Abstract
A three-metallic high-performance heterogeneous Ziegler–Natta-type catalyst for polymerization of ethylene was synthesized using titanium tetrachloride as the active center, magnesium ethoxide as the support, and ethylaluminum sesquichloride (EASC) as a chlorinating agent. The prepared catalyst was characterized by FTIR, XRD, TGA, and BET methods. FTIR and XRD patterns evidenced that Mg(OEt)2 was fully converted to MgCl2 during catalyst synthesis. The specific surface area (SSA) of the synthesized catalyst was calculated to be 44.83 m2/g. Morphological studies by the SEM technique demonstrated that the obtained catalyst had the particles with a disordered pattern. Elemental analysis of the catalyst, performed by X-ray fluorescence (XRF), titration, and UV–Vis spectroscopy techniques, confirmed a large amount of titanium on the support’s bed. Polymerization of ethylene was conducted by employing synthesized catalyst using triethylaluminum as cocatalyst. In the polymerization reaction, the synthesized tri-metallic catalyst exhibited high activity of 9.50 kg PE.g Cat−1. h−1. In the last part, to explore the possible interaction of EASC with catalytic reagents, density functional theory (DFT) simulation was conducted.
Graphic abstract
Similar content being viewed by others
References
Marques M, Almeida L, Cruz K (2010) Influence of the preparation technique of MgCl2/TiCl4 Ziegler-Natta catalyst on the performance in ethylene and propylene polymerization. ChChT 4(4):291–296
Pokasermsong P, Praserthdam PJEJ (2009) Comparison of activity of Ziegler-Natta catalysts prepared by recrystallization and chemical reaction methods towards polymerization of ethylene. Eng J 13(1):57–64
Galiè F (2016) Global market trends and investments in polyethylene and polypropylene. https://www.icis.com/explore/resources/global-market-trends-and-investments-in-polyethylene-and-polypropylene/
Zhou W, Zhong L, Li WD (2014) Progress in development of catalyst systems for coordinated polymerization of olefins. Adv Mater Res 900:11–14
Bahri-Laleh N, Hanifpour A, Mirmohammadi SA, Poater A, Nekoomanesh-Haghighi M, Talarico G et al (2018) Computational modeling of heterogeneous Ziegler-Natta catalysts for olefins polymerization. Prog Polym Sci 84:89–114
Zhao Z, Mikenas T, Zakharov VA, Nikolaeva M, Matsko M, Bessudnova E et al (2019) Copolymerization of ethylene with α-olefins over highly active supported Ziegler-Natta catalyst with vanadium active component. Polyolefins J 6(2):117–126
Wang D, Zhao Z, Mikenas T, Lang X, Echevskaya L, Zhao C et al (2012) A new high-performance Ziegler-Natta catalyst with vanadium active component supported on highly-dispersed MgCl 2 for producing polyethylene with broad/bimodal molecular weight distribution. Polym Chem 3(9):2377–2382
Zakharov V, Echevskaya L, Mikenas T, Matsko M, Tregubov A, Vanina M et al (2008) Supported Ziegler-Natta catalysts for ethylene slurry polymerization and control of molecular weight distribution of polyethylene. Chin J Polym Sci 26(05):553–559
Thongdonjui A, Trakarnpruk W, Strauss RH (2009) Effect of electron donor on PE polymerization. J Metals Mater Miner 19(1)
Rahbar A, Nekoomanesh-Haghighi M, Bahri-Lalēh N, Abedini H (2015) Effect of water on the supported Ziegler–Natta catalysts: optimization of the operating conditions by response surface methodology. Catal Lett 145(5):1186–1195
Hadian N, Hakim S, Nekoomanesh-Haghighi M, Bahri-Laleh N (2014) Storage time effect on dynamic structure of MgCl2.nEtOH adducts in heterogeneous Ziegler-Natta catalysts. Polyolefins J 1(1):33–41
Pokasermsong P, Praserthdam P (2009) Comparison of activity of Ziegler-Natta catalysts prepared by recrystallization and chemical reaction methods towards polymerization of ethylene. Eng J 13(1):57–64
Ahmadjo S, Jamjah R, Zohuri GH, Damavandi S, Nekoomanesh Haghighi M, Javaheri M (2007) Preparation of highly active heterogeneous Ziegler-Natta catalyst for polymerization of ethylene. Iran Polym J 16(1):31
Hiraoka Y, Dashti A, Kim SY, Taniike T, Terano M (2009) Spatial distribution of active Ti species on morphology controlled Mg (OEt) 2-based Ziegler-Natta catalyst. Curr Trends Polym Sci 13
