Gas-phase ethylene and hexene copolymerization using a silica-supported (n-BuCp)2ZrCl2
metallocene catalyst has been investigated in a 2 L laboratory reactor. Replicate experimental
runs were conducted to confirm the reproducibility of measured responses, which included
polymerization rate, reactant concentrations, and copolymer properties. Comparisons of polymerization rate profiles and catalyst activity were made using a number of designed experimental
runs. The experiments revealed that triisobutyl aluminum scavenger was the most important
cause of low catalyst activity, and a low initial polymerization rate that was followed by a rate
increase. The effects of other influencing factors, including residence time, temperature, pressure,
concentration of reactants, catalyst, and cocatalyst, were also investigated. As expected, hydrogen
concentration and hexene concentration had significant effects on molecular weight and short-chain branching, respectively. In addition, hexene enhanced the polymerization rate and catalyst
activity, while cocatalyst and hydrogen both led to a lower polymerization rate. The results
from this study provide important quantitative information that will be used for parameter
estimation in fundamental models.