Polyethylene with Reverse Co-monomer Incorporation: From an Industrial Serendipitous Discovery to Fundamental Understanding.

A triethylaluminium(TEAl)-modified Phillips ethylene polymerisation Cr/Ti/SiO2 catalyst has been developed with two distinct active regions positioned respectively in the inner core and outer shell of the catalyst particle. DRIFTS, EPR, UV-Vis-NIR DRS, STXM, SEM-EDX and GPC-IR studies revealed that the catalyst produces simultaneously two different polymers, i.e., low molecular weight linear-chain polyethylene in the Ti-abundant catalyst particle shell and high molecular weight short-chain branched polyethylene in the Ti-scarce catalyst particle core. Co-monomers for the short-chain branched polymer were generated in situ within the TEAl-impregnated confined space of the Ti-scarce catalyst particle core in close proximity to the active sites that produced the high molecular weight polymer. These results demonstrate that the catalyst particle architecture directly affects polymer composition, offering the perspective of making high-performance polyethylene from a single reactor system using this modified Phillips catalyst.

Aluminum-phosphate binder formation in zeolites as probed with X-ray absorption microscopy.

In this work, three industrially relevant zeolites with framework topologies of MOR, FAU and FER have been explored on their ability to form an AlPO4 phase by reaction of a phosphate precursor with expelled framework aluminum. A detailed study was performed on zeolite H-mordenite, using in situ STXM and soft X-ray absorption tomography, complemented with (27)Al and (31)P magic angle spinning nuclear magnetic resonance (MAS NMR) spectroscopy, XRD, FT-IR spectroscopy, and N2 physisorption. Extraframework aluminum was extracted from steam-dealuminated H-mordenite and shown to dominantly consist of amorphous AlO(OH). It was found that phosphoric acid readily reacts with the AlO(OH) phase in dealuminated H-mordenite and forms an extraframework amorphous AlPO4 phase. It was found that while AlPO4 crystallizes outside of the zeolitic channel system forming AlPO4 islands, AlPO4 that remains inside tends to stay more amorphous. In the case of ultrastable zeolite Y the FAU framework collapsed during phosphatation, due to extraction of framework aluminum from the lattice. However, using milder phosphatation conditions an extraframework AlPO4 α-cristobalite/tridymite phase could also be produced within the FAU framework. Finally, in steamed zeolite ferrierite with FER topology the extraframework aluminum species were trapped and therefore not accessible for phosphoric acid; hence, no AlPO4 phase could be formed within the structure. Therefore, the parameters to be taken into account in AlPO4 synthesis are the framework Si/Al ratio, stability of framework aluminum, pore dimensionality and accessibility of extraframework aluminum species.

Real-time Analysis of a Working Triethylaluminium-Modified Cr/Ti/SiO2 Ethylene Polymerization Catalyst with In†Situ Infrared Spectroscopy.

A diffuse reflectance infrared Fourier-transform (DRIFT) study has been conducted at 373 K and 1 bar on an industrial Cr/Ti/SiO2 Phillips-type catalyst modified with, and without, triethylaluminium (TEAl) as co-catalyst. The reaction rate of the polymerization of ethylene, as monitored by the increase in the methylene stretching band of the growing polyethylene (PE), has been investigated as a function of the titanium content. After an initial period of mixed kinetics, with the reaction rate significantly higher for the TEAl-modified catalysts compared with the non-modified catalysts, the polymerization proceeded as a pseudo-zero-order reaction with a reaction rate that increased as a function of titanium loading. Furthermore, it was found that the higher Ti loading caused the appearance of more acidic hydroxyl groups and modified the Cr sites by making them more Lewis acidic, ultimately shortening the induction time and increasing the initial polymerization rate.