A method for the prediction of metallocene-type catalyst activity in olefin (co)polymerisation reactions

The use of ultraviolet/visible spectroscopy (UV-Vis) for the prediction of metallocene catalyst potential for the polymerisation of olefins is described. Upon addition of methylaluminoxane (MAO) to rac-[C₂H₄(1-indenyl)₂ZrCl₂] ([Al]/[Zr] = 200) the ligand-to-metal charge transfer band shows a hypsochromic shift while a bathochromic shift is observed when more MAO is added ([Al]/[Zr] = 2000). These shifts can be explained by assuming that methylation of the zirconocene by MAO occurs in the case of [Al]/[Zr] = 200 while a cationic complex, the active catalytic system, is formed upon addition of more MAO, e.g., [Al]/[Zr] = 2000.     

Kinetics of propylene polymerization initiated by rac‐Me2Si(1‐C5H2‐2‐Me‐4‐tBu)2Zr(NME2)2/MAO catalyst

The kinetics of propylene polymerization initiated by ansa‐metallocene diamide compound rac‐Me₂Si(CMB)₂Zr(NMe₂)₂ (rac‐1, CMB = 1‐C₅H₂‐2‐Me‐4‐^tBu)/methylaluminoxane (MAO) catalyst were investigated. The formation of cationic active species has been studied by the sequential NMR‐scale reactions of rac‐1 with MAO. The rac‐1 is first transformed to rac‐Me₂Si(CMB)₂ZrMe₂ (rac‐2) through the alkylation mainly by free AlMe₃ contained in MAO. The methylzirconium cations are then formed by the reaction of rac‐2 and MAO. Small amount of MAO ([Al]/[Zr] = 40) is enough to completely activate rac‐1 to afford methylzirconium cations that can polymerize propylene. In the lab‐scale polymerizations carried out at 30°C in toluene, the rate of polymerization (R_p) shows maximum at [Al]/[Zr] = 6,250. The R_p increases as the polymerization temperature (T_p) increases in the range of T_p between 10 and 70°C and as the catalyst concentration increases in the range between 21.9 and 109.6 μM. The activation energies evaluated by simple kinetic scheme are 4.7 kcal/mol during the acceleration period of polymerization and 12.2 kcal/mol for an overall reaction. The introduction of additional free AlMe₃ before activating rac‐1 with MAO during polymerization deeply influences the polymerization behavior. The iPPs obtained at various conditions are characterized by high melting point (approximately 155°C), high stereoregularity (almost 100% [mmmm] pentad), low molecular weight (MW), and narrow molecular weight distribution (below 2.0). The fractionation results by various solvents show that iPPs produced at T_p below 30°C are compositionally homogeneous, but those obtained at T_p above 40°C are separated into many fractions. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 737–750, 1999     

Copolymerization of propene and 1-hexene using metallocene amide compounds

Copolymerization of propene and 1-hexene has been carried out at 30°C in toluene under atmospheric pressure by using three isospecific metallocene amide compounds, rac-(EBI)Zr(NMe₂₎₂ (EBI = ethylenebis(1-indenyl), rac- 1 ), rac-(EBI)Zr(NC₄H₈₎₂ (rac- 2 ), and rac-Me₂Si(1-C₅H₂-2-Me-4-t-Bu)₂Zr(NMe₂₎₂ (rac- 3 ), in the presence of methylaluminoxane (MAO) or [Ph₃C][B(C₆F₅)₄]. The rate enhancements in the presence of 1-hexene were recorded as a function of the catalytic systems. The incorporation of 1-hexene decreases in the following order: rac- 2 /MAO > rac- 3 /Al(i-Bu)₃/[Ph₃C][B(C₆F₅)₄] > rac- 1 /MAO. All copolymers investigated in this study have a nearly random sequence distribution.     

