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A full elucidation of chemisorbed donor behavior is of fundamental importance for tailoring the active species but has not yet been achieved for Ziegler–Natta catalysts. Herein, by exploiting the s...

The catalytic activity and stereospecificity of olefin polymerization by using heterogeneous TiCl4/MgCl2 Ziegler-Natta (Z-N) catalysts are determined by the structure and nature of active centers, which are mysterious and fairly controversial. In this work, the propylene polymerization kinetics under different polymerization temperatures by using Z-N catalysts were investigated through monitoring the concentration of active centers [C*] with different tacticity. SEM was applied to characterize the catalyst morphologies and growing polypropylene (PP) particles. The lamellar thickness and crystallizability of PP obtained under different polymerization conditions were analyzed by DSC and SAXS. The PP fractions and active centers with different tacticity were obtained with solvent extraction fractionation method. The catalytic activity, active centers with different tacticity and propagation rate constant kp, fragmentation of the catalyst, crystalline structure of PP are correlated with temperature and time for propylene polymerizations. The polymerization temperature and time show complex influences on the propylene polymerization. The higher polymerization temperature (60 °C) resulted higher activity, kp and lower [C*], and the isotactic active centers Ci* as the majority ones producing the highest isotactic polypropylene (iPP) components showed much higher kp when compared with the active centers with lower stereoselectivity. Appropriate polymerization time provided full fragmentation of the catalyst and minimum diffusion limitation. This work aims to elucidate the formation and evolution of active centers with different tacticity under different polymerization temperature and time and its relations with the fragmentation of the PP/catalyst particles, and provide the solutions to the improvement of catalyst activity and isotacticity of PP.

The scientific and technical advances in the field of polymer science has been abundant in recent years. Amongst the various polymeric materials available in market, synthesis of polyolefins has been in the forefront since decades. A major challenge in this domain remains in attaining stereoregular polyolefins especially polypropylene (PP) and significant efforts were carried out by synthesizing various internal donors (ID) aiding the catalysts involved in producing them. This short review gives an overview of i) various generations of Ziegler–Natta (ZN) catalyst systems ii) general classes of ID that has been demonstrated by the researchers over the past decades iii) their influence on PP isotacticity and polymer properties. The coordination modes of different donor classes on supported ZN system and comparative study especially between phthalate and diether ID classes were also addressed here. This review also presents the studies carried out on phthalate catalyst structure analysis, detailed comparison study on phthalate and diether IDs in terms of PP isotacticity, regioselectivity, hydrogen response, and also their cross combination study and competitive behavior. Further a brief description on other structurally varied IDs like malonates, maleates, silyl diol esters, bifunctional donors, multi ether donors demonstrated for isotactic PP were also presented. Studies conducted on compatibility of incorporation of two different classes of IDs on a single supported ZN system for the fundamental understanding of the catalyst behavior; and also on how mixed donor approach enables in tuning the catalyst for polymer properties were also presented. This review also provides an opportunity to the young minds and the basic researchers from academic point of view by and large to create new polymeric materials with useful properties or modify the existing materials for new applications by incorporating new IDs for further improvisation of the stereo regularity in obtaining the polymers. Graphic Abstract

MgCl2 supported Ziegler–Natta (Z–N) catalysts have emerged as the most exciting chemical process for polyolefin technology, which is responsible for the production of ∼150 million tons of polyolefin (polyethylene and polypropylene) per annum. However, fundamental chemistry of Z–N catalysts is not fully understood yet due to their multi-component nature as well as heterogeneous systems. Therefore, in this review, we have highlighted the chronological development of a heterogeneous Z–N catalyst and its polymerization (ethylene, propylene and 1-butene) process including termination steps. Then, we have discussed different structural and chemical aspects of the catalyst support, catalytically active sites, cocatalyst, internal/external electron donors and their different combinations. In the last two decades, density functional theory (DFT) has been employed in Z–N systems to strengthen the experimental work as well as to understand mechanistic aspects of Z–N systems. Future directions of Z–N catalysts have also been discussed.

