Hydrogen as a chain terminator in continuous gas phase polymerization of propylene

The effects of hydrogen on both degree and rate of polymerization have been determined for continuous, gas phase polymerization of propylene at industrial reactor conditions. The effects of molecular weight using three modifications of TiCl₃–DEAC catalyst are correlated by Natta's equation, using number average molecular weights determined from polymer melt flow rate. The coefficients of Natta's equation, when correlated against temperature in Arhenius plots, imply that the most active catalyst is diffusion controlled because the activation energy is abnormally low. Hydrogen increases overall polymerization rate. Rate is correlated by modification to Natta's equation that accounts for hypothesized increase in active sites on catalyst surface due to adsorbed molecular hydrogen.     

1‐Hexene Polymerization over Supported Titanium–Magnesium Catalyst: The Effect of Composition of the Catalytic System and Polymerization Conditions on Temperature Dependence of the Polymerization Rate

The effect of temperature on the rate of 1‐hexene polymerization over supported titanium–magnesium catalyst of composition TiCl₄/D₁/MgCl₂ + AlR₃/D₂ (D₁ is dibutyl phthalate, D₂ is propyltrimethoxysilane, and AlR₃ is an organoaluminum cocatalyst) is studied. The unusual data that the polymer rate decreases when temperature is increased from 30 to 70 °C are obtained. The 1‐hexene polymerization rate and the pattern of changes in polymerization rate with temperature depend on a combination of factors such as cocatalyst (AlEt₃ or Al(i‐Bu)₃) and presence/absence of hydrogen and an external donor in the reaction mixture. These factors differ in their effects on catalytic activity at different polymerization temperatures, so the temperature coefficient (E_eff) values calculated using the Arrhenius dependence of the polymerization rate on polymerization temperature vary greatly. The “normal” Arrhenius plot where polymerization rate increases with temperature is observed only for polymerization with the Al(i‐Bu)₃ cocatalyst in the presence of hydrogen and without an external donor. Formation of high‐molecular‐weight polyhexene at low polymerization temperatures results in catalyst particle fragmentation, which may additionally contribute to the increase in polymerization rate as polymerization temperature is reduced.     

Radiation-induced homogeneous polymerization of ethylene in cyclohexane

The radiation-induced polymerization of ethylene in cyclohexane was carried out in a reactor of 100 ml capacity under a range of temperature of 25–150°C, dose rate of 4.1 × 10⁴–2.9 × 10⁵ rad/hr, pressure of 200 kg/cm², and amount of cyclohexane of 20–90 ml. The polymerization was found to proceed at a steady state from the beginning. The polymerization rate is maximum at ca. 50 ml of cyclohexane. The dose rate exponent of the polymerization rate was 0.6 at every temperature from 25 to 150°C. The polymer molecular weight is in the range of 10³–10⁴, independent of dose rate, and decreases with increasing amount of cyclohexane. The molecular weight distribution is unimodal and narrow. Kinetic analysis of these results indicates that the polymerization proceeds via a simple scheme of homogeneous polymerization and the polymer molecular weight was determined by the chain transfer reaction which takes place mostly with cyclohexane. The unimodal and narrow molecular weight distribution is also consistent with the homogeneous polymerization scheme.     

Stereospecific polymerization of benzyl vinyl ether by BF3·OEt2

Polymerization of benzyl vinyl ether was carried out by BF₃·OEt₂, and the effects of polymerization conditions on the stereoregularity of the polymer were studied by NMR analysis. The polymerization at ?78°C in toluene gave a highly isotactic polymer. The isotacticity of the polymer was independent of the catalyst concentration but increased with a decrease in the initial monomer concentration and decreased slightly on raising the reaction temperature. When the polymerizations were carried out in toluene—nitroethane mixtures, a gradual decrease in the isotacticity and a rapid decrease in the molecular weight of the polymer were observed with increasing nitroethane in the solvent. The molecular weight of the polymer was almost constant, regardless of the catalyst concentration, and increased with increasing initial monomer concentration and decreasing polymerization temperature. When the polymerization was performed in toluene at ?78°C with a small amount of water or benzyl alcohol, a linear relationship was found between the reciprocal DP of the polymer and water or benzylalcohol concentration. The mechanisms of the initiation reaction and the stereoregulation in the polymerization were also discussed.     

