁵‐n‐BuC₅H₄C₅H₅)Cl₂ (3) and Ti(η⁵:η⁵‐n‐BuC₉H₆C₅H₅)Cl₂ (4) were synthesized as corresponding mononuclear complexes. All complexes were characterized by ¹H, ¹³C NMR, and IR spectroscopy. Homogenous ethylene polymerization catalyzation using those complexes has been conducted in the presence of methylaluminoxane (MAO). The influences of reaction parameters, such as [MAO]/[Cat] molar ratio, catalyst concentration, ethylene pressure, temperature, and time have been studied in detail. The results showed that the catalytic activities of both dinuclear titanocenes were higher than those of the corresponding mononuclear titanocenes. Although the two dinuclear complexes were different in only one [CH₂] unit, the catalytic activity of 2 was about 50% higher than that of 1; however, the molecular weight of polyethylene (PE) obtained by 2 was lower than that obtained from 1. The molecular weight distribution of PE produced by these dinuclear complexes reached 6.9 and 7.3, respectively. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 3317–3323, 2006     

Comparison of gas‐ and liquid‐phase polymerization of propylene with heterogeneous metallocene catalyst

Sorption measurements are executed to study the sorption behavior of propylene in a semicrystalline polymer. Decreasing values for the Flory–Huggins interaction parameter with increasing temperature are obtained. Large deviations are found, especially at higher temperatures, compared to data from the literature. Propylene is polymerized in liquid and gaseous propylenes with Me₂Si[Ind]₂ZrCl₂/MAO/SiO₂ as the metallocene catalyst. Lower relative reaction rates are found in the gas phase compared to the experiments in the liquid phase. The activation energies from the experiments in both phases are on the same order of magnitude. However, the literature versus experimental sorption data has a large effect on the determined kinetic parameters. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 1193–1206, 2001     

Propylene polymerization using combined syndio‐ and isospecific metallocene catalysts supported on silica/MAO

Syndiotactic and isotactic polypropylene were produced using the metallocene compounds Ph₂C(Flu)(Cp)ZrCl₂ and SiMe₂(2‐Me,4‐Ph‐Ind)₂ZrCl₂ in homogeneous system and supported on silica/MAO. These catalysts were evaluated either isolated or as a binary system. In the latter case, the iso‐ and syndiospecific metallocene complexes were immobilized together during the preparation of the supported catalyst. In a further experimental set, the syndio‐ and isospecific isolated heterogeneous catalysts were mixed at the moment of propylene polymerization. The polypropylenes obtained were evaluated using differential scanning calorimetry. The catalytic activities were also investigated. At all the studied polymerization temperatures, the results showed that the binary catalyst produced polypropylenes with lower melting temperatures in comparison with those obtained when the mixture of isolated supported syndio‐ and isospecific catalysts was employed. Moreover, the activation energies for the polymerization of all catalysts systems were calculated, resulting in a lower value for the binary system when compared to that employing the catalyst mixture and to both the isolated supported metallocene catalysts. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 99: 628–637, 2006     

Gas‐phase ethylene polymerization using zirconocene supported on mesoporous molecular sieves

Mesoporous molecular sieves, with pore diameters of 2.6–25 nm, were impregnated with methylaluminoxane and bis(butylcyclopentadienyl)zirconium dichloride and tested as catalysts for the gas‐phase homopolymerization of ethylene at ethylene pressures of 200 psi and temperatures of 50–100°C and for 1‐hexene/ethylene copolymerization at 70°C. The activities and activity profiles, at constant Zr and Al contents, depended on the pore size of the supports and the polymerization temperature. Maximum activities for both the homopolymerizations and copolymerizations were observed for catalysts made with supports having pore diameters of 2.6 and 5.8 nm. Homopolymerization activities were highest at temperatures of 70–80°C; average homopolymerization and copolymerization activities up to 9000 kg of polyethylene/(mol of Zr h) were obtained. The weight‐average molecular weights (M_w's) were not a function of the support pore size but decreased with increasing reaction temperatures, from about 260,000 at 50°C to about 165,000 at 100°C. The polydispersities were essentially constant at 2.5 ± 0.2 for the homopolymers. M_w's for the 1‐hexene/ethylene copolymers had an average value of 117,000 with an average polydispersity of 2.8. The amount of triisobutyl aluminum added to the reactor significantly affected the activity and activity profiles. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 87: 1161–1177, 2003     

Characteristics of ethylene polymerization over Ziegler–Natta/metallocene catalysts Comparison between hybrid and mixed catalysts

Two types of inorganic supports, MgCl₂ and SiO₂, for the impregnation of catalysts were prepared by the recrystallization and the sol–gel method, respectively. The polyethylene produced by the Ziegler–Natta/metallocene hybrid and mixed catalysts showed two melting temperatures and a bimodal MWD corresponding to products arising from each of the individual catalysts. This suggests that these Ziegler–Natta/metallocene catalysts acted as individual active species, and as a result, produced a blend of polymers.     

