Magnesium chloride supported high mileage catalyst for olefin polymerization. VII. Determinations of concentrations of titanium–polymer and aluminum–polymer bonds

Two methods were used in an attempt to determine by radioquenching the active site concentration, [Ti*], in a MgCl₂ supported high activity catalyst. For the reactions of tritium labelled methanol, the kinetic isotope effects were first determined: k_H/k_T = 1.63 for the total polymer and 1.67 for the isotactic polypropylene fraction. Polymerizations were quenched with an excess of isotopic CH₃OH after various lengths of time, at different A/T (amount of AlEt₃ with 0.33 equivalent of methyl-p-toluate to amount of Ti in the catalyst) ratios, and temperatures. From the known specific activity of tritium in CH₃OH and radioassay of the polymer, value of the total metal polymer bond, [MPB], can be obtained. [MPB] increases linearly with polymerization time. Extrapolation to t = 0 gives [MPB]₀, which should be close to [Ti*] because chain transfer with aluminum alkyls to produce Al–P bonds is negligible during very early stage of the polymerization. The values of [MPB]₀ range from 7–30% of the total Ti; the number of MPB is nearly equally distributed in the amorphous and isotactic fractions of polypropylene in most runs. The rate of incorporation of radioactive CO into polymers produced by the MgCl₂ supported high mileage catalyst is far slower than that claimed by some investigators for TiCl₃ type catalysts. There is an initial rapid phase of incorporation of CO which lasts for about 1 hr of contact time. The subsequent rate of CO incorporation steadily declines, yet there is no constant maximum value of radioactivity even after 48 h of reaction in the absence of monomer. Radioquenching of polymerizations with CO was also performed at several temperatures and A/T ratios. In all cases, the maximum [Ti–P] was reached after 30–40 min of polymerization, whereas the maximum rates of polymerization, R_p,m, occurred within 3–10 min. In fact, the rate of polymerization decays to a small fraction of R_p,m after 30–40 min. Furthermore, this maximum value of [Ti–P] remains constant until the end of polymerization (t = 90 min). Therefore, isotopic CO is not reacting with the initially formed active sites Ti₁*, but only with those sites, Ti₂*, which predominate during the later stage of polymerization.     

Polymer-supported Ziegler–Natta catalyst for the polymerization of isoprene

A polymer-supported Ziegler–Natta catalyst, polystyrene-TiCl₄AlEt₂Cl (PS–TiCl₄AlEt₂Cl), was synthesized by reaction of polystyrene–TiCl₄ complex (PS–TiCl₄) with AlEt₂Cl. This catalyst showed the same, or lightly greater catalytic activity to the unsupported Ziegler–Natta catalyst for polymerization of isoprene. It also has much greater storability, and can be reused and regenerated. Its overall catalytic yield for isoprene polymerization is ca. 20 kg polyisoprene/gTi. The polymerization rate depends on catalyst titanium concentration, mole ratio of Al/Ti, monomer concentration, and temperature. The kinetic equation of this polymerization is: R_p = k[M]^0.30[Ti]^0.41[Al]^1.28, and the apparent activation energy ΔE_act = 14.5 kJ/Mol, and the frequency factor A_p = 33 L/(mol s). The mechanism of the isoprene polymerization catalyzed by the polymer-supported catalyst is also described. © 1993 John Wiley & Sons, Inc.     

Polymerization of α-piperidone with M–AlEt3, MAlEt4, or KAlEt3(piperidone) as catalysts and N-acetyl-α-piperidone as initiator

Low-temperature polymerization of α-piperidone was carried out by using MAlEt₄, KAlEt₃(piperidone), and M–AlEt₃ (where M is Li, Na, or K) as catalysts and N-acetyl-α-piperidone as initiator. The behavior in polymerization of these catalysts was superior to alkali metal or aluminum triethyl, and a polymer having an intrinsic viscosity of 0.8 dl./g. was obtained. Polymerization results and infrared analyses of the metal salts of lactams suggest that a complex, the structure of which was analogous to the one formed from M–AlEt₃, is formed in the case of the alkali metal piperidonate–ethyl aluminum dipiperidonate catalyst system and that it is changed to another complex having a different composition and lower catalytic activity by heat treatment. The infrared absorption band of the metal salts of lactams and of KAlEt₃(piperidone) at 1570–1590 cm.^?1, which is attributable to the C?N group in enolate form, may be considered to be related to the catalytic activities of alkali metals and the polymerizabilities of lactams. Such special catalysts as MAlEt₄, alkali metal–AlEt₃, or KAlEt₃(piperidone) are supposed to suppress the consumption, by alkali metal, of N-acyl-α-piperidone group of growing polymer end. A prolonged polymerization required for obtaining a high molecular weight polymer, even when such catalysts are used, is ascribable to a greater difficulty in re-forming lactam anion from α-piperidone, the basicity of which is higher than that of the other lactams.     

