The characteristics of metallocene/Ziegler-Natta hybrid catalysts supported on the recrystallized MgCl2

A metallocene catalyst or a metallocene/Ziegler-Natta hybrid catalyst supported on MgCl₂ was studied for application to the commercial slurry phase process and to the control of MWD of the polymer produced. The MgCl₂ support was prepared by the recrystallization method with different solvents: alcohols and H₂O. The recrystallized MgCl₂ support was pretreated with triisobutylaluminum (TiBAL) or trimethylaluminum (TMA), methylaluminoxane (MAO), to give different supporting environments. Metallocene/Ziegler-Natta hybrid catalysts on MgCl₂ were prepared by first supporting the metallocene catalyst, followed by the Ziegler-Natta catalyst after pretreatment with an alkylaluminum compound. The type of solvent plays a role in providing a suitable environment in the support for impregnating catalysts. The hybrid catalyst, whose support was recrystallized in n-propanol (n-PrOH) and pretreated with TiBAL, showed the highest molar ratio of Zr/Ti= 1/2.71. But the hybrid catalyst, whose support was recrystallized in H₂O and pretreated with MAO, showed the best hybrid effect showing a variety of bimodal peaks in proportion to the ratio of MAO/TEA in GPC analysis. This effect might be due to steric factor and polarity of solvent, as well as the pretreatment material. It is concluded that the MWD of polyethylene produced by metallocene/Ziegler-Natta hybrid catalyst that is supported on MgCl₂ can be controlled by regulating the amounts of MAO and TEA added as cocatalysts and by the use of different solvents and pretreatment materials.     

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.     

Effect of Catalyst,Temperature, and Hydrogen Pressure on Slurry Hydrocracking Reactions of Naphthalene

Hydrocracking reactions of naphthalene were investigated in a slurry‐type reactor with different catalyst compositions consisting of iron‐based compounds, metal oxides, and elementary sulfur in order to evaluate the most efficient catalyst composition. The reactions were repeated with the optimal catalyst composition at different H₂ initial pressures, temperatures, and holding times to determine the influence of these parameters. At the end of each reaction, liquid samples were analyzed by gas chromatography and mass spectrometry. The most effective catalyst composition for hyrocracking reaction of naphthalene was found to be a mixture of FeSO₄·H₂O, Fe₂O₃, Al₂O₃, and sulfur. It can be concluded that hydrogenation, isomerization, cracking, and dealkylation take place during the hydrocracking reaction of naphthalene.     

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.     

Study of the compositional heterogeneity of ethylene/1–hexene copolymers produced over supported catalysts of different composition

Separation into narrow MWD fractions (liquid–liquid fractionation) and preparative TREF (temperature rising elution fractionation) with subsequent analysis of fractions by GPC, FTIR, and ¹³C NMR spectroscopy were used to study the comonomer distribution of ethylene/1–hexene copolymers produced over highly active supported titanium‐ and vanadium‐magnesium catalysts (TMC and VMC) and a supported zirconocene catalyst. These catalysts produce PE with different MWD: M_w/M_n values vary from 2.9 for zirconocene catalyst, 4.0 for TMC, and 15 for VMC. 1‐Hexene increases polydispersity to 25 for copolymer produced over VMC and hardly affects MWD of the copolymer produced over TMC and zirconocene catalysts. The most broad short chain branching distribution (SCBD) was found for ethylene/1–hexene copolymers produced over TMC. VMC and supported zirconocene catalyst produce copolymers with uniform profile of SCB content vs. molecular weight in spite of great differences in M_w/M_n values (22 and 2.5 respectively). TREF data showed that majority of copolymer produced over supported zirconocene catalyst was eluted at 70–90°C (about 85 wt %). In the case of VMC copolymer's fractions were eluted in the broad temperature interval (40–100°C). Accordingly, TREF data indicate a more homogeneous SCBD in copolymer, produced over supported zirconocene catalyst. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Kinetics of Liquid‐Phase Hydrogenation of Iso‐valeraldehyde to Iso‐amyl Alcohol Over A Ru/Al2O3 Catalyst

The liquid‐phase catalytic hydrogenation of iso‐valeraldehyde to iso‐amyl alcohol was studied in a slurry reactor. The kinetics of liquid‐phase hydrogenation of iso‐valeraldehyde over a 5% Ru/Al₂O₃ catalyst was studied in the range of temperature 373‐393 K and H₂ pressure 0.68‐2.72 MPa using 2‐propanol as the solvent. The selectivity to iso‐amyl alcohol was 100%. The kinetic data were analyzed using a simple power law model. A single site Langmuir‐Hinshelwood type model suggesting dissociative adsorption of hydrogen and surface reaction as the rate‐controlling step provided the best fit of the experimental data. The catalyst could be reused thrice without any loss in activity.     