Kinetics and stereochemical control of propylene polymerization initiated by ethylene bis(4,5,6,7-tetrahydro-1-indenyl) zirconium dichloride/methyl aluminoxane catalyst

The kinetics and sterochemical control of propylene polymerization initiated by rac-ethylene bis (4,5,6,7-tetrahydro-1-indenyl) zirconium dichloride/methyl aluminoxane ( 1 /MAO) and by rac-ethylene bis (1-indenyl) zirconium dichloride/MAO ( 2 /MAO) were investigated. The polymerization activities increase monotonically with temperature corresponding to an overall activation energy of 10.6 kcal mol^?1. This is accompanied, however, by reduction of stereochemical control as reflected in the amount of the polypropylene (PP) soluble in low boiling solvent. At a temperature of 30°C and higher, polymerization initiated by 1 /MAO produced no PP insoluble in refluxing n-heptane. Tritium radiolabeling showed that at [Al]/[Zr] ≥ 3500 and 30°C, two-thirds of 1 becomes catalytically active. There are at least two kinds of active species formed in about equal amounts; one has more stereoselectivity, 10–20 times greater rate constant of propagation, and a factor of 5–15 faster chain transfer to MAO than the second kind of Active species. This is also true at low [Al]/[Zr] of 350, except that the total amount of the two active species corresponds to only 13% of the [ 1 ]. Replacement of MAO with trimethyl aluminum resulted in the decrease of stereoselectivity and loss of catalytic activity proportional to the amount of replacement. A comparison was made with the polymers obtained with 2 /MAO.     

The effect of AlR3 on propylene polymerization by rac‐(EBI)Zr(NMe2)2/AlR3/[CPh3][B(C6F5)4] catalyst

Ansa‐zirconocene diamide complex rac‐(EBI)Zr(NMe₂)₂ [rac‐1, EBI = ethylene‐1,2‐bis(1‐indenyl)] reacted with AlR₃ (R = Me, Et, iBu) or Al(iBu₂)H and then with [CPh₃][B(C₆F₅)₄] (2) in toluene in order to perform propylene polymerization by cationic alkylzirconium species, which are in situ generated during polymerization. Through the sequential NMR‐scale reactions of rac‐1 with AlR₃ or Al(iBu₂)H and then with 2, rac‐1 was demonstrated to be transformed to the active alkyzirconium cations via alkylated intermediates of rac‐1. The cationic species generated by using AlMe₃, AlEt₃, and Al(iBu₂)H as alkylating reagents tend to become heterodinuclear complex; however, those by using bulky Al(iBu)₃ become base‐free [rac‐(EBI)Zr(iBu)]⁺ cations. The activity of propylene polymerization by rac‐1/AlR₃/2 catalyst was deeply influenced by various parameters such as the amount and the type of AlR₃, metallocene concentration, [Al]/[2] ratio, and polymerization temperature. Generally the catalytic systems using bulky alkylaluminum like Al(iBu)₃ and Al(iBu)₂H show higher activity but lower stereoregularity than those using less bulky AlMe₃ and AlEt₃. The alkylating reagent Al(iBu)₃ is not a transfer agent as good as AlMe₃ or AlEt₃. The polymerization activities show maximum around [Al]/[2] ratio of 1.0 and increase monotonously with polymerization temperature. The overall activation energy of both rac‐1/Al(iBu)₃/2 and rac‐1/Al(iBu)₂H catalysts is 6.0 kcal/mol. As the polymerization temperature increases, the stereoregularity of the resulting polymer decreases markedly, which is demonstrated by the decrease of [mmmm] pentad value and by the increase of the amount of polymer soluble in low boiling solvent. The physical properties of polymers produced in this study were investigated by using ¹³C‐NMR, differential scanning calorimetry (DSC), viscometry, and gel permeation chromatography (GPC). © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 1523–1539, 1999     

Propene polymerization with rac-Me2Si(2-Me-Benz[e]Ind)2ZrX2 [X = Cl,Me] using different cation-generating reagents