The crystallization behavior of butene-ethylene random isotactic copolymers prepared with a Ziegler-Natta catalyst, in particular the surprising crystallization of form II of isotactic polybutene in samples with a high ethylene concentration, provides novel evidence of the long-debated blocky molecular structure of these "random" copolymers.

Chain entanglement was very important for adjusting the processability and mechanical property of nascent ultrahigh molecular weight polyethylene (UHMWPE). So far, it is still a mystery to unravel ...

Bromoalkyl-functionalized poly(olefin)s were synthesized by copolymerization of 4-(4-methylphenyl)-1-butene with 11-bromo-1-undecene using Ziegler–Natta polymerization. The resulting bromoalkyl-fun...

By combining the elementary reactions described in Chapter 6, transformations catalyzed by organometallic complexes can be constructed. This chapter introduces representative reaction systems catalyzed by organometallic complexes, and outlines the reactions occurring. Ziegler catalysts, prepared from tetrachlorotitanium (TiCl4) and alkylaluminium reagents (AlEt3 or AlEt2Cl), and Natta catalysts, prepared from crystalline TiCl3 and alkylaluminium, are very effective for olefin and propylene polymerization, respectively. This development was a paradigm shift, and Ziegler and Natta received the Nobel Prize in Chemistry in 1963 for their discoveries in the field of the chemistry and technology of high polymers. Transition metal complexes serve as catalysts and are used industrially, such as in olefin isomerization, olefin hydroformylation, the production of acetaldehyde by ethylene oxidation (the Wacker process) and the production of acetic acid from methanol and carbon monoxide (the Monsanto process). These catalytic systems successfully apply the elementary organometallic chemistry reactions described in this book and the basis of the catalytic action in these reactions is explained.

Developing donors for Ziegler‐Natta (ZN) catalysis to control the polymerization reaction and produce polymers with desirable properties has always been challenging due to the multi‐component nature of the catalytic systems. Here, we have developed a new synthetic protocol for making two external donors, D 1 (2,2,2‐trifluoroethyl myristate) and D 2 (2,2,2‐trifluoroethyl palmitate) that show self‐extinguishing properties, followed by a systematic DFT study to understand this peculiar property of these donors. D 1 and D 2 can undergo parallel reactions with aluminum and titanium species present in the system to produce ketones and aldehydes, which are poisons for ZN catalytic systems, thus explaining their self‐extinguishing nature. The non‐covalent interaction between the long alkyl chain of the donors with the surface plays a vital role in determining the donors' self‐extinguishing nature. There is a significant thermodynamic preference for the binding of the donor with the longer alkyl chain at the titanium center. The current work, therefore, provides interesting insights into how self‐extinguishing donors function in ZN catalytic systems.

The innovation of Ziegler-Natta (Z-N) catalysts opened a novel aspect of chemistry in terms of polyolefin formation. Significant progress of more than fifty years in catalytic olefin polymerization simplified polyolefin production by optimizing the reaction conditions and internal donors. In this review, we particularly emphasized on recent development on different internal donor based Z-N catalyst systems, the role of external electron donors and co-catalyst chemistry. Furthermore, the Ziegler-Natta catalyst system, polymerization reaction, and polymer process technologies gradually upgrading to produce different polyolefin products. In particular, polyolefin fibers, composites, foam, blends and polyolefin-based 3D-printing products targeted in this review for substantial benefits of both society and highly diversified industries.