Kinetics and mechanism of acetylene polymerization

The kinetics of acetylene polymerization initiated by Ti(OBu)₄/4AlEt₃ catalyst was studied by radioquenching with C^*O to count the number of active sites [C] and by CH₃OT^* to determine the total metal polymer bonds [MPB] and M?_n of the polymer. The amount of quenching agent and time of reaction required and the kinetic isotope effect for CH₃OT^* were determined. The effects of Al/Ti ratio, catalyst aging, catalyst concentration, temperature, and monomer pressure on the polymerization were investigated. Detailed kinetic data on the variation of rate of polymerization, R_p, [C] [MPB], and M?_n with time were obtained at 298 and 195°K. The results required the assumption that the catalytic species C, is initially active and within less than 30 min all are converted by bimolecular kinetics to a far less active species. Analysis of the data yielded rate constants of propagation and termination and their energies of activation. Estimates of chain transfer efficiency were obtained. The mechanisms for the propagation, termination, and transfer processes were discussed. By drawing on our earlier EPR results we propose probable structures for the catalytically active species.     

Magnesium chloride supported high-mileage catalysts for olefin polymerizations. XVIII. Effect of hydrogen and lewis bases

Hydrogen has been found earlier to increase the initial rate of polymerization by MgCl₂/EB/PC/AlEt₃/TiCl₄-AlEt₃/MPT, CW-catalyst (+B_i, +B_e) (EB, ethyl benzoate; PC, p-cresol; MPT, methyl-p-toluate), but decays more rapidly as compared to polymerizations in the absence of H₂. In this study the effect of H₂ was studied when either the internal Lewis base, EB B_i, or the external Lewis base, MPT B_e, or both are deleted from the CW-catalyst. H₂ does not affect the stereospecificity of all the catalysts, but causes a slight increase of polymer yield, whereas the yield is virtually unchanged by H₂ for the catalysts activated with B_e. Unlike the catalyst (+B_i, +B_e) where H₂ increases active site concentrations [Ti^*] about threefold, it affects [Ti^*] negligibly when B_e is absent. The rate constants of propagation is about the same with or without H₂ for the CW-catalyst (+B_i, –B_e) or (–B_i, –B_e); the same statement can be said about the rate constant of chain transfer with AlEt₃ or with H₂. Hydrogen increases the rate of catalyst site deactivation for the various catalysts in the order of(+B_i, +B_e) > (–B_i, –B_e) > (+B_i, –B_e).     

Free-radical polymerizations initiated by triethylaluminum–cuprous chloride mixtures

Methyl methacrylate was polymerized by triethylaluminum—cuprous chloride catalyst. A study of the polymerization kinetics indicated that the overall rate was represented by the equation, R_p = K[AlEt₃] [CuCl]^½ [M]². The overall activation energy was 16.5 kcal/mole. From ESR measurement and the results of copolymerization of methyl methacrylate with styrene, it was suggested that the catalytic system has the character of a radical initiator. A polymerization scheme was also proposed.     

Magnesium chloride supported high mileage catalysts for olefin (decene-1) polymerization XV. Termination and energetics

Polymerizations of decene-1 were carried out from 0° to 70° at A/T = 167 and [M] = 0.75 M initiated by 0.17, 0.34, and 0.69 mM of Ti contained in the MgCl₂/ethylbenzoate/p-cresol/AlEt₃/TiCl₄-AlEt₃/methyl-p-toluate catalyst. The rate of polymerization is directly proportional to the catalyst concentration. About 12% of the Ti in the catalyst is initially active at 50°; they are 1.4%, 8.8%, and 9.4% at 0°, 25°, and 70°, respectively. The changes of R_p with temperature parallels the variations in the active site concentration. The decline of R_p with time has second-order plots with slopes which are inversely proportional to the catalyst concentration, but the rate constants for these deactivations are nearly the same for decene and propylene polymerizations. These results strongly support a mechanism of deactivation involving two adjacent sites in the catalyst particle surfaces. The rate constants of propagation and of chain transfer to AlEt₃, the energetics for these processes, and MW and MW distribution data have been obtained.     