Propene was polymerized with methylaluminoxane (MAO) and cationic activated rac-dimethylsilylene-2-methylbenz[e]indenylzirconocene [ MBI-Cl ₂] and [ MBI-Me ₂]. For cationic activation of the MBI-Me ₂ system tris(pentafluorophenyl)borane [I], N,N-dimethylanilinium tetra(pentafluorophenyl)borate [III] were used. The MAO-activated dimethyl complex showed higher activity with respect to the dichloride system using high catalyst concentrations and [Al]/[Zr] ratios. Most effective cationic activator for MBI-Me ₂ was N,N-dimethylanilinium tetra(pentafluorophenyl)borate [II] in combination with Al(i-Bu₃). Using tris(pentafluorophenyl)borane [I] at different polymerization conditions or N,N-dimethylanilinium tetra(pentafluorophenyl)borate [II] in combination with Al(Et)₃ no propene polymerization was observed due to the occurrence of reduction of the catalytically active site.     

In Situ Generation of Cationic Methylzirconium Complexes from rac-(EBI)Zr(NMe2)2 and NMR-Scale Polymerization of Propylene

ABSTRACT

Sequential NMR-scale reactions have been carried out in order to generate cationic methylzirconium complexes by the reaction of rac-(EBI)Zr(NMe₂)₂ (rac- 1 , EBI = Et(indenyl)₂) with methylaluminoxane (MAO) or various anionic compounds. By reacting 40 equiv. of MAO with rac- 1 in an NMR tube containing CD ₂CI₂ as a solvent at room temperature, rac- 1 is completely activated to give stable cationic methylzirconium complexes, [(EBI)ZrMe]⁺[MAO]^? which polymerize propylene to isotactic polypropylene (iPP). The formation of the cationic species is achieved after rac- 1 is methylated to form rac-(EBI)ZrMe₂ (rac- 2 ) by MAO and/or free Al₂Me₆ contained in MAO. The same sequential reaction has been performed by using rac(EBI)ZrCl₂ (rac- 3 ) for the comparison. MAO cannot generate the cationic species at the same reaction conditions in the reaction of rac- 3 and MAO, mainly due to the difficulties of methylation of rac- 3. Ansa ziconocene amide rac- 1 is stoichiometrically methylated by 2 equiv. of Al₂Me₆ to give rac- 2. Introduction of 1 equiv. of noncoordinating to the solution mixture of rac- 1 and 2 equiv. of Al₂Me₆ leads to the formation of stable cationic methylzirconium species, [rac-(EBI)Zr(μ-Me)₂AlMe₂]⁺. NMR-scale polymerizations have been carried out by adding a small amount of liquid propylene to these cationic species. The meso pentad values of iPP isolated in these polymerizations are in the range of 80.2–84.7%. By changing the order of sequential reaction, i.e., by reacting rac- 1 with noncoordinating anions prior to methylation by Al₂Me₆, the yield to give cationic methylzirconium species is decreased. Coordinative anions such as [HNMe₂Ph][BPh₄] and [HNBu₃][BP₄] are less effective for the generation of the active zirconium cations than noncoordinating anions. The amount of MAO needed to activate rac- 1 can be decreased by the pre-methylation of rac- 1 by Al₂Me₆.     

Metallocene–methylaluminoxane catalyst for olefin polymerization. II. Bis-η5-(neomenthyl cyclopentadienyl)zirconium dichloride

Bis(neomenthyl cyclopentadienyl)zirconium dichloride/methyl aluminoxane (η⁵-(NMCp)₂ZrCl₂/MAO) catalyst has been investigated for ethylene polymerization. About 51% of the Zr forms active sites more or less instantaneously according to quenching with tritiated methanol. There is an initial drop of rate of polymerization, R_p, of about 30% which remains constant thereafter. The catalytic activity increases monotonically with temperature; it is proportional to [MAO]^1.75 at a constant [Zr] = 1.5 μM and proportional to [Zr]^?1.2 at a constant [MAO] = 64.5 mM. At very large [MAO]/[Zr], the catalyst has extremely high activity; κ_p = 5 × 10³ (Ms)^?1 at 50°C. There is also facile chain transfer to aluminum, κ = 0.14 s^?1 at 50°C. Both κ_p and κ are about 30 times greater than the corresponding rate constants for MgCl₂ supported TiCl₃ catalysts. The TiCl₃/MgCl₂ and (NMCp)₂/MAO catalysts have nearly the same activation energy for propagation (ca. 7 kcal/mol^?1). The higher activity of the latter is due to its larger preexponential factor in κ_p. The dependence of catalytic activity on the [MAO]/[Zr] ratio may be explained by rapid association-dissociation equilibria of MAO involving acid-base and/or electron deficient bridge complexation.     