Slurry Phase Hydrogenation of CO2 to Methanol Using Supported In2O3 Catalysts as Promising Approach for Chemical Energy Storage

A promising approach for chemical energy storage from fluctuating renewable electricity is methanol synthesis from CO₂ and hydrogen in a slurry reactor concept, due to efficient heat storage and easy reactor control. In combination with a promising In₂O₃/ZrO₂ catalyst and mineral oil as carrier liquid, efficient methanol production under a wide range of changing process conditions is shown for the first time. A maximum methanol productivity of 2.1 g_MeOHg_In⁻¹h⁻¹ and multiple recycling stability of the catalyst and the carrier liquid was achieved, showing no significant decrease in methanol yields.     

Molecular weight distribution of polyethylene catalyzed by Ziegler–Natta catalyst supported on MgCl2 doped with AlCl3

Ti‐based Ziegler–Natta catalysts supported on MgCl₂ doped with AlCl₃ were prepared by the reaction of MgCl₂/AlCl₃–ethanol adduct with TiCl₄. No AlCl₃ crystallites were found in the AlCl₃‐doped catalysts by WAXD analysis, suggesting that AlCl₃/MgCl₂ solid solution was formed. The effect of doping on the catalyst performance in ethylene polymerization was investigated. The results showed that the catalysts based on AlCl₃‐doped MgCl₂ support exhibited a slightly higher activity than did the MgCl₂‐supported catalyst and the molecular weight distribution (MWD) of polyethylene (PE) markedly increased (from 10.8 to 47.9) with the increase of AlCl₃ content in catalysts. The changes in catalyst's active center distribution were studied based on nonlinear fitting of the polymer GPC curves by multiple Flory functions. It was found that increase of types of active centers by introducing AlCl₃ into the support should be responsible for the broadening of MWD of PE. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 1768–1772, 2006     

Effect of method of preparation on activity of Pd/Al2O3 monolith catalysts

Pd/Al₂O₃ monolithic catalyst of different washcoat thicknesses were prepared by two methods and tested for the activity of hydrogenation of α‐methyl styrene. These catalysts were prepared by two methods; either the palladium was impregnated on γ‐alumina and this Pd/Al₂O₃ powder was used to prepare the slurry for washcoating (Cat 1) or γ‐alumina washcoating was followed by impregnation of palladium (Cat 2). The effect of slurry concentration, pH of the slurry, and addition of binders on the catalyst properties was investigated. The monolithic catalysts were characterised by determination of metal dispersion, surface area, scanning electron microscopy, and weight loss of washcoat during ultrasonication. Well‐adhered washcoats were obtained with slurry prepared using milled γ‐alumina, whereas the adhesion of the washcoat prepared using Pd/Al₂O₃ powders was very poor. Addition of binders significantly improved the adhesion of the washcoats prepared from Pd/Al₂O₃. Metal dispersion for Cat 2 decreased with washcoat loading but did not change with loading for Cat 1. The activity tests were conducted at different washcoat loadings and the productivity of the monolithic catalyst prepared in both methods has been compared.     

Investigation of Fischer-Tropsch synthesis performance and its intrinsic reaction behavior in a bench scale slurry bubble column reactor

A bench scale slurry bubble column reactor (SBCR) with active-Fe based catalyst was developed for the Fischer-Tropsch synthesis (FTS) reaction. Considering the highly exothermic reaction heat generated in the bench scale SBCR, an effective cooling system was devised consisting of a U-type dip tube submerged in the reactor. Also, the physical and chemical properties of the catalyst were controlled so as to achieve high activity for the CO conversion and liquid oil (C₅₊) production. Firstly, the FTS performance of the FeCuK/SiO₂ catalyst in the SBCR under reaction conditions of 265 °C, 2.5 MPa, and H₂/CO = 1 was investigated. The CO conversion and liquid oil (C₅₊) productivity in the reaction were 88.6% and 0.226 g/g_cat-h, respectively, corresponding to a liquid oil (C₅₊) production rate of 0.03 bbl/day. To investigate the FTS reaction behavior in the bench scale SBCR, the effects of the space velocity and superficial velocity of the synthesis gas and reaction temperature were also studied. The liquid oil production rate increased up to 0.057 bbl/day with increasing space velocity from 2.61 to 3.92 SL/h-g_Fe and it was confirmed that the SBCR bench system developed in this research precisely simulated the FTS reaction behavior reported in the small scale slurry reactor.     

