Bimodal ultrahigh molecular weight polyethylenes produced from supported catalysts: the challenge of using a combined catalyst system

Molecular precatalysts complexes (nBuCp)₂ZrCl₂ (Zr) and (η1:η5-Me₂NCH₂CH₂C₅Me₄)CrCl₂ (Cr) have been successfully supported on silica nanoparticles, via a single support (SS) or a double support (DS) strategy. These catalyst systems have been successfully used to produce bimodal polyethylenes with an ultrahigh molecular weight polyethylene content in a single reactor. The SS and DS catalyst systems have been fully evaluated under an identical polymerization condition to assess the challenges in tailoring the molecular weight distribution. The results show that a detrimental interaction exists between Zr and Cr catalysts, part of the Cr catalyst species is deactivated during polymerization in the both DS and SS systems. The detrimental interaction in the DS system is reduced because the catalysts are supported on separate nanoparticles. But, surprisingly the two catalysts in the DS system are still able to “communicate” to each other via cocatalyst-induced catalyst leaching or other potential reasons. (Figure presented.).