Control of molecular weight distribution for polypropylene obtained by a commercial Ziegler–Natta catalyst: Effect of a cocatalyst and hydrogen

The polymerization of propylene was carried out with an MgCl₂‐supported TiCl₄ catalyst (with diisobutyl phthalate as an internal donor) in the absence and presence of hydrogen (H₂) as a chain‐transfer agent. Different structures of alkylaluminum were used as cocatalysts. The effects of the alkyl group size of the cocatalyst, H₂ feed, and feed time on the propylene polymerization behaviors were investigated. The catalyst activity significantly decreased with increasing alkyl group size in the cocatalyst. The molecular weight and polydispersity index (PDI) increased with increasing alkyl group size. With the introduction of H₂, the catalyst activity increased significantly, whereas the molecular weight and PDI of polypropylene (PP) decreased. Additionally, the effect of the polymerization time in the presence of H₂ on the propylene polymerization was studied. The molecular weight distribution curve was bimodal at short polymerization times in the presence of H₂, and we could control the molecular weight distribution of PP by changing the polymerization time in the presence of H₂. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Control of molecular weight distribution in propylene polymerization with Ziegler–Natta/metallocene catalyst mixtures

Propylene polymerization was investigated with a sequential addition of Ziegler–Natta and metallocene catalysts. From the fact that the molecular weights of polypropylene (PP) produced with Ziegler–Natta and with metallocene catalysts differ, it was possible to control the molecular weight distribution (MWD) of PP with a sequential addition of methylaluminoxane and rac-ethylenebis(indenyl)zirconium dichloride followed by triethylaluminum and magnesium dichloride-supported titanium tetrachloride catalyst. The obtained PP exhibited a wide MWD curve with shoulder peak. The position and height of each peak was controlled with the variation of polymerization time for each catalyst as well as the amount of each catalyst. The MWD of PP prepared with sequential addition of catalysts was much wider than that of PP obtained from each catalyst. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 67:2213–2222, 1998     

Fractal approach for modeling the morphology evolution of olefin polymerization with heterogeneous catalysts

Fractal theory and methodology were used to investigate the morphology of titanium–magnesium‐supported polyethylene catalysts and their relevant polymer particles. Through an analysis of the submicrostructures using scanning electron microscopy images, the surface fractal dimensions of the related particles were estimated with the box‐counting method. With consideration given to the fact that the growth process of a polymer is an evolving fractal process, which is controlled on the one hand by the initial conditions, including the initial fractal dimensions of the catalysts and the initial reaction conditions, and on the other hand by the previous morphology characteristics of the system, a novel polymerization fractal growth model was constructed. The simulation results showed good agreement with the experiment data. Moreover, the morphology evolution with the prepolymerization technique was predicted, and it was suggested that the duration of polymerization was 10–30 min. It was proven that the use of the surface fractal dimension as an important parameter describing the surface morphologies of the particles, either of catalysts or polymers, was real and effective. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 1463–1470, 2003     

Optimal operation of ethylene polymerization reactors for tailored molecular weight distribution

This work presents a comprehensive steady‐state model of the high‐pressure ethylene polymerization in a tubular reactor able to calculate the complete molecular weight distribution (MWD). For this purpose, the probability generating function technique is employed. The model is included in an optimization framework, which is used to determine optimal reactor designs and operating conditions for producing a polymer with tailored MWD. Two application examples are presented. The first one involves maximization of conversion to obtain a given MWD, typical of industrial operation. Excellent agreement between the resulting MWD and the target one is achieved with a conversion about 5% higher than the ones commonly reported for this type of reactor. The second example consists in finding the design and operating conditions necessary to produce a polymer with a bimodal MWD. The optimal design for this case involves a split of the initiator, monomer, and modifier feeds between the main stream and two lateral injections. To the best of our knowledge, this is the first work dealing with the optimization of this process in which a tailored shape for the MWD is included. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

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     

乙烯淤浆聚合动态分子量分布模拟计算

以乙烯淤浆聚合反应过程为研究对象,提出动态分子量分布的严格模型的数值计算方法。将动态分子量分布的大规模微分代数混合模型解耦为小规模微分代数方程组动态矩模型与大规模常微分方程组粒数衡算模型,然后通过变量解耦的方法进一步将大规模粒数衡算方程组转换为序贯差分方程组,实现了乙烯动态分子量分布严格模型的数值模拟计算。动态模拟乙烯聚合反应从一个稳态切换到另一个稳态,通过在切换后稳态的分子量分布计算结果与Flory分布计算方法进行比较,两者得到的分子量分布曲线吻合很好,证实了本文提出的动态模拟计算方法的精度和准确度都获得良好的保障。     