Three‐site mechanism and molecular weight: Time dependency in liquid propylene batch polymerization using a MgCl2‐supported Ziegler‐Natta catalyst

This article demonstrates that the molecular weight of propylene homopolymer decreases with time, and that the molecular weight distribution (MWD) narrows when a highly active MgCl₂‐supported catalyst is used in a liquid pool polymerization at constant H₂ concentration and temperature. To track the change in molecular weight and its distribution during polymerization, small portions of homo polymer samples were taken during the reaction. These samples were analyzed by Cross Fractionation Chromatograph (CFC), and the resulting data were treated with a three‐site model. These analyses clearly showed that the high molecular weight fraction of the distribution decreases as a function of time. At the same time, the MWD narrows because the weight‐average molecular weight decreases faster than the number‐average molecular weight. A probable mechanism based on the reaction of an external donor with AlEt₃ is proposed to explain these phenomena. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 1035–1047, 2001     

Synthesis of AlOOH slurry catalyst and catalytic activity for methanol dehydration to dimethyl ether

AlOOH slurry catalysts were prepared by complete liquid-phase technology from aluminum iso-propoxide (AIP). Dehydration of methanol to dimethyl ether (DME) over these catalysts was investigated in slurry reactor. The catalysts were characterized by X-ray diffraction (XRD), nitrogen adsorption, temperature-programmed desorption of ammonia (NH₃–TPD). The results showed that the slurry catalysts had high specific surface area and pore volume, and the specific surface area and the strength of weak acidic sites were influenced considerably by the molar ratio of H₂O/AIP and HNO₃/AIP. Activity tests indicated that AlOOH slurry catalysts had excellent catalytic activity and stability in slurry reactor for the dehydration of methanol to dimethyl ether, and the activity correlated well with the strength of weak acidic sites of catalysts, which can be controlled by changing the H₂O/AIP and HNO₃/AIP molar ratios. The average methanol conversion at even stage reaches nearly 80% and DME selectivity almost 100% over CAT-P1 catalyst. No deactivation was found during the reaction of 500 h. It is also expected that CAT-P1 becomes a promising methanol dehydration catalyst for the STD process based on CuZuAl methanol synthesis catalyst.     

Preparation of MoO3/Al2O3 Catalysts with Sharp Eggshell Mo Distribution by Slurry Impregnation

MoO₃/Al₂O₃ catalysts with eggshell Mo concentration profiles were prepared by reaction of Al₂O₃ extrudates or balls with slurry of MoO₃ in water. The Mo concentration wave penetrating Al₂O₃ particles during this slurry impregnation was almost rectangular. Its height was close to the filled monolayer loading. The thickness of the shell was regulated either by impregnation time or by the MoO₃ amount in the slurry. The hydrodesulfurization activity of Mo species deposited by slurry impregnation was about the same or better (depending on the Al₂O₃ used) as in industrial MoO₃/Al₂O₃ catalyst.     

Co γ-Initiated polymerization of vinyl monomers in room temperature ionic liquid/THF mixed solutions

Radiation induced polymerization of styrene (St), methyl methacrylate (MMA) and n-butyl methacrylate (BMA) is carried out in a room temperature ionic liquid (RTIL), [Me₃NC₂H₄OH]⁺[ZnCl₃]⁻, and in its mixed solutions with THF. The presence of ionic liquid (IL) leads to a significant increase in monomer conversion and polymer's molecular weight. Molecular weight distribution (MWD) of resulting polymer varies with the IL fraction in the RTIL/THF solutions and is also dependent on the monomer used. For polystyrene (PSt) and poly(n-butyl methacrylate) (PBMA), multi-modal broad MWD is observed at IL >50 v% while single-modal narrow MWD is observed at IL <40 v%. For poly(methyl methacrylate) (PMMA), however, nearly a single-modal MWD is observed at THF >20 v%. The measured miscibility of polymer with RTIL is in the order: PMMA>PBMA>PSt. Here we propose that the difference in MWD is due to the inhomogeneous nature of the ionic liquid in micro-region and the immiscibility of polymer with medium.     