Oxidative polymerization of acrylamide in the presence of thioglycolic acid

Chemical polymerization of acrylamide at room temperature was examined by using thioglycolic acid-cerium (IV) sulfate and thioglycolic acid-KMnO₄ redox systems in acid aqueous medium. Water soluble polyacrylamides containing thioglycolic acid end groups were synthesized. The effects of the molar ratio of acrylamide to Ce(IV) n _AAm /n _Ce(IV) , the polymerization time, the temperature, the monomer concentration, the molar ratio of cerium (IV) sulfate to thioglycolic acid and the concentration of sulfuric acid on the yield and molecular weight of polymer were investigated. Lower molar ratios of acrylamide/Ce(IV) at constant monomer concentration resulted in an increase in the yield but a decrease in molecular weight of polymer. The increase of reaction temperature from 20 to 70°C resulted in a decrease in the yield but generally resulted in a constant value for the molecular weight of polymer. With increasing polymerization time, the yield and molecular weight of polymer did not change substantially. Ce(IV) and Mn(VII) ions are reduced to Ce(III) and Mn(II) ions respectively in the polymerization reaction. The existence of Ce(III) ion bound to polymer was investigated by UV-visible spectrophotometry and fluoresce measurements. The amount of Mn(II) incorporated into the polymer was determined using graphite furnace atomic absorption spectrometry. The mechanism of this phenomenon is discussed.     

Gas-phase polymerization of propylene: Reaction kinetics and molecular weight distribution

Gas-phase polymerizations have been executed at different temperatures, pressures, and hydrogen concentrations using Me₂Si[Ind]₂ZrCl₂ / methylaluminoxane / SiO₂(Pennsylvania Quarts) as a catalyst. The reaction rate curves have been described by a kinetic model, which takes into account the initially increasing polymerization rate. The monomer concentration in the polymer has been calculated with the Flory–Huggins equation. The kinetic parameters have been determined by fitting the reaction rate curves with the model. At high temperatures, pressures, and hydrogen concentrations a runaway on particle scale may occur leading to reduced polymer yields. The molecular weight and molecular weight distribution of the polymer samples could be described by a “two-site model.” At constant temperature the chain-transfer probability of sites 1 and 2 depends only on the hydrogen concentration divided by the monomer concentration. © 2001 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 500–513, 2001     

A discussion on the kinetic behavior of Ziegler–Natta ethylene polymerization at early moments of the reaction via modeling

The gas-phase ethylene polymerizations with SiO₂-supported Ziegler–Natta (ZN) catalyst at early moments of reaction is modeled. The experimental data used in this work show that at initial stages of the polymerization there is a sharp reduction in the reaction rate and a sharp rise in molecular weight. In the modeling, multi-active sites assumption and diffusion limitations inside the particle are studied. Energy balance to calculate the temperature at early moment is applied. Kinetic model including initiation, propagation, chain transfers and active site deactivation steps are used to predict the reaction rate and molecular weights. Polymeric flow model (PFM) is applied for single particle model (SPM). The results show two distinct regions. First region with sharp gradient for reaction rate and molecular weights and then, shortly there is a smooth region in which the changes in rate and molecular weights are slow. To fit this sharp gradient followed by a nearly steady state behavior two types of active sites are necessary. A group of highly active sites which deactivated soon and the active sites with lower activity and relatively long-lasting.     

Radiation-Induced Copolymerization of Thiophene with Maleic Anhydride

Radiation-induced copolymerization of thiophene with maleic anhydride has been studied. On the copolymerization in chloroform solution, the effects of dose rate, polymerization temperature, and, monomer composition and concentration on the yield and molecular weight of the copolymer were determined. The copolymerization proceeds via a radical mechanism with bimolecular termination of propagating polymer radicals, and the apparent activation energy is 5.3 kcal/mole. By NMR spectroscopy of copolymer, it was also found that these monomers copolymerize alternately to give a copolymer having structure I. In this copolymerization, the higher initial rates were obtained at an equimolar composition of monomers and by using solvents containing chlorine, such as CC1₄, CHC1₃, and C₆H₅C1.     

Polymerization of butadiene sulfone

Polymerization of butadiene sulfone (BdSO₂) by various catalysts was studied. Azobisisobutyronitrile (AIBN), butyllithium, tri-n-butylborn (n-Bu)₃B, boron trifluoride etherate, Ziegler catalyst, and γ-radiation were used as catalysts. Butadiene sulfone did not polymerize with these catalysts at low temperatures (below 60°C.), but polymers were obtained at high temperature with AIBN or (n-Bu)₃B. The polymerization of BdSO₂ initiated by AIBN in benzene at 80–140°C. was studied in detail. The obtained polymers were white, rubberlike materials and insoluble in organic solvents. The polymer composition was independent of monomer and initiator concentrations and reaction time. The sulfur content in polymer decreased with increasing polymerization temperature. The polymers prepared at 80 and 140°C. have the compositions (C₄H₆)_1.55- (SO₂) and (C₄H₆)_3.14(SO₂), respectively, and have double bonds. These polymers were not alternating copolymers of butadiene with sulfur dioxide. The polymerization mechanism was discussed from polymerization rate, polymer composition, and decomposition rate of BdSO₂. From these results, the polymerization was thought to be “decomposition polymerization,” i.e., butadiene and sulfur dioxide, formed by the thermal decomposition of BdSO₂, copolymerized.     

