Efficient
sustainable synthesis of high-performance poly(trimethylene
terephthalate) (PTT) with simultaneously high molecular weight, narrow
molecular weight distribution, and tiny cyclic dimer suitable for
high end applications at low cost still faces challenges. Novel nontoxic
and 1,3-propanediol-soluble Ti/Mg bimetal catalyst mainly based on
biobased 1,3-propanodiol and food grade materials has been productively
synthesized and also carefully characterized. The Ti/Mg catalyst was
found to be exceptionally active catalysts for the polycondensation
of terephthalic acid and 1,3-propanediol from a renewable resource
capable of producing high-molecular-weight PTT as an environmentally
friendly and recyclable material in both laboratory reactor and continuous
pilot plant. The high-quality PTT samples with the highest number-average
molecular weight up to 68 870 g/mol ever reported so far, the
narrowest molecular weight distribution index down to 1.92, and the
second lowest cyclic dimer content down to 2.21% simultaneously were
synthesized for the first time at optimal Ti/Mg catalyst content and
polycondensation temperature. Solid-phase polycondensation will result
in even higher molecular weight up to 77 740 and even lower
cyclic dimer content down to 1.92% at the same time. The kinetic analysis
demonstrates that the polymerization by the Ti/Mg catalyst is faster
and the degradation is slower than those by other catalysts reported.
Pilot scale polymerization for productively synthesizing PTT was also
carried out in a continuous plant, achieving cost-effective large-scale
synthesis of PTT with the highest molecular weight and high performance.
The properties of PTT obtained thus were superior to that of commercial
grade. A systematical characterization signifies that the PTT catalyzed
by Ti/Mg catalyst shows obvious characteristics including strong thermal-induced
crystallinity, high glass transition temperature, elevated melting
temperature, high melt viscosity, high storage modulus, high thermal
stability, and excellent melt-spinnability.