Poly(4‐vinylpyridine)‐supported cationic bis(cyclopentadienyl)zirconocene catalyst: Development of a new simple method to prepare polymer‐supported cationic zirconocene and its application to ethylene polymerization

Bis(cyclopentadienyl)zirconocene dimethyl (Cp₂ZrMe₂) combined with triphenylcarbenium tetrakis(pentafluorophenyl)borate ([Ph₃C][B(C₆F₅)₄]) was brought into contact with a suspension of 2% cross‐linked poly(4‐vinylpyridine) to give a new type of polymer‐supported cationic zirconocene catalyst. The resulting polymer‐supported catalyst system combined with Al(i‐Bu₃) showed markedly high activity for ethylene polymerization in even a non‐polar solvent like hexane at 25–60°C and [Al]/[Zr] molar ratio 40–200. By the analysis of Zr content of the hexane solution, it was found that no Zr was detected in the solution, i. e. no leaching of the cationic catalyst into the hexane medium. The catalytic activity was found to increase with an increase of polymerization temperature and showed the highest at [Al]/[Zr] = 100. The molecular weight, crystalline melting temperature, crystallinity, and bulk density of polyethylene formed were higher than those of the polymer obtained from the homogeneous system.     

Hexene-1 polymerization by homogeneous zirconocene and heterogeneous-supported TiCl3 catalysts

MgCl₂-supported TiCl₃ catalysts, with and/or without electron donor modifier (internal B_i or external B_e), were compared with rac-ethylenebis(indenyl)zirconium dichloride ( 1 ) activated with either MAO or the cation forming agent, triphenyl carbenium tetrakis(pentafluorophenyl)borate ( 2 ), with triethylalumium (TEA). The activities of the heterogeneous catalysts depend on the presence or absence of the Lewis base, were relatively insensitive to the temperature of polymerization, and produce poly(hexene) with molecular weights up to 10⁶. The 1 /MAO catalyst has about five times higher activity at 50°C but is almost inactive at ?30°C; the overall activation energy is 12.4 kcal mol^?1. In contrast, the activity for hexene polymerization by the 1/2 /TEA catalyst is actually slightly greater at lower temperature. The MW's of poly(hexene) obtained with the zirconocenium catalysts are only in the tens of thousands because of rapid β-hydride elimination by the electrophilic cationic Zr center. © 1993 John Wiley & Sons, Inc.     

Ethylene polymerization with ansa-metallocene systems rac-(Me2SiOSiMe2)[Ind]2ZrCl2-MAO and rac-(Me2SiOSiMe2)[IndH4]MtCl2-MAO; (Mt = Zr,Ti)

Ethylene was polymerized in toluene using methylalumoxane (MAO) activated rac-(Me₂SiOSiMe₂)[Ind]₂ZrCl₂ ( 1 ) and rac-(Me₂SiOSiMe₂)[IndH₄]₂MtCl₂ (Mt = Zr ( 2 ); Mt = Ti ( 3 )). All three catalyst systems polymerize ethylene with high activity. The molecular weight of polymer produced with zirconocene ( 1 ) was up to a weight-average molecular weight M̄_w = 1.1 × 10⁶ at low polymerization temperature (<20°C) under atmospheric pressure. The titanocene catalyst 3 shows lower activity and produced lower molecular weight polyethylene than zirconocenes 1 and 2. Replacement of aromatic rings in 1 by cyclohexane rings, leading to 2 , increases activity and reduces molecular weight. The catalyst systems show a dependency of the activity on temperature.     