Radiation-induced polymerization of 1,1,2-trichlorobutadiene

The γ-ray-induced polymerization of 1,1,2-trichlorobutadiene, m.p. ?48.5°C., was investigated in the temperature range from +55 to ?196°C. In the liquid state, the following results were obtained: (1) the rate decreases with decrease of temperature (E_a = 8.0 kcal./mole); (2) the dose rate dependences of rate and of molecular weight are 0.49 and ?0.25, respectively; (3) the reaction is inhibited by DPPH; (4) the structure of the polymer is predominantly 1,4 units. It was concluded that the liquid-state polymerization proceeds by a radical mechanism, and the radical yield was found to be 19.7. In the solid state, the following results were obtained: (1) the rate is considerably higher than in the liquid state immediately above the melting point and gradually decreases with decrease of temperature (E_a = 0.34 kcal./mole); (2) the dependence of the rate on dose rate is unity while the molecular weight is independent of the dose rate; (3) the reaction rate is unaffected by DPPH and accelerated by dimethylformamide; (4) the structure of the polymer, 3,4 units, is completely different from that of the polymer obtained in the liquid-state polymerization. The solid-state polymerization is probably of a different nature and is not well elucidated.     

Stereospecific and molecular weight‐controlled polymerization of 1,3‐butadiene with Co(acac)3‐MAO catalyst

The polymerization of butadiene (Bd) with Co(acac)₃ in combination with methylaluminoxane (MAO) was investigated. The polymerization of Bd with Co(acac)₃‐MAO catalysts proceeded to give cis‐1,4 polymers (94 – 97%) bearing high molecular weights (40 × 10⁴) with relatively narrow molecular weight distributions (M_w's/M_n's). The molecular weight of the polymers increased linearly with the polymer yield, and the line passed through an original point. The polydispersities of the polymers kept almost constant during reaction time. This indicates that the microstructure and molecular weight of the polymers can be controlled in the polymerization of Bd with the Co(acac)₃‐MAO catalyst. The effects of reaction temperature, Bd concentration, and the MAO/Co molar ratio on the cis‐1,4 microstructure and high molecular weight polymer in the polymerization of Bd with Co(acac)₃‐MAO catalyst were observed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2793–2798, 2001     

Titanium (IV) chloride complexes with salen ligands supported on magnesium carrier: Synthesis and use in ethylene polymerization

The magnesium support with the formula MgCl₂(THF)_0.32(Et₂AlCl)_0.36 was used for immobilization of salen complexes of titanium [Ti(salen)Cl₂, Ti(salen(OMe)₂)Cl₂]. The effects of the catalyst composition (i.e. type of titanium complex and type of activator), polymerization temperature, polymerization time, and the effect of comonomer (1‐octene) on the activity of the obtained supported catalysts, on the polymer characteristics (molecular weight, molecular weight distribution, melting point), and on the polymer morphology were studied. The findings were compared to those obtained for corresponding unsupported systems. Catalysts immobilization results in considerable changes in catalysts activity and in properties of resultant polymers. The studied supported catalysts are highly active in ethylene polymerization, their activity increases with increasing temperature and lasts at least 2 hours. Their copolymerizing ability towards 1‐octene is rather low. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6693–6703, 2009     

ANIONIC POLYMERIZATION WITH COMPLEX BASE. I. POLYMERIZATION OF PHENYLISOCYANATE

In this work, phenylisocyanate was polymerized in bulk and in a solution of THF by the complex base (CB), NaNH₂/(CH₃)₃CONa catalyst under vacuum. The percent yield for bulk polymerization at ?20°C first increased with a slow rate reaching 32% conversion in 3 hours, then with a greater rate up to 86% in 6 hours. However, at 0°C the yields were relatively smaller and not very reproducible. The product obtained was a high molecular weight polymer, insoluble in most solvents, and partially crystalline. The polymerization in THF at ?20° gave 58% conversion in 9 hours with a high rate first, then a slower rate. The polymer samples were characterized by fractionation, FT-IR, DSC, NMR, TGA, and X-ray powder diffraction. The polymer samples in the solution polymerization contained trimer and oligomeric components. No glass transition temperature was observed at the temperature interval studied.     

