TiCl4/MgCl2/MCM-41 Bi-Supported Ziegler–Natta Catalyst: Effects of Catalyst Composition on Ethylene/1-Hexene Copolymerization

TiCl4/MgCl2/MCM-41 type bi-supported Ziegler-Natta catalysts with different MgCl2/MCM-41 ratios were synthesized by adsorbing TiCl4 onto MgCl2 crystallites anchored in mesopores of MCM-41 (mesoporous silica with 3.4 nm pore size). Ethylene/1-hexene copolymerization with the catalysts was conducted at different 1-hexene concentrations and ethylene pressures. MgCl2/MCM-41 composite supports and the catalysts were characterized by X-ray diffraction (XRD), nitrogen adsorption analysis (BET), and elemental analysis. The copolymers were fractionated by extraction with boiling n-heptane, and comonomer contents of the fractions were determined. Under 4 bar ethylene pressure, the bi-supported catalysts showed higher activity and a stronger comonomer activation effect than the TiCl4/MgCl2 catalyst. In comparison with the TiCl4/MgCl2 catalyst, the bi-supported catalysts produced much less copolymer fraction of low molecular weight and high 1-hexene content, meaning that the active center distribution of the catalyst was significantly changed by introducing MCM-41 in the support. The copolymer produced by the bi-supported catalysts showed similar melting temperature to that produced by TiCl4/MgCl2 under the same polymerization conditions. The space confinement effect of the mesopores of MCM-41 on the size and structure of MgCl2 crystallites is proposed as the main reason for the special active center distribution of the bi-supported catalysts.

Bottom-Up Synthesis of Multi-Grained Ziegler–Natta Catalyst Based on MgO/MgCl2/TiCl4 Core–Shell Catalyst

Morphology control plays a major role in the design of solid catalysts. Since the heterogeneous Ziegler–Natta catalyst (ZNC) is based on the in situ synthesis of MgCl2 support in a top-down manner, the individual control of the exterior and the interior structure of the catalyst macro-particles is challenging. In this study, we successfully prepared a ZNC with a multi-grain interior structure by the spray-drying of MgO nanoparticles, inspired by the fact that the MgO/MgCl2/TiCl4 core–shell catalyst can maintain the morphology of the raw MgO nanoparticles. This catalyst is the first example of the bottom-up preparation of MgCl2-supported ZNC. Here, we report its basic preparation method, characterization results, and performance in the homo-polymerization of ethylene and propylene, and copolymerization with 1-hexene.