Long‐chain‐branched polyethene by the copolymerization of ethene and nonconjugated α,ω‐dienes

Ethene was copolymerized (1) with 1,5‐hexadiene with rac‐ethylenebis(indenyl)zirconium dichloride/methylaluminoxane (MAO) used as a catalyst and (2) with 1,7‐octadiene with bis(n‐butylcyclopentadienyl)zirconium dichloride/MAO and rac‐ethylenebis(indenyl)hafnium dichloride (Et[Ind]₂HfCl₂)/MAO used as catalysts at 80 °C in toluene. The copolymer microstructure and the influence of diene incorporation on the rheological properties were examined. Ethene and 1,5‐hexadiene formed a copolymer in which a major fraction of the 1,5‐hexadiene was incorporated into rings and a small fraction formed 1‐butenyl branches. The copolymerization of ethene with 1,7‐octadiene resulted in a higher selectivity toward branch formation. Some of the branches formed long‐chain‐branching (LCB) structures. The ring formation selectivity increased with decreasing ethene concentration in the polymerization reactor. Melt rheological properties of the diene copolymers resembled those of metallocene‐catalyzed LCB homopolyethenes and depended on the vinyl content, the catalyst, and the polymerization conditions. At high diene contents, all three catalysts produced crosslinked polyethene. This was especially pronounced with Et[Ind]₂HfCl₂, where only 0.2 mol % 1,7‐octadiene in the copolymer was required to achieve significantly modified rheological properties. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3805–3817, 2001     

Gas phase polymerization of ethylene with a silica-supported metallocene catalyst: influence of temperature on deactivation

Ethylene was polymerized at 5 bar in a stirred powder bed reactor with silica supported rac-Me₂Si[Ind]₂ZrCl₂/methylaluminoxane (MAO) at temperatures between 40°C and 80°C using NaCl as support bed and triethylaluminium (TEA) as a scavenger for impurities. For this fixed recipe and a given charge of catalyst. the average catalyst activity is reproducible within 10% for low temperatures. The polymerization rate and the rate of deactivation increase with increasing temperature. The deactivation could be modeled using a first order dependence with respect to the polymerization rate.     

Comparative ethylene polymerization via imino-quinolinol catalysts

A series of zirconium catalysts based on tridentate 8-hydroxyquinoline Schiff base ligands were prepared and successfully used for polymerization of ethylene. The highest activities of the prepared catalysts were obtained at polymerization temperatures about 30–45ºC. By increasing the [Al]/[Zr] molar ratio productivity of all the catalysts enhanced to an maximum value then decrease at higher [Al]/[Zr] molar ratio with the exception of catalyst 4, which showed no optimum activity in the range studied. Also, the activities and selectivities to produce low-carbon olefins were profoundly influenced by the catalysts structure indicating the dramatic effects of the substitution on the polymerizations behavior. Fouling of the reactor was strongly related to polymerization parameters like as monomer pressure and [Al]/[Zr] ratio in the homogeneous polymerization. Heterogeneous polymerization of ethylene using the catalysts and the MAO modified silica decreased the fouling. The obtained polyethylenes have a melting point of about 125–130°C, crystallinities of about 45–55% and PDI of 2.45–3.45.     

Influences of methylaluminoxane separated by porous inorganic materials on the isospecific polymerization of propylene

Inorganic siliceous porous materials such as MFI type zeolite, mesoporous silica MCM‐41 and silica gel with different average pore diameters were applied to the adsorptive separation of methylaluminoxane (MAO) used as a cocatalyst in α‐olefin polymerizations. The separated MAOs combined with rac‐ethylene‐(bisindenyl)zirconium dichloride (rac‐Et(Ind)₂ZrCl₂) were introduced to propylene polymerization, and their influences on the polymerization activity and stereoregularity of the resulting polymers were investigated. The polymerization activity and isotactic [mmmm] pentad of the produced propylene were markedly dependent upon the pore size of the porous material used for adsorptive separation. From the results obtained from solvent extraction of the produced polymers, it was suggested that there are at least two kinds of active species with different stereospecificity in the rac‐Et(Ind)₂ZrCl₂/MAO catalyst system.     