Funako T, Chammingkwan P, Taniike T, Terano M (2015) Alternation of pore architecture of Ziegler-Natta catalysts through modification of magnesium ethoxide. Macromol React Eng 9(4):325–332
Tanase S, Katayama K, Inasawa S, Okada F, Yamaguchi Y, Konakazawa T et al (2008) Particle growth of magnesium alkoxide as a carrier material for polypropylene polymerization catalyst. Appl Catal A 350(2):197–206
Tanase S, Katayama K, Inasawa S, Okada F, Yamaguchi Y, Sadashima T et al (2008) New synthesis method using magnesium alkoxides as carrier materials for Ziegler-Natta catalysts with spherical morphology. Macromol React Eng 2(3):233–239
Taniike T, Funako T, Terano M (2014) Multilateral characterization for industrial Ziegler-Natta catalysts toward elucidation of structure–performance relationship. J Catal 311:33–40
Funako T, Chammingkwan P, Taniike T, Terano M (2015) Addition of a second alcohol in magnesium ethoxide synthesis as a way to vary the pore architecture of Ziegler-Natta catalysts. Polyolefins J 2(2):65–71
Dashti A, Ramazani S, Hiraoka Y, Kim SY, Taniike T, Terano M (2009) Kinetic and morphological investigation on the magnesium ethoxide-based ziegler-natta catalyst for propylene polymerization using typical external donors. Macromol Symp. https://doi.org/10.1002/masy.200951107
Xiaoheng Z, Zifang G, Wei C, Bingquan M (2011) Ethylene polymerization using improved polyethylene catalyst. Chin J Chem Eng 19(1):52–56
Wolf CR, de Camargo Forte MM, dos Santos JHZ (2005) Characterization of the nature of chemical species of heterogeneous Ziegler-Natta catalysts for the production of HDPE. Catal Today 107:451–457
Yang H, Zhang L, Zang D, Fu Z, Fan Z (2015) Effects of alkylaluminum as cocatalyst on the active center distribution of 1-hexene polymerization with MgCl 2-supported Ziegler-Natta catalysts. Catal Commun 62:104–106
Hu J, Han B, Shen X-r, Fu Z-s, Fan Z-q (2013) Probing the roles of diethylaluminum chloride in propylene polymerization with MgCl2-supported Ziegler-Natta catalysts. Chin J Polym Sci 31(4):583–90
Nitta T, Liu B, Nakatani H, Terano M (2002) Formation, deactivation and transformation of stereospecific active sites on TiCl 4/dibutylphthalate/Mg (OEt) 2 catalyst induced by short time reaction with Al-alkyl cocatalyst. J Mol Catal A Chem 180(1):25–34
Dwivedi S, Taniike T, Terano M (2014) Understanding the chemical and physical transformations of a Ziegler-Natta Catalyst at the initial stage of polymerization kinetics: the key role of alkylaluminum in the catalyst activation process. Macromol Chem Phys 215(18):1698–1706
Hongmanee G, Sripothongnak S, Jongsomjit B, Praserthdam P (2014) Observation on different reducing power of cocatalysts on the Ziegler-Natta catalyst containing alkoxide species for ethylene polymerization. J Appl Polym Sci. https://doi.org/10.1002/app.40884
Trischler H, Höchfurtner T, Ruff M, Paulik C (2013) Influence of the aluminum alkyl co-catalyst type in Ziegler-Natta ethene polymerization on the formation of active sites, polymerization rate, and molecular weight. Kinet Catal 54(5):559–565
Frisch MJ, Trucks GW, Schlegel HB (2009) Gaussian 09. Gaussian, Inc., Wallingford, CT
Ernzerhof M, Perdew JP (1998) Generalized gradient approximation to the angle- and system-averaged exchange hole. J Chem Phys 109:3313
Correa A, Bahri-Laleh N, Cavallo L (2013) How well can DFT reproduce key interactions in Ziegler-Natta systems? Macromol Chem Phys 214(17):1980–1989
Bahri-Laleh N, Poater A, Cavallo L, Mirmohammadi SA (2014) Exploring the mechanism of Grignard metathesis polymerization of 3-alkylthiophenes. Dalton Trans 43(40):15143–15150
Schäfer A, Horn H, Ahlrichs R (1992) Fully optimized contracted Gaussian basis sets for atoms Li to Kr. J Chem Phys 97(4):2571–7
Bahri-Laleh N (2016) Interaction of different poisons with MgCl2/TiCl4 based Ziegler-Natta catalysts. Appl Surf Sci 379:395–401
Dongare M, Sinha A (1982) Thermal analysis of some metal alkoxides. Thermochim Acta 57(1):37–45
Dana M, Zohuri GH, Asadi S (2019) Improvement in volume resistivity and morphology of a blend of polyolefin elastomer with linear low-density polyethylene. Iran Polym J 28(7):587–595