We report on the synthesis of three perylene-tagged electron donors representing three major types – phthalates, diethers, and alkoxysilanes – which are of importance for the subsequent studies of MgCl2-supported Ziegler–Natta catalysts by means of laser scanning confocal fluorescence microscopy. The obtained products were unambiguously characterized, including by X-ray crystal structure analysis; their photophysical properties (absorption and emission spectra) were investigated as well. Additionally, a reliable and convenient protocol for the multigram synthesis of the required starting material – 3-bromo­perylene (PerBr) – was developed. The key step of this method was synthesis of trialkylsilyl-substituted perylenes, which were further separated by means of flash chromatography followed by conversion of the isolated 3-trialkylsilyl-substituted product to PerBr.

It was well known that the defects in the polymer chains could significantly influence the crystallization process of semi-crystalline polymers. In this work, the role of defect distribution in the melt memory effects was studied by comparatively investigating a pair of Ziegler-Natta and metallocene-made isotactic polypropylene (ZN-iPP and M-iPP) fraction specimens with the same total defect content which were obtained from two raw parent samples through the solvent extraction. The characterization results of melting behaviors, polymorphic structures, and the successive self-nucleation and annealing analysis demonstrated that these two fractions exhibited the different distribution of defects, i.e., the defect distribution in the M-iPP specimen was random while that in the ZN-iPP specimen was nonstatistical. The results of self-nucleation (SN) experiments indicated that the M-iPP exhibited much wider temperature range of Domain II than the ZN-iPP with similar total defect content, which indicated that the M-iPP showed a much stronger melt memory effect. Considering the effect of the microstructure on the crystallization behavior and the sequences containing defects could be excluded from the crystalline regions during the formation of crystal, we speculated that the random distributed defects in M-iPP could form a continuous interface between the crystalline regions and amorphous phase which could cause a heterogeneous melt and strengthen the melt memory effect.

A series of (SiO2/MgO/ID/MgCl2)·TiCl x Ziegler-Natta catalysts for propylene polymerization has been prepared with a new method. These catalysts were synthesized using soluble Mg-compounds as the Mg-source and the preparation progress was relatively simple. The catalyst could copy the spherical shape of the carrier very well. The propylene polymerization results showed that the catalyst revealed the best activity with 9,9-di(methoxymethyl)fluorene (BMMF) as internal donor at 50 °C with the optimal molar ratio Al/Ti = 5, which was much lower than what the industrial polypropylene catalyst used (at least molar ratio Al/Ti = 100), resulting in great cost saving. Additionally, the polymerization kinetics of the catalyst exhibited very stable property after achieving a relatively high value. These catalysts possessed rather high activity and good hydrogen response. The isotactic index (II.) value of the PP products could be higher than 98% in the presence of both internal and external electron donors. Moreover, temperature rising elution fractionation method was used to understand the influence of donors and H2 on the properties of the PP products.

Medium- and high-resolution SEM analysis of several Ti-based MgCl2-supported Ziegler–Natta catalysts and isotactic polypropylene produced with them is carried out. Each catalyst particle, 35–55 μ in size, produces one polymer particle with an average size of 1.5–2 mm, which replicates the shape of the catalyst particle. Polymer particles contain two distinct morphological features. The larger of them are globules with Dav ∼400 nm; from 1 to 2 × 1011 globules per particle. Each globule represents the combined polymer output of a single active center. The globules consist of ∼2500 microglobules with an average size of ∼20 nm. The microglobules contain several folded polymer molecules; they are the smallest thermodynamically stable macromolecular ensembles in propylene polymerization reactions. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017, 55, 3832–3841

Titanium-magnesium Ziegler-Natta catalysts are the basis of the modern processes for polypropylene production. These catalysts have been the object of numerous studies for many decades. Nevertheless, the structure of the catalysts remains a significant research focus. One of the major questions to be answered is the nature of the active sites precursor − the titanium compound, its form and structure on the surface of the catalysts. In the present study, the experimental data show that the precursor of the catalyst active site is TiCl 4 , which is weakly bound to the surface of the catalyst. This TiCl 4 is able to migrate outside the catalyst particles and to adsorb on activated MgCl 2 , giving rise to new precursors of the active sites. The quantity of TiCl 4 , which is able to migrate easily, amounts to about half the total amount of titanium compounds in the catalysts. At the same time, the rest of titanium is tightly bound to the catalyst surface and does not produce the active sites.