Polymerization mechanism for in situ supported metallocene catalysts

The polymerization of ethylene was carried out with a novel in situ supported metallocene catalyst that eliminated the need for a supporting step before polymerization. In the absence of trimethyl aluminum (TMA), in situ supported Et[Ind]₂ZrCl₂ was not active, but the addition of TMA during polymerization activated the catalyst. Et[Ind]₂Zr(CH₃)₂ was active even in the absence of TMA, whereas the addition of TMA during polymerization enhanced the catalytic activity. The polymerization‐rate profiles of the in situ supported metallocene catalysts did not show rate decay as a function of time. A polymerization mechanism for the in situ supported metallocene catalysts is proposed for this behavior. During polymerization, the in situ supported metallocene catalysts may deactivate, but homogeneous metallocene species present in the reactor may form new active sites and compensate for deactivated sites. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 462–468, 2000     

The composition of catalysts prepared from tri-n-propylaluminum,anisole, and titanium tetrachloride

Catalysts were prepared from titanium tetrachloride and tri-n-propylaluminum or tri-n-propylaluminum anisole at [Al]/[Ti] molar ratios of 0.20–1.10. They were aged and filtered, and the solid and liquid portions were analyzed for aluminum, titanium, chlorine, and certain organic constituents. The analyses indicate that the solid of the nonetherate catalyst is predominantly TiCl₃, some AlCl₃ or aluminum alkyl chlorides being included. Only at [Al]/[Ti] = 1.10 was any alkyl group found in the solid. The same general results were found for the etherate catalyst, but the solid had a somewhat lower [Cl]/[Ti] ratio, indicating greater reduction or alkylation, or both, of the titanium species than in the nonetherate catalyst. The solid also contained some anisole at the higher [Al]/[Ti] ratios. The results lend general support to proposed reactions for the catalyst formation. The main differences in the etherate catalysts relative to the non-etherate system, particularly at the higher [Al]/[Ti] ratios, are the apparently greater reduction or alkylation of the titanium in the solids, the presence of anisole in the liquid and solid portions, and the presence of phenol in the liquid portion. The phenol presumably comes from cleavage of the anisole during the catalyst formation. Not all of the anisole has been accounted for in a materials balance, nor has all of the chlorine in the etherate catalysts. No propyl or isopropyl chloride was found in the catalysts; there is no significant amount of polypropylene in any of the catalyst solids. Hence the fate of the alkyl groups remains undetermined at present.     

Selective vinyl polymerization of 4-vinyl-1-cyclohexene with ziegler–natta catalyst

The polymerization of 4-vinyl-1-cyclohexene (4VCHE) with Ziegler–Natta catalysts was studied. The polymerization of 4VCHE by the vinyl group took place with TiCl₃–aluminum alkyls catalysts, while vinylene group of 4VCHE did not participate in the reaction, but it affected the polymerization rate of 4VCHE. The effects of aluminum alkyl and type of TiCl₃ on the polymerization were examined. The overall activation energy for the polymerization was estimated to be 41.9kJ/mol. Monomer-isomerization copolymerization of 4VCHE and trans-2-butene occurred with the TiCl₃-(i-C₄H₉)₃Al catalyst to give copolymers consisting of 4VCHE and 1-butene units.     

Kinetics of propylene polymerization in the initial acceleration stage

The kinetics of propylene polymerization catalyzed over a superactive and stereospecific catalyst for the initial build-up period was investigated in slurry-phase. The catalyst was prepared from Mg(OEt)₂/benzoyl chloride/TiCl₄ co-activated with AlEt₃ in the absence or presence of external donor. Despite a very fast activation of the prepared catalyst the acceleration stage of polymerization could be identified by the precise estimation of polymerization kinetics for a very short period of time after the commencement of polymerization (ca. 2 min). The initial polymerization rate, (dR_p/dt)₀ extrapolated to the beginning of the polymerization was second order with respect to monomer concentration. The dependence of initial polymerization rate on the concentration of AlEt₃ could be represented by Langmuir adsorption mechanism. The initial rate was maximum at about Al/Ti ratio of 20. The activation energy for the initiation reaction was estimated to be 14.3 kcal/mol for a short-time polymerization. The addition of a small amount of p-ethoxy ethyl benzoate (PEEB) as an external donor increased the percentage of isotactic polymer, which was obtained after 120 s of polymerization, to 98% and the initial polymerization rate decreased sharply as [PEEB]/[AlEt₃] increased. © 1994 John Wiley & Sons, Inc.     