Calculation method of molecular weight averages in polymerization with chain-length-dependent termination

A systematic method for calculating the molecular weight distribution moments in free radical polymerization where termination rate depends on the size of the participating radicals, is presented. The central part of the method is the evaluation of the distribution of termination rates in the balance equations. From an adopted functional form of the termination rate constant, the moment equations are derived. For evaluating the moments of the termination rate distribution an approximate reconstruction of the radical chain length distribution using Laguerre polynomials is proposed. The calculation method can handle termination by disproportionation and combination simultaneously and allows easily to take into account diffusioncontrolled initiation, propagation and chain transfer reactions. The usefulness of the method is illustrated by simulating the bulk polymerization of methyl methacrylate and styrene. The calculated results of conversion, molecular weight averages (M _n,M _w,M _z and M _z+1) and polydispersity are in good agreement with the reported experimental data.     

基于聚合物分子量分布的乙烯淤浆聚合工艺优化

分子量及分布是聚合物生产过程中极其重要的质量指标,但目前的技术水平并不能实现分子量及其分布的实时测量,基于反应机理的动态建模是实现其软测量的重要方法。以乙烯淤浆聚合工艺为研究对象,基于聚合机理,分别以聚合物的平均分子量和分子量分布为目标,以循环气中氢气乙烯比为决定变量,采用稳态优化方法求取聚合物生产的工艺条件。结果表明:以平均分子量为优化目标所得的结果与分析值的偏差较大,虽然聚合物的平均分子量符合要求,但聚合物的分子量分布曲线与所需产品的分子量分布曲线之间的最大误差可达0.092;而以分子量分布曲线为目标所得的最大误差只有0.069。因此,以分子量分布曲线作为目标的优化方法明显比常规的以平均分子量为目标的优化方法优越。     

Modeling of molecular weight distribution of gas‐phase polymerization of butadiene

A mathematical model of the molecular weight distribution (MWD) based on a multilayer model and an improved intrinsic kinetics model was proposed to simulate the MWD of the gas‐phase polymerization of butadiene with a heterogeneous catalyst. Intrinsic kinetics and heat and mass‐transfer resistances based on the multilayer model of a polymeric particle were considered in the modeling of the MWD. The effects of the reaction conditions, catalyst particle size, mass‐transfer resistance, deactivation of active sites, and transfer of the polymer chain on the molecular weight and MWD were simulated. The results show that the effects of the deactivation of active sites and transfer of the polymer chain on the average molecular weight are significant and that the effect of the catalyst particle size on the MWD is not significant. The simulation results of the molecular weight and MWD are compared with the experimental results. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 88–103, 2003     

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     

On the molecular weight distribution polydispersity of continuous living‐radical polymerization

Batch living‐radical polymerization techniques were used to produce polymers with molecular weight distributions approaching the narrowness of truly living (ionic) systems. Continuous reactors may offer some advantages for living polymerization in copolymer morphology, but continuous polymerization with any level of backmixing will broaden the molecular weight distribution. This study used simple moment techniques to demonstrate that idealized living‐radical polymerization in a single stirred tank reactor will have a polydispersity of 2. This is also the theoretical minimum polydispersity for a truly living polymerization. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 539–542, 2004     

Ethylene polymerization using a novel MgCl2/SiO2‐supported Ziegler–Natta catalyst

A novel MgCl₂/SiO₂‐supported Ziegler–Natta catalyst was prepared using a new one‐pot ball milling method. Using this catalyst, polyethylenes with different molecular weight distributions were synthesized. The effects of the [Si]/[Mg] ratio, polymerization temperature and [Al]/[Ti] ratio on the catalytic activity, the kinetic behaviour and the molecular weight and the polydispersity of the resultant polymer were studied. It was found that the polydispersity index of the polymer could be adjusted over a wide range of 5–30 through regulating the [Si]/[Mg] ratio and polymerization temperature, and especially when the [Si]/[Mg] ratio was 1.70, the polydispersity index could reach over 25. This novel bi‐supported Ziegler–Natta catalyst is thus useful for preparing polyethylene with a required molecular weight distribution using current equipment and technological processes. Copyright © 2005 Society of Chemical Industry     

Aspects of coordination polymerization in heterogeneous and homogeneous catalysis. A computational survey

