Summary: Silica‐supported single‐site catalysts show limitations with respect to catalyst homogeneity and maximum metal content. A novel emulsion‐based catalyst heterogenization concept is described, which allows these limitations to be overcome. The method produces catalyst particles with an inherently perfect spherical shape and unique intra‐ and inter‐particle homogeneity. The catalyst particles are very compact and have a low surface area. Video microscopic studies confirm that the improved catalyst homogeneity leads to a more uniform polymerization behavior on a single particle level. The catalysts contain significantly more complex, compared to silica‐supported catalyst systems, which leads to correspondingly higher catalyst activities. No differences, in terms of the mass‐transfer kinetics of these low‐porosity catalysts, compared to porous catalyst systems have been observed.
Electron microscopy image of self‐supported single‐site catalyst prepared by the emulsion‐based method.
