A new heterogenization technique for single-site polymerization catalysts

Silica-supported single-site catalysts show limitations with respect to catalyst homogeneity and maximum metal content. A novel emulsion-based catalyst heterogenization concept is described, which allows these limitations to be overcome. The method produces catalyst particles with an inherently perfect spherical shape and unique intra- and inter-particle homogeneity. The catalyst particles are very compact and have a low surface area. Video microscopic studies confirm that the improved catalyst homogeneity leads to a more uniform polymerization behavior on a single particle level. The catalysts contain significantly more complex, compared to silica-supported catalyst systems which leads to correspondingly higher catalyst activities. No differences, in terms of the mass-transfer kinetics of these low-porosity catalysts, compared to porous catalyst systems have been observed.