Theoretical studies on ethylene polymerization by single site homogeneous catalysts, as well as by Ziegler–Natta heterogeneous catalysts, have been reviewed. Studies on cation–anion interactions in ion-pair systems of the type [LLMR]⁺[A]^– [L, L=Cp, NCR₂, NPR₃; M=Ti, Zr; A=MeB(C₆F₅)₃^–, MAOMe^–, B(C₆F₅)₄^–] provided indications as to which ancillary ligands on the cation acted as good electron donors, and also revealed the importance of having a weakly coordinating anion to enable the ion-pair to separate more easily in solution. Subsequent calculations of barriers to ethylene insertion into the metal-methyl bond in ion-pair systems of the type LLMeM--B(C₆F₅)₃[M=Ti, Zr] revealed that the ease of separation of the anion from the cation in solution was an important criterion in determining the activity of the catalysts. The barrier to insertion was found to be the rate determining step during the first insertion of ethylene into the metal–methyl bond, but second insertion studies conducted for two different ion-pair systems showed that the barrier to uptake of the monomer became the rate determining step during the second insertion of the ethylene monomer. Theoretical studies conducted on TiCl₄/MgCl₂ heterogeneous Ziegler–Natta catalysts provided insights into the nature of the binding of the titanium catalysts (with the Ti in different oxidation states) on to the MgCl₂ support. The results indicated that the support worked best when a few Ti atoms replaced Mg atoms in the crystal lattice of the support. Ethylene polymerization studies, along with investigations on chain termination, led to the conclusion that the TiCl₃-based edge site on MgCl₂ would be the most promising model for the actual catalytic species. Studies on addition of tetrahydrofuran (THF) to the active sites showed that the presence of the base would lead to higher molecular weights of the polymers, as it acted to increase the barrier to termination (by chain transfer to monomer) more than the barrier to insertion.     

Ethylene polymerization over supported titanium‐magnesium catalysts: Effect of polymerization parameters on the molecular weight distribution of polyethylene

The data on the effects of polymerization duration, cocatalyst, and monomer concentrations upon ethylene polymerization in the absence of hydrogen, and the effect of an additional chain transfer agent (hydrogen) on the molecular weight (MW), molecular weight distribution (MWD), and content of vinyl terminal groups for polyethylene (PE) produced over the supported titanium‐magnesium catalyst (TMC) are obtained. The effects of these parameters on nonuniformity of active sites for different chain transfer reactions are analyzed by deconvolution of the experimental MWD curves into Flory components. It has been shown that the polymer MW grows, the MWD becomes narrower and the content of vinyl terminal groups in PE increases with increasing polymerization duration. It is assumed to occur due to the reduction of the rate of chain transfer with AlEt₃ with increasing polymerization duration. The polydispersity of PE is found to rise with increasing AlEt₃ concentration and decreasing monomer concentration due to the emergence of additional low molecular weight Flory components. The ratios of the individual rate constants of chain transfer with AlEt₃, monomer and hydrogen to the propagation rate constant have been calculated. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Effect of fatty amine and perfluorocarbon as anti‐fouling agent on the catalyst activity and titanium oxidation state in slurry polymerization of ethylene

In this work, the effect of two antifouling materials on the activity of catalyst used to produce polyethylene in a 1‐L slurry reactor and on the titanium oxidation state of the catalyst was investigated. Armostat 300 with the formula alkyl C₁₄‐C₁₈ bis(2‐hydroxyethyl)amine is an antistatic agent that reduces static electricity of the polymer particles. It was found that within the concentration of 0.16–1.32 g/mmol Ti, Armostat 300 helps to increase the catalyst activity to 1.3–2 times. The variation of the titanium oxidation state of the catalyst in the presence of Armostat 300 at 80°C with Al/Ti molar ratio of 100 showed that Ti (III) species increased. The effect of Armostat 300 on T_m, % X_c, density, bulk density, and MFI of polymer was insignificant. In this work, Zonyl FSN‐100 with the formula R_f(CH₂CH₂O)_xH, R_f = F(CF₂CF₂)_y, y = 1–9, x = 1–26 was used as antifouling agent in copolymerization of ethylene with 1‐butene. It was found that Zonyl FSN‐100 at the concentration range of 5–20 ppm reduces the catalyst activity to 1.11–1.9 times. It was also shown that Ti (III) species in the presence of Zonyl FSN 100 decreased. This antifouling agent slightly decreased the properties of polymer including % X_c, density, and M_w. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 257–260, 2006     

Synthesis of branched polyethylene by in situ polymerization of ethylene with combined iron catalyst and Ziegler–Natta catalyst

