Elucidating the Sectioning Fragmentation Mechanism in Silica‐Supported Olefin Polymerization Catalysts with Laboratory‐Based X‐Ray and Electron Microscopy

Strict morphological control over growing polymer particles is an indispensable requirement in many catalytic olefin polymerization processes. In catalysts with mechanically stronger supports, e. g., polymerization-grade silicas, the emergence of extensive cracks via sectioning fragmentation mechanism requires severe stress build-up polymerizing catalyst particle. Here, we report on three factors that influence degree silica-supported catalysts. Laboratory-based X-ray nano-computed tomography (nanoCT) and focused ion beam-scanning electron microscopy (FIB-SEM) were employed to study particle morphology crack propagation two showcase systems, i.e., a zirconocene-based (i.e., Zr/MAO/SiO2, Zr=2,2’-biphenylene-bis-2-indenyl zirconium dichloride MAO=methylaluminoxane) Ziegler-Natta TiCl4/MgCl2/SiO2), during slurry-phase ethylene polymerization. The absence macropores some catalysts’ larger constituent silica granulates, sufficient accessibility interior at reaction onset, high initial rate found favor occurrence pathway different length scales. While beneficial for reducing diffusion limitations, its appearance supports can indicate suboptimal support structure or unfavourable conditions.