The investigation of novel non‐metallocene catalysts with phenoxy‐imine ligands for ethylene (co‐)polymerization

Phthaldialdehyde and phthaldiketone were treated with substituted phenols of 2‐amino‐4‐methylphenol, 2‐amino‐5‐methylphenol and 2‐amino‐4‐t‐butylphenol, respectively, and then treated with transition metal halides of TiCl₄, ZrCl₄ and YCl₃. A series of novel non‐metallocene catalysts (1–12) with phenoxy‐imine ligands was obtained. The structures and properties of the catalysts were characterized by ¹H NMR and elemental analysis. The catalysts (1–12) were used to promote ethylene (co‐)polymerization after activation by methylaluminoxane. The effects of the structures and center atoms (Ti, Zr and Y) of these catalysts, polymerization temperature, Al/M (M = Ti, Zr and Y) molar ratio, concentration of the catalysts and solvents on the polymerization performance were investigated. The results showed that the catalysts were favorable for ethylene homopolymerization and copolymerization of ethylene with 1‐hexene. Catalyst 10 is most favorable for catalyzing ethylene homopolymerization and copolymerization of ethylene with 1‐hexene, with catalytic activity up to 2.93 × 10⁶ gPE (mol Y)^?1 h^?1 for polyethylene (PE) and 2.96 × 10⁶ gPE (mol Y)^?1 h^?1 for copolymerization of ethylene with 1‐hexene under the following conditions: polymerization temperature 50 °C, Al/Y molar ratio 300, concentration of catalyst 1.0 × 10^?4 L^?1 and toluene as solvent. The structures and properties of the polymers obtained were characterized by Fourier transform infrared spectroscopy, ¹³C NMR, wide‐angle X‐ray diffraction, gel permeation chromatography and DSC. The results indicated that the obtained PE catalyzed by 4 had the highest melting point of 134.8 °C and the highest weight‐average molecular weight of 7.48 × 10⁵ g mol^?1. The copolymer catalyzed by 4 had the highest incorporation of 1‐hexene, up to 5.26 mol%, into the copolymer chain. © 2012 Society of Chemical Industry     

Influence of supported metallocene catalysts on polymer tacticity

Metallocene catalysts in dissolved form are in most cases unsuitable for the production of polyethylene or polypropylene on an industrial scale. In order to use them in existing technical processes, metallocenes have to be supported. C_s-symmetric zirconocenes show a high activity and no leaching additional triisobutyl aluminum is used as scavenger and MAO-covered silica for heterogenization. The aluminum : zirconium ratio can be reduced to values of 500:1 to get optimal activities. The syndiotacticity of the obtained polypropylene is lower compared with polymers of the homogeneous catalyst and decreases strongly with a thinner propene concentration. This revised version was published online in June 2006 with corrections to the Cover Date.     

Gamma‐irradiated metallocenic polyethylene and ethylene‐1‐hexene copolymers

The aim of this work is to present a detailed study of the changes introduced by gamma radiation on several metallocenic polyethylene copolymers. Therefore, metallocenic polyethylene and copolymers with 3.3, 9.2, and 16.1 mol % of hexene comonomer content were synthesized and irradiated with ⁶⁰Co gamma radiation under vacuum at room temperature with radiation doses ranging from 0 to 100 kGy. Size Exclusion Chromatography data show that crosslinking reactions predominate over scission, even for the copolymer with the highest tertiary carbon content. Over a certain critical dose, which depends on the molecular weight and molecular structure of the initial polymer, an insoluble gel forms. The irradiated polymers also exhibit complex rheological behavior with increasing melt viscosity and elasticity, consistent with long chain branching and/or crosslinking. FTIR confirms depletion of terminal vinyl groups and increase of trans unsaturations with dose. The rate at which these two reactions evolve seems to depend on the comonomer content of the irradiated copolymers. Differential scanning calorimetry and Raman spectroscopy analyzes indicate less crystallinity and thicker interphases in irradiated materials. A mathematical model, which accounts for scission and crosslinking reactions, fitted well the evolution with radiation dose of the measured molecular weight data. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010