A novel self-supported emulsion-based catalyst and a conventional MgCl2-supported Ziegler–Natta catalyst were used in the copolymerization of propylene and ethylene under industrial conditions using triethyl aluminium as cocatalyst and dicyclopentyl dimethoxy silane as external donor. The effects of the concentration of ethylene and hydrogen on the polymerization behaviors and polymer properties were investigated. The combined effect of both ethylene and hydrogen increased the relative activity of the novel catalyst more than for the conventional catalyst. This trend was consistent with our earlier observed higher degree of dormancy, due to 2,1 insertions, found with the novel catalyst. More importantly, the work has uncovered that the self-supported catalyst incorporates ethylene in a more random fashion and produces copolymers with relatively narrow molecular weight distribution (MWD). These results in combination with polymer microstructure studies using Fourier transform infrared spectroscopy, 13C-NMR spectroscopy, and differential scanning calorimetry all indicated that the novel catalyst has a narrower distribution of active site types than the conventional reference catalyst. The narrow composition of active site structures, the narrow MWD, and the random incorporation of ethylene into the polymer chain indicated that the emulsion-based catalyst possesses features that to a certain degree tend to be more indicative for a single-site-like catalyst structure and behavior.