This paper describes our recent results in the field of zirconocene-catalyzed α-oltfin transformations, and focuses on questions regarding the reaction mechanism, rational design of zirconocene pre-catalysts, as well as prospective uses of α-olefin products. It has been determined that a wide range of α-olefin-based products, namely vinylidene dimers, oligomers and polymers, can be prepared via catalysis by zirconocene dichlorides, activated by a minimal (10–20 eq.) amount of MAO. We assumed that in the presence of minimal quantities of MAO, various types of zirconocene catalysts form different types of catalytic particles. In the case of bis-cyclopentadienyl complexes, the reactive center is formed under the influence of R2AlCl, which makes the chain termination via β-hydride elimination significantly easier, with α-olefin dimers being formed as the primary product. Bis-indenyl complexes and their heteroanalogues, form stable cationic catalytic particles and effectively catalyze the polymerization. Mono-indenyl and mono-substituted bis-cyclopentadienyl-ansa complexes catalyze α-olefin oligomerization. Effective catalysts of dimerization, oligomerization and polymerization of α-olefins in the presence of minimal MAO quantities are proposed. Prospects of using α-olefin dimers, oligomers and polymers in the synthesis of branched hydrocarbon functional derivatives (dimers), high quality, low viscosity motor oils (oligomers), and thickeners and absorbents (polymers) are examined.

Isotactic polypropylene (i-PP) is mainly produced with heterogeneous Ziegler-Natta (ZN) catalyst systems. Direct structural information on the active species is very difficult to achieve; as a matter of fact, the 13C NMR microstructure of the polymer has long been used as an indirect "fingerprint". For a long time, however, the intrinsically poor sensitivity of natural abundance 13C NMR spectroscopy hampered a complete evaluation of the microstructure, and many rare albeit important details escaped detection with standard tools and methods. The most prominent case is that of the regiodefects, which are specially important because they dictate ZN catalyst response to molecular hydrogen used as a chain transfer agent. In recent papers we have reported on the quantification of regioirregular 2,1 units in ZN i-PP by means of high-temperature cryoprobe 13C NMR. Here we shift the focus onto the stereochemical environment of such units, which was highlighted by comparing the spectra of suitable ZN PP fractions with those of model PP samples made with molecular catalysts of different structures and symmetries. The results lend support to our three-site model of ZN catalytic species, originally based on the stereochemistry of regioregular PP chains/blocks.

International audience; Ziegler-Natta precatalysts were synthetized from Lewis-base-modified-MgCl2 supports and treated by various Lewis acids, prior to activation by triethylaluminum, in order to increase their activity in ethylene polymerization. BCl3 provided the highest increase in activity. Interestingly, polymerization results showed no substantial modification of polymer properties, which is consistent with the Lewis acid only promoting the creation of new active sites, after activation by TEA, possessing very similar features than the original ones achievable with conventional precatalysts (i.e. without Lewis-acid treatment).

Chemical routes for preparing Ziegler-Natta (ZN) catalysts accompany the formation of by-products that remain in final catalysts in different amounts. In the history of ZN catalysts, much less emphasis has been given to analyze such by-products present in catalysts. Herein, we prepared various Mg(OEt)2-based ZN catalysts and conducted solution-state NMR measurements to characterize and quantify the organic components of these catalysts. It was found that, depending on the molecular structure of the internal donor (ID) and catalyst preparation conditions, an ID can undergo side reactions to produce organic by-products. All the catalysts contained different amounts of titanium alkoxy by-products formed in the reaction between Mg(OEt)2 and TiCl4, which were detrimental for the catalyst activity. These by-products were responsible for increasing the amount of the amorphous fraction in polypropylene and decreasing the highly crystalline fraction's stereoregularity. Possible hypotheses to explain the negative impacts of titanium alkoxy by-products are discussed.