Linear polybenzyls. III. Sterically assisted linear polymerization of 2,5-dimethylbenzyl chloride and α-methylbenzyl chloride

The low-temperature Friedel-Crafts step-growth polymerization reactions of 2,5-dimethylbenzyl chloride with TiCl₄—(C₂H₅)₂AlCl catalyst, and of α-methylbenzyl chloride with AlCl₃ catalyst were investigated for the effect of reaction conditions on polymer molecular weight, linearity, glass transition temperature, and crystalline properties. Premature precipitation of highly crystalline poly(2,5-dimethylbenzyl) prevented the preparation of high molecular weight products from this monomer, while most likely an indanyl-type termination reaction limited the molecular weight of poly(α-methylbenzyl). Model reactions indicated that, under proper conditions, the latter could be prepared with 99% para substitution, and these polymers were crystalline.     

“Nascent” Cu(0) nanoparticles‐mediated single electron transfer living radical polymerization of acrylonitrile at ambient temperature

Zn(0)/ppm concentrations of CuBr₂ from 10 to 50 ppm was firstly used to catalyze radical polymerization of acrylonitrile at ambient temperature. The polymerization displayed typical living radical polymerization (LRP) characteristics, as evidenced by pseudo first‐order kinetics of polymerization, linear increase of number‐average molecular weight, and low polydispersity index (PDI) value. Effects of solvent, copper concentration, and initiator concentration on the polymerization reaction and molecular weight as well as PDI were investigated in detail. EC excelled NMP, DMF, and DMSO in terms of rate of polymerization as well as control of molecular weight and PDI. The increase of the copper concentration from 2.5 to 50 ppm leads to a higher rate of polymerization and a better control over the polymerization reaction. ¹H NMR and GPC analyses as well as chain extension reaction confirmed the very high chain‐end functionality of the resultant polymer. © 2013 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Radiation-induced heterogeneous polymerization of ethylene in the presence of ethyl alcohol

The radiation-induced heterogeneous polymerization of ethylene in ethyl alcohol was carried out in a reactor with a capacity of 100 ml under the following reaction conditions: temperature, 24 ± 3°C; pressure, 200–400 kg/cm²; amount of ethyl alcohol, 30–70 ml; dose rate, 3.7 × 10⁴?1.05 × 10⁵ rad hr. The effects of amount of ethyl alcohol, pressure, and dose rate on the rate of polymerization at the steady state, the amount of polymerized monomer, the molecular weight of polymer, and the number of polymer chains were studied compared with the results obtained in the polymerization in tert-butyl alcohol. It was found that there is an acceleration period in the early stage of reaction followed by a steady state. The rate of polymerization was maximum when about 50 ml of ethyl alcohol was used. The molecular weight of polymer increased with a decrease in the amount of ethyl alcohol. The dependences of pressure (p) and dose rate (I) on the rate of polymerization at steady state (R_s) and the molecular weight of polymer (M?_n) were expressed as follows; R_s ∝ p^0.74, M?_n ∝ p^0.3?0.4, R_s ∝ I^0.9 and M?_n ∝ I^{?0.1 ?0.0}. The results were analyzed by a kinetic treatment based on a reaction mechanism containing both first-and second-order terminations. The rate constant of first-order termination by radical occlusion was considerably larger than that in the polymerization in tert-butyl alcohol, because the affinity of ethyl alcohol for polyethylene is smaller than that of tert-butyl alcohol. It was found that chain transfer to ethyl alcohol takes place easily and the G value of ethyl alcohol for initiation is larger than 1.5.     

Kinetics of ethylene polymerization in the presence of a homogeneous catalyst based on a bis(phenoxyimine) complex of zirconium(IV)

Changes in the molecular-weight characteristics of the product of ethylene polymerization in the course of reaction in the presence of a homogeneous catalytic system and in the number and reactivity of catalyst active sites were studied. The catalytic system consisted of bis[N-(3-tert-butylsalicylidene)anilinato]zirconium dichloride and methylalumoxane as an activator. This catalytic system exhibited the signs of unsteady-state conditions: the rate of polymerization dramatically decreased as the reaction time increased. At the onset of polymerization (to 5 min), the catalyst was single-site, and it produced low-molecular-weight polyethylene with M _w = (4–10) × 10³ g/mol. The fraction of active sites at the initial point in time was as high as 11% based on the initial amount of the zirconium complex. The reactivity of these centers was very high (the rate constant of polymer chain growth was 5.4 × 10⁴ l mol⁻¹ s⁻¹ at 35°C). As the polymerization time increased, the number of active sites decreased and the molecular-weight distribution of polyethylene broadened because of the decay of a portion of initial centers and the formation of new centers that produced high-molecular-weight polyethylene with M _w to 130 × 10⁴ g/mol. The propagation rate constant measured at a sufficiently long polymerization time (20 min) was lower than that at the initial point in time; this fact suggests the much lower reactivity of the new active sites.     

