Polymer-coated particles were used to develop a novel
catalyst
technology for the production of broad/bimodal polyethylene in a single
reactor. The methods for broad/bimodal polyethylene by catalyst technology,
such as hybrid catalyst, composite support, and diffusion control,
were combined together in this catalyst technology. An improved phase
inversion method was used to fabricate poly[styrene-co-(acrylic acid)] (PSA) coated silica particles (SiO2/PSA).
Core–shell structure was obviously observed in the resulting
SiO2/PSA. SiO2/PSA showed a significant barrier
effect to the diffusion of 1-hexene and n-hexane
but no barrier effect to the diffusion of ethylene. This means the
PSA layer has a selective barrier effect to the diffusion of small
molecules. PSA-coated silica particles were used to support (n-BuCp)2ZrCl2/TiCl4, TiCl3/TiCl4, and Cp2ZrCl2/Fe based
hybrid catalysts. The ethylene polymerization results indicated that
the two different active sites can perform independently, and broad/bimodal
polyethylene was obtained by all hybrid catalysts. The polydispersity
index of the resulting polyethylene was as high as 18.13, even 44.5.
The style of the activity profile was determined by whether the active
sites in the core needed a cocatalyst or not.