Full quantum chemical calculations, using density functional theory (DFT), have been conducted to explain the effect of donors on the “activation mechanism” in the Ziegler–Natta (Z–N) catalyst system. In the activation mechanism, the inactive TiIVCl4 catalyst converts into the active TiIIICl2Et catalyst with the help of the AlEt3 present in the system. The donors that have been considered in this study are: ethyl benzoate (eb), two representative diether cases, a phthalate donor, and a silyl ester donor. The results indicate that eb and the diether donor cases donor have a negative effect on the barriers for the activation mechanism. However, the eb donor can be displaced from the MgCl2 surface by AlEt3, which matches experimental observations. For the phthalate, silyl ester and TiCl3–OC4H8Cl cases, the results indicate that a significant induction period would be present in Z–N systems employing such donors or having such a catalytic center, before catalysis could commence.

The penta-ether compound was synthesized by the reaction of di(trimethylolpropane) with sodium hydride as the strong base and methyl iodide as the alkyl halide. This compound was characterized by NMR, FTIR, and GC techniques. The MgCl2-supported titanium catalysts were incorporated with varying amounts of penta-ether compound as the internal donor and also the catalysts without the internal donor were synthesized. The synthesized catalysts and the conventional Ziegler- Natta catalyst were characterized. The titanium contents were determined by spectrophotometry, magnesium by complexometric titration and chloride by argentometric titration. The effects of the new internal donor on propylene polymerization with the prepared MgCl2-supported Ziegler-Natta catalysts were investigated and then these results were compared to the results obtained using the conventional diisobutyl phthalate-besed-Ziegler-Natta catalyst. The highest crystallinity degree, melting temperature, and isotacticity of polypropylene were obtained using the catalyst with a penta-ether/Mg molar ratio equal to 0.21.

The electron paramagnetic resonance (EPR) method was used to investigate the formation of alkylated Ti(III) species in superactive titanium–magnesium catalysts with a low titanium content during their interaction with an organoaluminum activator (AlMe3), as well as the interaction of alkylated Ti(III) surface species with carbon monoxide. EPR data on the content of alkylated Ti(III) species in these catalysts agree well with the number of Ti–R bonds that are determined after the interaction of radioactive carbon monoxide (14CO) with catalyst activated by triethylaluminum in the absence of monomer. Parameters of EPR spectra of the Ti(III) species having different structure and composition on the surface of titanium–magnesium catalysts were calculated by quantum-chemical simulations. The calculated g-values are consistent with the g-values observed in EPR spectra of the catalysts. Analysis of the literature data and results of our study made it possible to propose the parameters of EPR spectra characterizin...

Since 1963, when Karl Ziegler and Giulio Natta were jointly awarded the Nobel Prize for their discoveries of the catalytic polymerization of olefins with Ti-chlorides and Al-alkyls, heterogeneous Ziegler-Natta (ZN) catalysts have become the main catalysts for the industrial production of polyolefins. Despite of the relevance of ZN catalysts for the large-scale production of polyolefins, a clear mechanistic understanding of these catalysts is still incomplete due to the elusive nature of the active site structures. Over the last two decades, researchers have used density functional theory (DFT) methods to clarify the polymerization mechanisms and to identify the nature of the active sites, unraveling the influence of supports, cocatalysts, and the effect of internal and external donors on the polymerization processes. Major efforts were dedicated to understanding the origin of stereoselectivity in α-olefin polymerization as well as the termination reactions mechanisms, and the role that impurities can play in heterogeneous ZN catalysis. Here, we review the DFT studies on heterogeneous ZN catalysts and suggest promising areas for future research.