Molecular weight distribution studies. I. Radiation-induced polymerization of liquid α-methylstyrene

The concentration of water in purified and BaO-dried α-methylstyrene was found to be 1.1 × 10^?4M. The radiation-induced bulk polymerization of the α-methylstyrene thus prepared was studied in the temperature range of ?20°C to 35°C. The polymerization rate varied as the 0.55 power of the dose rate. The theoretical molecular weights and molecular weight distribution were calculated from a proposed kinetic scheme and these values were then compared with those found experimentally. The agreement between these two was reasonably close, and therefore it was concluded that, from the molecular weight distribution point of view, the proposed kinetic scheme for the cationic polymerization of α-methylstyrene is an acceptable one. The rate constant for chain transfer to monomer k_f changed with temperature and was found to be responsible for the decrease in the molecular weight of the polymer with increase in temperature. k_f and k_p at 20°C were found to be 0.95 × 10⁴ l./mole-sec and 0.99 × 10⁶ l./mole-sec, respectively.     

Ethylene polymerization and ethylene/hexene copolymerization with vanadium(III) catalysts bearing heteroatom‐containing salicylaldiminato ligands

A series of novel vanadium(III) complexes bearing heteroatom‐containing group‐substituted salicylaldiminato ligands [RN?CH(ArO)]VCl₂(THF)₂ (Ar = C₆H₄, R = C₃H₂NS, 2a ; C₇H₄NS, 2c ; C₇H₅N₂, 2d ; Ar = C₆H₂tBu₂ (2,4), R = C₃H₂NS, 2b ) have been synthesized and characterized. Structure of complex 2c was further confirmed by X‐ray crystallographic analysis. The complexes were investigated as the catalysts for ethylene polymerization in the presence of Et₂AlCl. Complexes 2a–d exhibited high catalytic activities (up to 22.8 kg polyethylene/mmol_V h bar), and affording polymer with unimodal molecular weight distributions at 25–70 °C in the first 5‐min polymerization, whereas produced bimodal molecular weight distribution polymers at 70 °C when polymerization time prolonged to 30 min. The catalyst structure plays an important role in controlling the molecular weight and molecular weight distribution of the resultant polymers produced in 30 min polymerization. In addition, ethylene/hexene copolymerizations with catalysts 2a–d were also explored in the presence of Et₂AlCl, which leads to the high molecular weight and unimodal distributions copolymers with high comonomer incorporation. Catalytic activity, comonomer incorporation, and polymer molecular weight can be controlled over a wide range by the variation of catalyst structure and the reaction parameters, such as comonomer feed concentration, polymerization time, and polymerization reaction temperature. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3573–3582, 2009     

Ethylene polymerization and ethylene/hexene copolymerizaion with vandium catalysts bearing thiophenolphosphine ligands

Vanadium(Ⅲ) complexes bearing thiophenol-phosphine ligands (2a-2b) (2-R-6-PPh2-C6H2S) VCl2(THF)2 (2a: R=H; 2b: R=Me3Si) were prepared from VCl3(THF)3 by treating with 1.0 equiv of the ligand in tetrahydrofuran in the presence of excess triethylamine. The two complexes were characterized by FTIR and mass spectra as well as elemental analyses. On activation with Et2AlCl, these complexes exhibited high catalytic activities (up to 22.1 kg PE/(mmolV·h·bar)) even at high temperature (70℃), and produced high molecular weight polymers with unimodal molecular weight distributions, indicating the polymerization took place in a single-site nature. This result may be attributed to benefits of introduction of second-row donor atoms for adjusting charge density of the vanadium centers. In addition, these complexes also exhibited high catalytic activities for ethylene/1-hexene copolymerization. Catalytic activity, comonomer incorporation and polymer molecular weight can be controlled in a wide range by the variation of catalyst structure and the reaction parameters such as Al/V molar ratio, comonomer feed concentration and polymerization reaction temperature.