2,6‐Bis(imino)pyridyl iron catalyst and traditional Ziegler–Natta catalyst were combined together as tandem catalytic system, activated with the mixture of TEA and MAO, and used for synthesis of branched polyethylene by in situ polymerization of ethylene. The branched polyethylene with branches from 8/1000C to 29/1000C was produced by adjusting reaction conditions: the amount of TEA, MAO, iron catalyst used, and reaction temperatures. Not only the short branches such as ethyl and butyl but also the longer branches (hexyl and longer than hexyl) were detected in the products. The products exhibited higher molecular weight and broader molecular weight distribution than those obtained from metallocene catalysts, which would provide the materials excellent mechanical properties and processability. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci, 2006     

Mathematical modeling of molecular weight distribution in miniemulsion polymerization with oil‐soluble initiator

A mathematical model for the study of reaction kinetics and molecular weight distributions in miniemulsion polymerization systems with oil‐soluble initiators is presented. The mathematical model allows the computation of the evolution of the complete molecular weight distribution with chain lengths of up to 10⁵ mers in miniemulsion polymerization by direct integration in reasonable computational time. Also, no restriction in the kinetic regime is needed, as the model is able to represent both compartmentalized and pseud‐bulk systems. The model was validated with experimental results for methyl methacrylate and styrene homopolymerizations, with two different oil‐soluble initiators, and adequately represented both the kinetics and molecular weight distributions of these systems. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2128–2140, 2017     

MgCl2‐supported TiCl4 catalysts containing diethyl norbornene‐2,3‐dicarboxylate internal electron donor for 1‐butene polymerization: Effects of internal electron donor configuration

Three isomeric 5‐norbornene‐2,3‐dicarboxylic acid diethyl ester (NDDE) with endo‐, exo‐, and trans‐configuration have been synthesized and employed as internal electron donors (IED) in 1‐butene polymerization over magnesium chloride supported Ziegler–Natta catalysts. It was found that the configuration of NDDE plays a key role in tuning the catalyst activity, stereospecificity, molecular weight (MW), and polydispersity index (PDI) of resulting poly(1‐butene). The type of catalyst with cis‐5‐norbornene‐endo‐2,3‐dicarboxylic acid diethyl ester as IED shows the highest catalyst activity, while catalyst with trans‐NDDE as IED yields the poly(1‐butene) with the highest MW and the most broad PDI. IR results showed that the NDDE with endo‐, exo‐, and trans‐configuration have different coordination way to MgCl₂, subsequently affecting the catalysts performance. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40758.     

Copolymerization of ethylene and propylene catalyzed by novel magnesium chloride supported,vanadium‐based catalysts

Two novel magnesium chloride supported, vanadium‐based Ziegler–Natta catalysts with 9,9‐bis(methoxymethyl)fluorene and di‐i‐butyl phthalate as internal donors were prepared and used in the copolymerization of ethylene and propylene. The catalytic behaviors of these catalysts were investigated and compared with those of traditional magnesium chloride supported, vanadium‐based catalysts without internal donors. Differential scanning calorimetry, gel permeation chromatography, and ¹³C‐NMR spectroscopy analysis were performed to characterize the melting temperatures, molecular weights, and molecular weight distributions as well as structures and compositions of the products. The copolymerization kinetic results indicated that the novel catalyst with 9,9‐bis(methoxymethyl)fluorene as an internal donor had the highest catalytic activity and optimal kinetic behavior in ethylene–propylene copolymerization with an ethylene/propylene molar ratio of 44/56. Low‐crystallinity and high‐molecular‐weight copolymers were obtained with these novel magnesium chloride supported, vanadium‐based catalysts. The reactivity ratio data indicated that the catalytic systems had a tendency to produce random ethylene–propylene copolymers. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

High temperature polymerization of propylene catalyzed by MgCl2‐supported Ziegler–Natta catalyst with various cocatalysts

Four cocatalysts, referred to as ethylaluminoxanes, were synthesized by the reaction between triethylaluminium (AIEt₃) and water under various molar ratios of H₂O/Al at ?78°C. Aluminoxanes were used as cocatalysts for a MgCl₂‐supported Ziegler–Natta catalyst for propylene polymerization at temperatures ranging from 70 to 100°C. When the polymerization was activated by AlEt₃, the activity as well as the molecular weight and isotacticity of the resulting polymer gradually dropped as the temperature varied from 70 to 100°C. When ethylaluminoxane was employed as the cocatalyst, good activity and high molecular weight and isotacticity were obtained at 100°C. Furthermore, when the cocatalyst varied from AlEt₃ to ethylaluminoxane, the atactic fraction and polymer fraction with moderate isotacticity decreased and the high isotactic fraction slightly increased, which indicated that the variation of the cocatalyst significantly affects the isospecificity of active sites. It was suggested that the reactivity of the Al‐Et group and the size of the cocatalyst were correlated to the performance of the Ziegler–Natta catalyst at different temperatures. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 1978–1982, 2006