Development of Large-Scale Stopped-Flow Technique and its Application in Elucidation of Initial Ziegler-Natta Olefin Polymerization Kinetics

The stopped-flow (SF) technique has been extensively applied to study Ziegler-Natta (ZN) olefin polymerization kinetics within an extremely short period (typically <0.2 s) for understanding the nature of the active sites as well as the polymerization mechanisms through microstructure analyses of obtained polymers. In spite of its great applicability, a small amount of polymer that is yielded in a short-time polymerization has been a major bottleneck for polymer characterizations. In order to overcome this limitation, a large-scale SF (LSF) system has been developed, which offers stable and scalable polymerization over an expanded time range from a few tens milliseconds to several seconds. The scalability of the LSF technique has been further improved by introducing a new quenching protocol. With these advantages, the LSF technique has been effectively applied to address several unknown issues in ZN catalysis, such as the role of physical and chemical transformations of a catalyst on the initial polymerization kinetics, and regiochemistry of ZN propylene polymerization. Here, we review the development of the LSF technique and recent efforts for understanding heterogeneous ZN olefin polymerization catalysis with this new system.

High-Throughput Synthesis of Support Materials for Olefin Polymerization Catalyst

Rational catalyst design necessitates fundamental knowledge on the structure-performance relationship, while the synthetic throughput for heterogeneous Ziegler-Natta olefin polymerization catalysts has long prevented the acquisition of a statistical database. In this contribution, an in-house reactor system was developed to realize the parallel synthesis of support materials for Ziegler-Natta catalysts for the first time. The developed system enabled parallel synthesis of 24 magnesium ethoxide samples with excellent reproducibility and morphological control comparable to a conventional experiment. Our demonstration revealed that the generation of diverse particle characteristics could be achieved through the addition of a third component as a structural modulator, in which the in-house parallel reactor system combined with the first principle component analysis enabled fast screening of effective modulators.