Summary Diolefins can be used as comonomers in propylene copolymerizations in order to modify some of the final properties of the obtained poly(propylene) (PP) resins. Although reduction of catalyst activity can be expected when such copolymerizations are performed with standard heterogeneous Ziegler- Natta catalysts, copolymers containing 1,5-hexadiene (HD) and 1,7-octadiene (OD) can be produced at high rates when the comonomer content is sufficiently low (below 2 mol%); however, the presence of very small amounts of 5-ethylidene-2-norbornene (ENB) leads to complete catalyst inhibition. It is shown that incorporation of dienes lead to decrease of the melting point of the final product, especially in presence of ENB. When compared to HD, addition of OD causes more pronounced modification of the melt flow index and weight-average molecular weight, although the xylene solubles is less sensitive to the comonomer feed when the comonomer composition is low. Obtained results indicate that small amounts of dienes can be used at plant site to modify the final properties of PP resins produced with standard heterogeneous Ziegler-Natta polymerizations.

The discovery of Ziegler − Natta catalysts has been one of the greatest developments in technology for the synthesis of stereoregular polymers in both academy and industry since the 1950s. In particular, the development of the fourth generation Ziegler − Natta catalyst with MgCl2 as support brings a revolutionary improvement to the properties of manufactured polyolefins and stimulates people to explore the stereospecific polymerization of α-olefin and diene monomers, which supplies the power to synthesize a new type of polyolefin materials. Although research on single-site catalysts has attracted a lot of attention in recent years, the ‘old’ and conventional Ziegler − Natta catalysts are still being developed vigorously due to their unique industrial advantages such as low cost, high catalytic efficiency and high stereospecificity. In this mini-review, we mainly summarize the development of the conventional supported Ziegler − Natta catalyst system and the stereoregular polyolefins synthesized with supported Ziegler − Natta catalysts. © 2013 Society of Chemical Industry

Summary Comprehensive polymer architectural studies were carried out on a group of Ziegler-Natta (Z-N) polyethylene homopolymers via size-exclusion chromatography coupled with multi-angle light scattering (SEC-MALS) and rheology. Although Z-N resins are traditionally viewed as linear polymers, both SEC-MALS and rheology results strongly indicate that there are topological variations, presumably long-chain branching (LCB) or possibly hyper-branches, in this group of supposedly linear Z-N homopolymers. These Z-N homopolymers exhibit very complex elution behavior that resulted in anomalous elution profiles in SEC. It appeared that some high molecular weight (MW) and long-chain branched components followed a non-size exclusion separation mechanism on SEC columns, co-eluting with low MW and linear polyethylene components, causing a delayed elution. The possible origin of LCB in these Z-N polymers is also discussed.

Copolymerization of propylene and ethylene and terpolymerization of propylene, ethylene, and 1-butene were carried out to compare the characteristics of diether- and phthalate-based Ziegler-Natta catalysts in a reaction system of pilot scale. The ethylene incorporation with the diether-based catalyst was higher but the 1-butene incorporation was lower compared with those of the phthalate-based catalyst. In the case of copolymers from the diether-based catalyst, melting behavior, determined through differential scanning calorimetry (DSC), showed a distinct shoulder peak and lots of nuclei were formed during crystallization. The diether-based catalyst led to polymers having blockier ethylene sequences compared with those of the phthalate-based catalyst; the highly crystallizable fraction (HIS) containing blockier ethylene sequences was produced with the diether-based catalyst. These results seem to be the result of regio-irregular characteristics of the diether-based catalyst. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 851-859, 2013

The success of polyolefins is governed to a large extent by the development of robust and versatile catalysts offering excellent morphology control. This review highlights the major evolution steps made in the polyolefin catalyst systems in terms of productivity and possibilities to control the molecular architecture of both polypropylene and polyethylene. Starting from the initial TiCl3-types, the continuous improvement of the Ziegler-Natta catalysts in terms of performance and cost is the major factor behind their wide market penetration. On the other hand, metallocene and the other “single-site” catalysts enable an unprecedented fine-tuning of chain microstructure by ligand design. In this article, special emphasis is placed on the influence of catalyst type on polymer structure characteristics such as molecular weight distribution, stereoregularity, and comonomer distribution and, ultimately, on the end-use properties of polyolefins. It is the excellent balance among price, performance, and processability that will further strengthen the position of polyolefins as a dominant class of materials in the polymer industry.