Liquid phase methanol and dimethyl ether synthesis from syngas

The Liquid Phase Methanol Synthesis (LPMeOH^TM) process has been investigated in our laboratories since 1982The reaction chemistry of liquid phase methanol synthesis over commercial Cu/ZnO/Al₂O₃ catalysts, established for diverse feed gas conditions including H₂-rich, CO-rich, CO₂-rich, and CO-free environments, is predominantly based on the CO₂ hydrogenation reaction and the forward water-gas shift reactionImportant aspects of the liquid phase methanol synthesis investigated in this in-depth study include global kinetic rate expressions, external mass transfer mechanisms and rates, correlation for the overall gas-to-liquid mass transfer rate coefficient, computation of the multicomponent phase equilibrium and prediction of the ultimate and isolated chemical equilibrium compositions, thermal stability analysis of the liquid phase methanol synthesis reactor, investigation of pore diffusion in the methanol catalyst, and elucidation of catalyst deactivation/regenerationThese studies were conducted in a mechanically agitated slurry reactor as well as in a liquid entrained reactorA novel liquid phase process for co-production of dimethyl ether (DME) and methanol has also been developedThe process is based on dual-catalytic synthesis in a single reactor stage, where the methanol synthesis and water gas shift reactions takes place over Cu/ZnO/Al₂O₃ catalysts and the in-situ methanol dehydration reaction takes place over -Al₂O₃ catalystCo-production of DME and methanol can increase the single-stage reactor productivity by as much as 80%. By varying the mass ratios of methanol synthesis catalyst to methanol dehydration catalyst, it is possible to co-produce DME and methanol in any fixed proportion, from 5% DME to 95% DMEAlso, dual catalysts exhibit higher activity, and more importantly these activities are sustained for a longer catalyst on-stream life by alleviating catalyst deactivation.     

Fischer–Tropsch synthesis in slurry-phase reactors over Mn- and Zr-modified Co/SiO2 catalysts

Fischer–Tropsch (F–T) synthesis was carried out in a gas-flowed slurry-phase reaction system over Mn- and Zr-modified Co/SiO₂ catalysts. A 0.5 L stirred tank slurry reactor (STSR) was used for catalyst screening and a 12.5 L slurry bubble column reactor (SBCR) was used for trial pilot operation. While using the 0.5 L reactor for catalyst screening, Co supported on the SiO₂ with an average pore size of 10 nm showed a high catalytic performance for the F–T synthesis due to the suitable Co particle size in the catalyst. Zr promoter improved the activity and Mn promoter improved the stability of Co/SiO₂ catalyst for the F–T synthesis. H₂-TPR profiles indicated that Zr and Mn promoters improved the reduction degree of Co₃O₄ particles (on SiO₂ surface) to Co⁰ active species in H₂ flow at low temperature. While using the 12.5 L reactor for trial pilot operation over Mn–Zr–Co/SiO₂ catalyst, the space-time yield (STY) of C₅₊ hydrocarbons (liquid fuel) showed almost the same values when various solvents (n-C₁₆H₃₄, n-C₁₄H₃₀, diesel from petrol station, F–T crude oil) were used. Diesel and F–T crude oil are suitable for using in a large-scaled F–T synthesis plant owing to the low prices. Mn–Zr–Co/SiO₂ catalyst achieved a STY of C₅₊ hydrocarbons larger than 1000 g-C₅₊ kg-cat^? 1 h^? 1 in the 12.5 L reactor. The production capacity of liquid fuel from the 12.5 L reactor reached to 15.6 L per day (assumed for 24 h continuous operation). The stirring was very important for the F–T synthesis both reaction in the 0.5 L reactor and reaction in the 12.5 L reactor. The shape of slurry reactor also influenced the CO conversion for the F–T synthesis: reaction in the 12.5 L SBCR gave a higher CO conversion than that of reaction in the 0.5 L STSR (at the same W/F value under the same stirring speed) because the slender column reactor (SBCR) extended the residue time of reaction gas in the slurry-phase containing catalyst.     