Supported catalysts for stereospecific polymerization of propylene

Tetrabenzyltitanium (B₄Ti), tribenzyltitanium chloride (B₃TiCl), tetra(p-methylbenzyl)titanium (R₄Ti) and tri(p-methylbenzyl)titanium chloride (R₃TiCl) have been used as catalysts for ethylene and propylene polymerization activated by AlEt₂Cl. B₄Ti-AIEt₂Cl in solution polymerizes ethylene readily but its activity decays rapidly. B₄Ti was also supported on Cab-O-Sil, Alon C, and Mg(OH)Cl. The last support was found to give catalyst with longest lifetime with a rate of polymerization, R_p = 7.0 g/hr-mmole Ti-atm ethylene. ¹⁴CO counting techniques gave 1.13 × 10^?3 mole of propagating center per mole of B₄Ti; the rate constant of propagation, k_p = 540 l./mole-sec. None of the tetravalent titanium compounds polymerize propylene in solution. However, when supported on Mg(OH)Cl, Cab-O-Sil, Alon C, Cab-O-Ti, and charcoal, they all polymerize propylene. In this work the supports were characterized by various techniques, including the paramagnetic probe method, to determine the concentration and nature of surface hydroxyls. Those factors controlling the rate and stereospecificity of propylene polymerization were investigated. The system B₃TiCl–Mg(OH)Cl–AlEt₂Cl is the most active with R_p = 2.89 g/hr-mmole Ti-atm propylene. The concentration of propagation center is 0.9 × 10^?3 mole per mole of B₃TiCl; k_p = 32 l./mole-sec. This catalyst gave only about 70% stereoregular polymer. Diethyl ether is found to raise stereospecificity to 100%, but there is a concommittent tenfold decrease of activity. Other interesting catalyst systems are: (π-C₅H₅)TiMe₃–Mg(OH)Cl–AlEt₂Cl (1.56, 89.5); (π-C₅H₅)TiMe₂–Mg(OH)Cl–AlEt₂Cl (0.075, 94.5); and (π-C₅H₅)TiMe₃–Alon C–Al-Et₂Cl (0.08,97.2), where the first number in the parenthesis is R_p in g/mmole Ti-hr-atm and the second entry corresponds to percentage yield of stereoregular polypropylene. Hafnocene and titanocene supported on Mg(OH)Cl produce only oligomers of propylene.     

Magnesium chloride supported high mileage catalysts for olefin polymerization. XIII. Effect of external Lewis base on ethylene polymerization

The effect of external Lewis base (B_e) on the polymerization of ethylene by the MgCl₂/ethyl benzoate/p-cresol/AlEt₃/TiCl₄ catalyst was studied by activation with AlEt₃ alone without the use of methyl-p-toluate. The initially formed active site concentration, [Ti], is about doubled in the absence of B_e; at 50°C about 93% of the total titanium became catalytic. The same increment of [Ti] was observed without B_e. The rate constants of propagation are not appreciably affected by B_e; the values are the same at 50° with and without B_e. At other temperatures the k_p values are somewhat smaller without B_e. One major effect was the very large k values for chain transfer with aluminum alkyls in the absence of B_e as compared to those with B_e. This can be attributed to the greater monomeric AlEt₃ concentration in the former, but in much smaller amounts in the presence of B_e due to complexation. The rate constants of chain transfer with hydrogen are not much affected by B_e. However, the termination rate constants are generally much smaller when Lewis base is not present.     

Kinetics and mechanism of stereospecific polymerization of methyl methacrylate with VOCl3–AlEt2Cl catalyst system

Methyl methacrylate was polymerized at 40°C with VOCl₃–AlEt₂Cl catalyst system in n-hexane. The rate of polymerization was proportional to catalyst and monomer concentration at Al/V ratio of 2 and overall activation energy of 9.25 kcal/mole support a coordinate anionic mechanism of polymerization. The catalytic activity and stereospecificity of this catalyst system is discussed in comparison with that of VOCl₃–AlEt₃ catalyst system.     

