Highly active MgCl2‐supported catalysts containing novel diether donors for propene polymerization

A new generation of MgCl₂‐supported catalysts for the polymerization of propene without any external donors was prepared. Two diethers, 9,9‐bis(methoxymethyl)fluorene (for Cat‐A) and 2,2‐dipropyl‐1,3‐dimethoxypropane (for Cat‐B) differing in the bulkiness of alkyl substituents in position 2, have been used as internal donors in MgCl₂/TiCl₄/diether‐AlR₃ catalysts. The weight‐average molecular weights produced with both catalysts were over 3.5×10⁵ at low temperature in slurry polymerization (< 40°C). Cat‐A showed higher activity and produced higher isotactic polypropene than Cat‐B. The activity of both catalysts proved to be dependent on the temperature.     

Direct observation of MgCl2‐supported Ziegler catalysts by high resolution transmission electron microscopy

The surface atomic structure of MgCl₂ crystalline particles and MgCl₂‐supported Ziegler catalysts was observed by means of high resolution transmission electron microscopy. Step‐terrace surface structures, characteristic of the structure of the MgCl₂ crystal, are found in the observed images of MgCl₂ particles. The observation of the structure of MgCl₂‐supported Ziegler catalysts shows that the MgCl₂ crystals are severely deformed by the processes of catalyst preparation. Due to the preparation procedure used the structure of the catalyst changes from crystalline to amorphous.     

The discovery and progress of MgCl2‐supported TiCl4 catalysts

Polyolefins represented by polyethylene (PE) and polypropylene (PP) are indispensable materials in our daily lives. TiCl₃ catalysts, established by Ziegler and Natta in the 1950s, led to the births of the polyolefin industries. However, the activities and stereospecificities of the TiCl₃ catalysts were so low that steps for removing catalyst residues and low stereoregular PP were needed in the production of PE and PP. Our discovery of MgCl₂‐supported TiCl₄ catalysts led to more than 100 times higher activities and extremely high stereospecificities, which enabled us to dispense with the steps for the removals, meaning the process innovation. Furthermore, they narrowed the molecular weight and composition distributions of PE and PP, enabling us to control the polymer structures precisely and create such new products as very low density PE or heat‐sealable film at low temperature. The typical example of the product innovations by the combination of the high stereospecificity and the narrowed composition distribution is high‐performance impact copolymer used for an automobile bumper that used to be made of metal. These process and product innovations established these polyolefin industries. The latest MgCl₂‐supported TiCl₄ catalyst is very close to perfect control of isotactic PP structure and is expected to bring about further innovations. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1–8, 2004     

Recent advances in propylene polymerization with MgCl2 supported catalysts

The role of Lewis bases in MgCl₂ supported catalysts for olefin polymerization is a subject of continuous interest and discussion in order to obtain more and more active and stereospecific catalysts and to explain their stereoregulating mechanism. Through molecular calculation and conformational analysis it was possible to identify chelating diethers that have the correct oxygen-oxygen distance necessary to tightly coordinate with the Mg ions of the support, even in the presence of other strong Lewis acids, and unable to give secondary reactions with TiCl₄, AlR₃, Ti-C and Ti-H bonds. The use of these donors has allowed the synthesis of catalytic systems that are both highly active and stereospecific even in the absence of external donors. Kinetic data of propylene polymerization with these catalyst systems are reported. The importance of the distance between the donor atoms in bifunctional Lewis bases has been proved also in the case of new classes of internal donors. Molecular modelling studies have enabled us to formulate models of active sites, located on some corners of MgCl₂ crystallites, whose chirality is induced by the presence of a donor molecule in their environment. These models could explain, at least in part, the exceptional increase of isotactic polymer productivity observed for stereospecific catalyst systems, containing only the internal donor, with respect to catalysts lacking the Lewis base and could account for the influence of the donor on the molecular properties of the obtained polymers.     

Active center determinations on MgCl2‐supported fourth‐ and fifth‐generation Ziegler–Natta catalysts for propylene polymerization

Active center determinations on different Ziegler–Natta polypropylene catalysts, comprising MgCl₂, TiCl₄, and either a diether or a phthalate ester as internal donor, have been carried out by quenching propylene polymerization with tritiated ethanol, followed by radiochemical analysis of the resulting polymers. The purpose of this study was to determine the factors contributing to the high activities of the catalyst system MgCl₂/TiCl₄/diether—AlEt₃. Active center contents (C*) in the range 2–8% (of total Ti present) were measured and a strong correlation between catalyst activity and active center content was found, indicating that the high activity of the diether‐containing catalysts is due to an increased proportion of active centers rather than to a difference in propagation rate coefficients. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1635–1647, 2006     

Highly active MgCl2‐supported CpMCl3 (M = Ti,Zr) catalysts for ethylene polymerization

Monocyclopentadienyl compounds, CpMCl₃ (M = Ti, Zr) supported on activated MgCl₂ were used for the polymerizations of ethylene in the presence of methylaluminoxane (MAO) or a common alkylaluminium as a cocatalyst. By supporting CpMCl₃ on MgCl₂, the catalyst activity was increased drastically to show high activity similar to MgCl₂‐supported TiCl₄ catalysts. The activity of the CpZrCl₃ /MgCl₂ catalyst was higher than that of the CpTiCl₃/MgCl₂ one. Both catalysts gave polymers with high molecular weight (M_w) and broad molecular weight distribution (M_w/M_n) in comparison with the corresponding soluble half‐metallocene catalysts.     

