Ziegler-type catalysts
are the grand old workhorse of the polyolefin
industry, yet their hierarchically complex nature complicates polymerization
activity–catalyst structure relationships. In this work, the
degree of catalyst framework fragmentation of a high-density polyethylene
(HDPE) Ziegler-type catalyst was studied using ptychography X-ray-computed
nanotomography (PXCT) in the early stages of ethylene polymerization
under mild reaction conditions. An ensemble consisting of 434 fully
reconstructed ethylene prepolymerized Ziegler catalyst particles prepared
at a polymer yield of 3.4 g HDPE/g catalyst was imaged. This enabled
a statistical route to study the heterogeneity in the degree of particle
fragmentation and therefore local polymerization activity at an achieved
3-D spatial resolution of 74 nm without requiring invasive imaging
tools. To study the degree of catalyst fragmentation within the ensemble,
a fragmentation parameter was constructed based on a
k
-means clustering algorithm that relates the quantity of polyethylene
formed to the average size of the spatially resolved catalyst fragments.
With this classification method, we have identified particles that
exhibit weak, moderate, and strong degrees of catalyst fragmentation,
showing that there is a strong heterogeneity in the overall catalyst
particle fragmentation and thus polymerization activity within the
entire ensemble. This hints toward local mass transfer limitations
or other deactivation phenomena. The methodology used here can be
applied to all polyolefin catalysts, including metallocene and the
Phillips catalysts to gain statistically relevant fundamental insights
in the fragmentation behavior of an ensemble of catalyst particles.