Kheradmand A, Abadi ARS, Khorasheh F, Baghalha M, Bahrami H (2016) Preparation and study of bi-supported Ziegler-Natta catalyst with nano graphene oxide and magnesium ethoxide supports for polymerization of polyethylene. Polym Sci Ser B 58(3):271–277
Di Noto V, Bresadola S (1996) New synthesis of a highly active δ-MgCl2 for MgCl2/TiCl4/AlEt3 catalytic systems. Macromol Chem Phys 197(11):3827–3835
Lee D-W, Lee H-M, Wang JP (2011) Chemical synthesis of aluminum chloride (AlCl3) by cost-effective reduction process. Rev Adv Mater Sci 28:40–43
Shijing X, Honglan L, Minghui Z (1990) Studies on TiCI4/Mg (OEt) 2/EB Supported catalysts for Propylene Polymerization. Chin J Polym Sci 8(3):253–260
Sinthusai L, Trakarnpruk W, Strauss R (2009) Ziegler-Natta catalyst with high activity and good hydrogen response. J Metals Mater Miner 19(2)
Abedi S, Majdabadi-Farahani N, Daftari-Besheli M, Ghasempour H, Azadi FJPB (2015) Promoting ethylene polymerization through cocatalyst modification. Polym Bull 72(9):2377–2388
Kashiwa N (1980) Super active catalyst for olefin polymerization. Polym J 12(9):603–608
Bahri-Laleh N, Arabi H, Mehdipor-Ataei S, Nekoomanesh-Haghighi M, Zohuri G, Seifali M et al (2012) Activation of Ziegler-Natta catalysts by organohalide promoters: a combined experimental and density functional theory study. J App Polym Sci 123(4):2526–2533
Bahri-Laleh N, Seifali Abbas-Abadi M, Nekoomanesh-Haghighi M, Akbari Z, Tavasoli MR, Mirjahanmardi SH (2010) Effect of halocarbon promoters on polyethylene properties using MgCl2 (ethoxide type)/TiCl4/AlEt3/H2 catalyst system. J Appl Polym Sci 117(3):1780–6
Sarma KR, Padmanabhan S, Patel V (2010) Estimation of the components in titanation mixture used in the synthesis of polyolefin catalysts. Anal Methods 2(7):912–915
Bazvand R, Bahri-Laleh N, Nekoomanesh-Haghighi M, Abedini H (2015) Highly efficient FeCl3 doped Mg(OEt)2/TiCl4-based Ziegler-Natta catalysts for ethylene polymerization. Des Monomers Polym 18(7):599–610
Nouri-Ahangarani F, Bahri-Laleh N, Nekomanesh Haghighi M, Karbalaei M (2016) Synthesis of highly isotactic poly 1-hexene using Fe-doped Mg(OEt)2/TiCl4/ED Ziegler-Natta catalytic system. Des Monomers Polym 19(5):394–405
Cossee P (1967) The mechanism of Ziegler-Natta polymerization. II. Quantum-chemical and crystal-chemical aspects, chap 3. In: Ketley AD (ed) The stereochemistry of macromolecules, vol 6. Marcel Dekker, New York
Xiao A, Wang L, Liu Q, Yu H, Dong X (2008) Synthesis of low isotactic polypropylene using MgCl2/AlCl3-supported Ziegler-Natta catalysts prepared using the one-pot milling method. Des Monomers Polym 11(2):139–145
Bahri-Laleh N, Correa A, Mehdipour-Ataei S, Arabi H, Nekoomanesh-Haghighi M, Zohuri GH et al (2011) Moving up and down the Ti-oxidation state in Ziegler Natta catalysis. Macromolecules 44(4):778–83
Correa A, Credendino R, Pater JTM, Morini G, Cavallo L (2012) Theoretical investigation of active sites at the corners of MgCl2 crystallites in supported Ziegler-Natta catalysts. Macromolecules 45(9):3695–3701
Correa A, Piemontesi F, Morini G, Cavallo L (2007) Key elements in the structure and function relationship of the MgCl2/TiCl4/lewis base Ziegler-Natta catalytic system. Macromolecules 40(25):9181–9189
Busico V, Corradini P, De Martino L, Proto A, Savino V, Albizzati E (1985) Polymerization of propene in the presence of MgCl2‐supported Ziegler‐Natta catalysts, 1. The role of ethyl benzoate as “internal” and “external” base. Die Makromol Chem Macromol Chem Phys 186(6):1279–1288
Acknowledgements
Naeimeh Bahri-Laleh thanks the MOLNAC (www.molnac.unisa.it) for its computer facilities and Iran Polymer and Petrochemical Institute for the financial support of computational section.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Supplementary Information
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Abazari, M., Jamjah, R., Bahri-Laleh, N. et al. Synthesis and evaluation of a new three-metallic high-performance Ziegler–Natta catalyst for ethylene polymerization: experimental and computational studies. Polym. Bull. 79, 7265–7280 (2022). https://doi.org/10.1007/s00289-021-03848-x
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00289-021-03848-x