For the initial steps of propylene bulk phase polymerization with a silica‐supported metallocene/MAO‐catalyst the processes of polymer growth, particle expansion and carrier fragmentation are investigated. Gravimetric analysis of the kinetics is given. Light optical examination of the particles shows a significant particle expansion during the first minutes of polymerization, which is not comparable to known observation from the slurry process. Electron microscopic investigation on cross sections of the polymer particles allows a detailed insight into the process of polymer growth, carrier fragmentation and particle expansion. The results are compared with the polymer growth and particle expansion model developed with slurry polymerizations under mild model conditions. In bulk phase polymerization particle expansion and carrier fragmentation are much faster due to more drastic reaction conditions. Nevertheless, it is still possible to observe a shell‐by‐shell degradation of the carrier material. Varying start up behaviors of single catalyst grains are observed. We are able to correlate the initial polymerization activity of individual grains with the cocatalyst loading and distribution on the catalyst carrier by means of microanalytical techniques. The results explain the varying start up behaviors of single grains. It becomes clear why different states of fragmentation are mixed up in the observed polymer samples.

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In this paper, a mathematical model describing olefin polymerization with metallocene catalysts is presented. It is an improvement of a previous model, the “particle growth model” (PGM) proposed by, among others, one of the authors of the present work and derives from the so-called “multigrane model” (MGM). The main differences between this work and others is a more sophisticated approach to fragmentation with respect to the MGM. Additionally, there is a more specific modeling for the unfragmented core with respect to the PGM. The numerical results obtained by the model are compared with experimental data. The results of this work allow to extend the PGM to catalysts with lower activity. The importance of those catalysts depends on the fact that high activity catalysts could bring, in some cases, too poor polymer morphology

The slurry phase polymerization of propylene with a silica‐supported metallocene/MAO catalyst was kinetically investigated by two different methods at several polymerization conditions. Heat flow calorimetry on the one hand as an innovative method and flowmeter‐technique on the other hand as a well established classical method led to consistent kinetic profiles. Thus, the principle applicability of the heat flow calorimetry for the kinetic investigation of the described polymerization process was demonstrated, contrary to some expectations in literature. Furthermore, the sensitivity of the calorimetric method is shown and polymerization heats for the slurry process have been determined.