In Ziegler–Natta catalysis,
the catalyst particle size has
a strong influence not only on catalyst performance but also on the
morphology and particle size distribution of the final polymer particles.
Fundamental insight into the catalyst particle formation process is
therefore of industrial importance when addressing specific requirements
in the final products. In the present work, we fully characterize
a single-step catalyst preparation process, which comprises a reactive
precipitation of a MgCl2-supported Ziegler–Natta
catalyst, through decomposition of the hetero-bimetallic complex,
Mg(OR)2·Ti(OR)4, by addition of ethyl aluminum
dichloride (EADC). We track the evolution of both of the concentrations
of the metals (Mg, Ti, Al) as well as Cl in the liquid phase and the
size of the formed catalyst particles. It is observed that the liquid-phase
composition is governed by the EADC feed rate under fully Cl-starved
conditions. The process can be divided into two stages: The first
stage is dominated by the precipitation of the Mg-based support, and
the second stage involves complex adsorption–precipitation
of the Ti species. The growth of the catalyst particle size occurs
only in the first stage and is controlled by the aggregation and breakage
events during the MgCl2 precipitation. It follows that
the hydrodynamic stress in the reactor plays the essential role in
controlling the catalyst size. In the second stage, no further particle
growth occurs, not only because of the depletion of Mg in the liquid
phase but also because the adsorbed Ti complex stabilizes the particles
against aggregation. Finally, we have performed polymerization tests
with the prepared catalysts and found that the size distribution of
the polymer particles indeed closely replicates the one of the used
catalyst particles.