Immobilization of Ziegler–Natta Catalyst for Ethylene Polymerization on Macropores SiO2 with an Open-Framework Structure

A macroporous SiO2 (Macro-SiO2), which has uniformed macropores, an open-framework structure, and thin walls, was synthesized to support Ziegler–Natta catalysts. The immobilization behaviors of the Ziegler–Natta catalysts inside the Macro-SiO2 were investigated. Notable agglomerations of δ-MgCl2/titanium complex were observed because of the unconstrained environment of the Macro-SiO2. A highly superficial Ti content and a heterogeneously chemical structure of Ti active sites were thus achieved inside the Macro-SiO2. The ethylene polymerization results revealed that the Macro-SiO2/MgCl2/TiCl4 exhibited much higher catalytic activity (i.e., 12.1 × 106 g PE·(mol Ti·h)−1 or 17.8 × kg PE·(g cat·h)−1) than that of the traditional 955-SiO2 supported catalyst (i.e., 2.0 × 106 g PE·(mol Ti·h)−1 or 2.7 × kg PE·(g cat·h)−1). Finally, the fragmentation behavior of Macro-SiO2/MgCl2/TiCl4 was investigated during the polymerization. This unconstrained environment of Macro-SiO2 afforded fewer resistances to the diffusion of reactants and also the polymer growth.