Industrial Ziegler–Natta catalysts for polypropylene production are complex formulations with a reputation for being “black boxes”. In this paper, we report the results of an extensive investigation of the three latest commercial generations, performed with advanced high-throughput experimentation tools and methods. The thus obtained database of structure–property relationships, of extraordinary width and depth, provided a high-definition picture of the screened systems, allowing us to highlight important details of their inner workings. In particular, the delicate relationship between surface coverage and lateral steric pressure on the stereoselectivity of the catalytic species, as well as the role of chemisorbed donor and Al-alkyl species on said parameters for different formulations, was revealed.

The authors thank the PSMN, CINES, and IDRIS for the computational resources.; International audience; The Ziegler-Natta polymerization is one major example of application of catalysis in industry. Since the first discovery of Ziegler and Natta, several modifications of the catalyst have been developed, in order to improve its performance. Nowadays, a typical Ziegler-Natta catalyst for polyethylene synthesis consists of a precatalyst, composed of TiCl4 supported on MgCl2 in the presence of a Lewis base, activated by organoaluminum. The atomic-scale characterization of the Ziegler-Natta catalyst is crucial for further improvement of the catalyst. Here, the precatalyst TiCl4-MgCl2 with EtOH as internal. Lewis base is characterized combining solid-state NMR spectroscopy and periodic density functional theory calculations. From total energy and NMR spectra, eight surface species were proposed showing EtO- ligands on the Ti and EtOH/EtO- on the surface Mg species, These species lead to a complete interpretation of the NMR two-dimensional spectra. Hence a detailed molecular scale description of the precatalyst was obtained.

The melt fracture of high-density polyethylenes (HDPEs) is studied primarily as a function of molecular weight and its distribution for broad molecular weight distribution metallocene and Ziegler–Natta catalyst resins. It is found that sharkskin and other melt fracture phenomena are very different for these two classes of polymers, although their rheological behaviors are nearly the same for many of these. Moreover, the metallocene HDPE shows significant slip at the die wall without exhibiting stick-slip transition. Important correlations are derived between the critical conditions for the onset of melt fracture and molecular characteristics.

Ziegler Natta (ZN) catalysts are used to produce a wide range of polyolefins on an industrial scale. It has long been known that polymer produced on these catalysts have a relatively wide distribution in chain lengths; values for the Poly-Dispersity Index (PDI) are generally well above 2, the value that would be expected if a single catalyst site type were active. These catalysts are conceptualised as containing a number of different active sites, which produce polymer with different average molecular weights. No physical explanation for the existence of different site types has been offered. In fact it has been shown that there is a close link between activity and oxidation state, and that only a single type of polymerising site is present. In this work, we propose that sites differ not in propagation rate but in the rate at which chain growth is terminated by a range of terminating agents, including hydrogen, monomer and co-monomer. Each terminating agent is considered to act at a particular “pseudo-site”. The ability of this interpretation to simulate a wide range of polymer properties is demonstrated. The pseudo-sites model is then used to investigate experimentally-determined chain length distribution data for ethylene-1-butene copolymer produced in lab reactors. It is shown that this new view of the heterogeneity of ZN active sites can successfully reproduce key polymer properties, including PDI and mean chain lengths. Based on these results, it is proposed that the pseudo-sites model can be used to consolidate experimental data into a single set of parameters to describe the behaviour of a Ziegler-Natta catalyst for polyolefin production.