Increase of the average reactivity of active species due to a shift to the more reactive species in ionic propagation accompanied by termination

The presented simulations demonstrate that in polymerizations proceeding on two kinds of species, differing in reactivity and being in equilibrium, the expected decrease of the rate of polymerization due to termination may happen to be compensated by the relative increase of concentration of the more reactive species. This takes place, for instance, in the polymerization proceeding simultaneously on ions and ion pairs if ions are more reactive. Because of termination the total concentration of ionic species during the course of polymerization decreases while the proportion of ions increases due to increasing dilution. The maximum compensation is observed when simultaneously k_(ions)/k_{(ion pairs)} → and K_d/[I]₀ → 0, where k are the propagation rate constants, K_d is the equilibrium constant of dissociation and [I]₀ is the starting concentration of initiator. Then, the degree of compensation (the ratio of the rate with compensation to the rate without termination) is becoming equal to ([P*]/[P*]₀)^1/2, where [P*] is the actual, total concentration of the growing species and [P*]₀ is the initial total concentration (before any termination has taken place).     

New coordination catalysts based on rare earth compounds for polymerization of 1-octene

The study of rare earth coordination catalysts for polymerization of 1-octene has been successfully carried out for the first time. Some features and kinetic behavior of polymerization of 1-octene by Nd(naph)₃–AIEt₃ catalyst system in tetrachloro-methane are described. The overall polymerization activation energy E_a measured was 74.5 kJ/mol and the rate equation could be expressed as R_p = k_p [Nd] [M] (k_p = 3.21 × 10^?3 L/mol s, at 50°C). The catalytic activity of various rare earth elements in Ln (naph)₃ and ligands in NdL₃ for the polymerization was compared. A 1-octene oligomer with double bonds was obtained. It is either a white or pale yellow waxy semi-solid. Its number-average molecular weight is about 10³ and the molecular weight distribution is less than 2.     

Polymerization of vinylcyclohexane with ziegler–natta catalyst

Polymerization of vinylcyclohexane (VCHA) with TiCl₃–aluminum alkyl catalysts was investigated. The polymerization rate of VCHA was low due to the branch at the position adjacent to the reacting double bond. The effects of aluminum alkyl on the polymerization and monomer-isomerization were observed; the polymer yield decreased in the following order: (CH₃)₃Al > (i–C₄H₉)₃Al > (C₂H₅)₃Al. Isomerization of VCHA was observed with the TiCl₃–(i–C₄H₉)₃Al and the TiCl₃–(C₂H₅)₃Al catalysts during the polymerization, while with the TiCl₃–(CH₃)₃Al catalyst such isomerization was not observed. Monomer-isomerization copolymerization of VCHA and trans-2-butene took place to give copolymers consisting of VCHA and 1-butene units.     

Magnesium chloride supported high-mileage catalysts for olefin polymerization. XVII. Effect of lewis base on propylene polymerization

A systematic study has been made on the functions of external Lewis base (B_e, methyl-p-toluate, MPT) and internal Lewis base (B_i, ethyl benzoate, EB) for the CW-catalyst system MgCI₂/EB/PC/AlEt₃/TiCl₄–AlEt₃/MPT (PC, p-cresol). B_i is a nonstereoselective modifier. It increases the active site concentrations and rate constants of propagation, k_p, of both the isospecific and nonspecific sites, and thus the productivities of the stereoregular and irregular polypropylenes by five- to tenfold. It seems that B_i complexes with the MgCl₂ support to lower the electronegativity of the surface Mg atoms. It also acts to lower the rate constant of chain transfer to aluminum alkyl, k, by two- to fourfold. The action of B_e is highly stereospecific. The isotacticity index of polypropylene is ? 95% in the presence of B_e but ? 68% without it. Addition of B_e decreases nonspecific [Ti^*]_a by about (11 ± 2)-fold; there is only about a twofold reduction of the isospecific [Ti^*]_i. It decreases k_p,a about three times but has no effect on k_p,i, so that the latter is (21 ± 4) times the former. B_e decreases k for transfer with aluminum alkyl much more than it does to k; but it does not affect the rates of chain transfer with monomer and by β-hydride elimination or the rate of catalyst deactivation. The number of active sites without B_e is [Ti^*]_i = 15% and [Ti^*]_a = 55% for a total of 70%. In the presence of B_e they are both about 6%. Optimum performance in propylene polymerizations requires both B_i and B_e in the case of the CW-catalyst.