Metallocene–methylaluminoxane catalysts for olefin polymerization. I. Trimethylaluminum as coactivator

Ethylene was polymerized by Cp₂ZrCl₂–methylaluminoxane (MAO) catalysts where a portion of the MAO was replaced with trimethyl aluminum (TMA). At a total Al to Zr ratio of 1070, there is neither appreciable loss of productivity nor change in polymerization profile for TMA/MAO ≤ 10. The productivity is reduced only by two- to three-fold for TMA/MAO ≤ 100 accompanied by a 10 min induction period. Aging of this catalyst did not affect the induction period, but improves its productivity. The kinetic isotope effect for radiolabeling with tritiated methanol is 2.0. About 40% of the Zr is active for the catalyst with {99 [TMA] + 1[MAO]} to Zr ratio of 100. The rate constants for propagation and chain transfer were obtained. The mechanisms for the mixed TMA and MAO cocatalyst system are discussed. The results of this work have important practical significance. MAO is a hazardous material to synthesize and only in low yields. The replacement of > 90% of MAO with TMA represents a substantial saving since as much as 0.1M of the former is commonly used for a polymerization.     

Zirconocenium cation catalysis of propene polymerization

rac-Ethylenebis(1-η⁵-indenyl)dimethylzirconium (1) was reacted with triphenylcarbenium tetrakis(pentafluorophenyl)borate (2) to produce in situ the rac-ethylenebis(indenyl)methylzirconium cation (3). This aluminium-free catalyst showed propene polymerization activity (A) and stereoselectivity which both increase with the decrease of polymerization temperature (T_p). At very low T_p, 3 behaved as a “single-site” catalyst. An efficient way to produce such cation is to react ansa-zirconocene dichloride with 2 in the presence of TEA (=triethylaluminium). A superior cationic catalyst was obtained from rac-dimethylsilylenebis(1-η⁵-indenyl)dichlorozirconium, 2, and TEA, which polymerizes propene at −20°C(−55°C) with activity of 2×10⁹ (3×10⁸) g polypropene per (mol Zr η mol C₃H₆ η h) to polypropenes which are 93.8% (99.4%) isotactic with melting temperature T_m = 152.6°C (159.9°C) and viscosity-average molecular weight M_v = 1.4×10⁵ (2.2×10⁵). The addition of methylaluminoxane lowers the A of the cationic catalyst especially at low T_p. Rigorously speaking, the cation derived from 1 or 3 behaves as a “single site” catalyst only at very low T_p. The use of TEA significantly and unexpectedly enhances the efficiency of the zirconocenium catalyst system.     

Effective activation of metallocene catalysts with supported‐type Ph3CClO4 in ethylene polymerization

Supported type cocatalysts using triphenylcarbenium perchlorate (Ph₃CClO₄) were prepared by impregnation on inorganic carrier, magnesium chloride (MgCl₂) and applied to ethylene polymerizations with rac‐Et[Ind]₂ZrCl₂. Homogeneous polymerizations with Ph₃CClO₄ were also carried out for comparison. The activity of homogeneous polymerization was much lower than that obtained with methylaluminoxane (MAO). On the other hand, rac‐Et[Ind]₂ZrCl₂ activated by the supported type Ph₃CClO₄/MgCl₂ system displayed high activity comparable to that obtained with MAO. From the results of fractionation and polymerization of the rac‐Et[Ind]₂ZrCl₂‐Ph₃CClO₄/MgCl₂ catalyst system, it was found that the increased activity mainly came from the active species in the supernatant part. UV‐vis spectroscopic measurements combined with ICP analysis indicate that the active species in the supernatant fraction are composed of a stoichiometric amount of perchlorate and metallocene catalyst.