The influence of the structure of external alkoxysilane donors on stereoslectivity and molecular weight distributions in MgCl2-supported Ziegler–Natta catalysis has been examined. We shall demonstr...

Silica-supported titanium(IV) chloride is readily reduced by Mashima and co-workers' reagent (1-methyl-3,6-bis(trimethylsilyl)-1,4-cyclohexadiene) to afford materials active in ethylene polymerisation without need of aluminum alkyl cocatalyst.

This communication reports a strategy for scale-up of an in situ polymerization technique for polyolefin-based nanocomposites preparation, taking layered silicate (clay) and multi-walled carbon nanotubes (MWCNTs) as examples of nanofillers. The strategy is realized by transforming the nanofillers into granular "nanosupports" for Ziegler-Natta catalysts. With a catalyst to polymer replication effect on particle morphology, the in situ prepared nanocomposites are of controlled granular particle morphology. With the polymer particle morphology controlled, the in situ polymerization technique becomes suitable for industrial olefin polymerization processes for mass production of polyolefin nanocomposites.

Polypropylene homopolymer samples were prepared with a Ziegler–Natta catalyst using two different external donors, namely diphenyldimethoxysilane (DPDMS), and methylphenyldimethoxysilane (MPDMS). Each donor was used in varying molar ratios to the catalyst in order to prepare samples for physical testing. The polymers were fully characterised and also fractionated by preparative TREF with characterisation of the fractions. In terms of the polymerisation reactions the DPDMS external donor exerts greater influence at the active sites than the MPDMS and produces polymer of higher molar mass and lower polydispersity. The physical properties of the polymers were investigated using microhardness measurements. It is revealed that the microhardness is strongly dependent on the stereoregularity of the samples.

Deconvolution of the MWD of a polymer produced by multi-site catalysts into independent Flory modes is the first step in modeling the polymerization process. A new deconvolution procedure for GPC data is developed that does not require an a priori assumption concerning the nature of the discrete distribution and can be used with a continuous distribution. The MWD measured via GPC is a linear function of the individual catalytic sites, but it is numerically ill-conditioned, preventing direct inversion of the GPC data. Tikhonov regularization has been developed to uniquely invert the MWD. Applying the regularizing method to a polyethylene produced via a Ziegler-Natta catalyst, seven discrete sites were found, and the kinetic constant ratios were determined for each of these sites.

Two types of industrial heterogeneous Ziegler-Natta propylene polymerization catalysts, TiCl3 type and MgCl2 supported TiCl4 type, were examined by paired interacting orbitals (PIO) analysis proposed by Fujimoto et al.. The ligand located trans to propylene was found to obstruct the insertion but was essential for the stereospecific insertion of propylene. The ligand located trans to the alkyl group of the active site was found to be necessary for activating the alkyl-Ti bond. The regioselectivity and stereoselectivity of the iso-specific polymerization site on the heterogeneous Ziegler-Natta catalyst system were confirmed. The polymerization activity of MgCl2 supported TiCl4 catalyst was larger than that of the TiCl3 catalyst.

The deactivation behaviors of TiCl3/MgCl2 model catalysts with molecularly dispersed TiCl3 were investigated to clarify the role of the dispersion state of the Ti species in the deactivation of MgCl2-supported Ziegler-Natta (ZN) catalysts for propylene and ethylene polymerization. The propylene and ethylene polymerization activities of clustered Ti species supported on MgCl2 were approximately one tenth of those of isolated Ti species, which is indicative of the significance of the aggregation of Ti species in the deactivation of ZN catalysts for olefin polymerization. Moreover, the time-course depression of monomer consumption for the clustered Ti species was slower than that for the isolated Ti species in propylene polymerization, whereas the dispersion state barely affected the depression rate in ethylene polymerization. The reduction rate of the Ti species was concluded to be important for the time-course depression of propylene consumption, whereas ethylene polymerization was insensitive to the oxidation state of the Ti species.