Effect of H2O on Cu-based catalyst in one-step slurry phase dimethyl ether synthesis

One-step dimethyl ether (DME) synthesis in slurry phase was catalyzed by a hybrid catalyst composed of a Cu-based methanol synthesis catalyst and a γ-Al₂O₃ methanol dehydration catalyst under reaction conditions of 260 °C and 5.0 MPa. It was found that instability of the Cu-based catalyst led to rapid deactivation of the hybrid catalyst. The stability of the Cu-based catalyst under DME synthesis conditions was compared with that under methanol synthesis conditions. The results indicated that harmfulness of water, which formed in DME synthesis, caused the Cu-based catalyst to deactivate at a high rate. Surface physical analysis, elemental analysis, XRD and XPS were used to characterize the surface physical properties, components, crystal structures and surface morphologies of the Cu-based catalysts. It was found that Cu⁰ was the active component for methanol synthesis and Cu₂O might have less activity for the reaction. Compared with methanol synthesis process, crystallite size of Cu became bigger in DME synthesis process, but carbon deposition was less severe. It was also found that there was distinct metal loss of Zn and Al caused by hydrothermal leaching, impairing the stability of the catalyst. In slurry phase DME synthesis, a part of Cu transformed into Cu₂(OH)₂CO₃, causing a decrease in the number of active sites of the Cu-based catalyst. And some ZnO converted to Zn₅(OH)₆(CO₃)₂, which caused the synergistic effect between Cu and ZnO to become weaker. Crystallite size growth of Cu, carbon deposition, metal loss of Zn and Al, formation of Cu₂(OH)₂CO₃ and Zn₅(OH)₆(CO₃)₂ were important reasons for rapid deactivation of the Cu-based catalyst.     

Strong dependence on pressure of the performance of a Co/SiO2 catalyst in Fischer–Tropsch slurry reactor synthesis

A 10 wt% Co/SiO₂ catalyst was prepared by the incipient wet-impregnation method and tested in Fischer–Tropsch synthesis in a slurry reactor under conditions approaching industrial practice. The catalyst precursor was investigated by X-ray diffraction (XRD), temperature-programmed reduction (TPR), transmission electron microscopy (TEM) and photoelectron spectroscopy (XPS). The XPS and XRD techniques revealed the presence of a crystalline Co₃O₄ spinel-type phase, while-in addition-TEM and XPS analyses pointed to the formation of another amorphous Co₃O₄ spinel phase, both species interacting weakly with the silica substrate. The influence of total pressure on the conversion, selectivity and stability of the catalyst was studied. Upon increasing the overall pressure from 20 to 40 bar, not only activity increased but also the catalyst are not deactivating. These results are explained in terms of an increase of gases solubility in the solvent, this increment of CO concentration in the liquid phase favours carbonyl species formation and the cobalt particles segregation that implies an increase in the metal surface area.     

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.     

Inhibition of liquid Si infiltration into carbon-carbon composites by the addition of Al to the Si slurry pre-coating: mechanism analysis

The mechanism of the inhibition of liquid Si infiltration (LSI) into a two-dimensional carbon-carbon composite (2D-C/C) by the addition of Al to the Si slurry pre-coating was investigated. It was shown by means of a vapor treatment experiment designed intentionally that the surface composition of the inner pores beneath the Si slurry pre-coating before the occurrence of LSI was pure carbon and SiC, while before the occurrence of the LSI with the Si-6 wt.%Al slurry pre-coating, the surface composition of the inner pores was Al₄C₃, SiC and a small amount of pure carbon. The formation of the SiC and the Al₄C₃ was the result of the evaporation of almost all the Al additive and a little Si during the heating. For reactive infiltrations, reactions at the vapor-liquid-solid triple line are believed to affect the final infiltration depth. Faster reactions at the triple line lead to faster infiltration velocity and hence deeper reactive infiltration. The reaction at the triple line for the LSI with the Si-6 wt.%Al slurry pre-coating was mainly between liquid Si and the surface Al₄C₃, which was probably slower than the reaction of liquid Si with the pure carbon at the triple line corresponding to the LSI with the Si slurry pre-coating. Therefore, the extent of the penetration of liquid Si during the LSI with Si-6 wt.%Al slurry pre-coating was lower than that with the Si slurry pre-coating.