Detitanation of MgCl2‐supported Ziegler‐Natta catalysts for the study of active sites organization

Thermal treatments under vacuum of conventional supported Ziegler‐Natta precatalysts (MgCl₂/TiCl₄/Dibutylphthalate) were conducted to gradually remove titanium to modify the active sites distribution. Only limited detitanations of precatalysts were achieved paying attention not to chemically alter the internal donor (T < 150 °C). Used in combination with the required cocatalyst and external donor in the propylene slurry polymerization, the modified precatalysts exhibited a drop of activity versus decreasing titanium content but the distributed polymer properties are almost not affected (a slight narrowing of molecular weight distribution was observed). After a titanium chloride secondary impregnation (possibly done in presence of an additional Lewis base), activity resumed but polymer properties are once again unchanged. These findings highlight the difficulty to separate the different families of active sites and lead us to propose a cluster organization of titanium active sites. Active sites are composed of titanium clusters having a size distribution at the precatalyst surface, possessing a critical operating size and operating collectively in polymerization. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5461–5470, 2008     

Superactive and stereospecific catalysts. IV. Influence of structure of esters on MgCl2 supported olefin polymerization catalysts

CH-type catalysts were prepared by reacting MgCl₂ · ROH, where ROH is 2-ethyl hexanol (EH), (R)-2-octanol (R-20), and (S)-2-octanol (S-20), with TiCl₄ in the presence of di-i-butyl phthalate (BP), di-i-butyl terephthalate (BT), (-)-dimenthyl phthalate (MP), or (-)-dimenthyl terephthalate (MT). The MT catalysts were found to incorporate 8.9 to 13% Ti whereas the BP catalysts contain only 1.9 to 2.6% Ti. Comparison of the CH(EH, BP) and CH(EH, MT) catalysts showed that they have about equal number of isospecific active sites per gram of catalyst and the same rate constants of propagation for their nonspecific sites, however, the isospecific sites in the latter are less active by comparison. Consequently, the CH(EH, BP) catalysts is five times more active than the CH(EH, MT) catalysts and produces polypropylene which is 97% isotactic (reflux n-heptane insoluble) as compared to 84.7% for the latter. The catalysts derived from 2-octanols are much less active than the corresponding catalysts prepared with 2-ethyl hexanol due to lack of reactivity with phthalic anhydride which permits excessive incorporation of TiCl₄ to form nonstereospecific catalytic sites as well as inactive Ti species.     

The role of dormant sites in propene polymerization using methylalumoxane activated metallocene catalysts

Propene polymerization of methylalumoxane (MAO) activated rac-Me₂Si(Benz[e]Indenyl)₂ZrCl₂ ( BI ) and rac-Me₂Si(2-Me-Benz[e]Indenyl)₂ZrCl₂ ( MBI ) was studied to investigate the influence of the ligand substitution pattern and the role of dormant sites. Poly(propene) end group composition as well as regio- and stereoirregularities were examined by means of ¹H- and ¹³C-NMR spectroscopy. Dormant sites, resulting from 2, 1-propene insertion, were reactivated either by β-hydrogen transfer to propene, yielding 2-butenyl end groups, or by 1, 2-insertion of propene, yielding regioirregularities. Propene polymerization in the presence of hydrogen gave n-butyl end groups and less regioirregularities as expected for hydrogenolysis of such dormant sites. Methyl substitution in 2-position of the benz[e]indenyl ligand suppressed β-hydrogen transfer to propene, and increased molecular weight with increasing propene concentration. Also, activation energy increased from 30 kJ/mol ( BI /MAO) to 59 kJ/mol ( MBI /MAO). For both catalysts activity depended on propene concentration. The order of reaction relative to propene was 1.7.     

Unusual temperature effects in propene polymerization using stereorigid zirconocene catalysts.

Free Car-Parrinello molecular dynamics (CPMD) simulations of four diastereomers of the zirconium-propene complexes [{iPr(3-iPr-CpFlu)}ZriBu(C3H6)]+ (Cp=cyclopentadienyl; Flu=fluorenyl) provide valuable insight into the mechanism and stereocontrol of propene polymerization with stereorigid metallocenes. Spontaneous insertion of propene into the zirconium-isobutyl bond is not observed, and propene is found to be weakly bound and to rotate relatively freely around the C--C bond to be formed. Large-amplitude rotation of the isopropyl substituent around the Cp--iPr bond may play a role in triggering dissociation of propene. Three of the four diastereomers eliminate propene during the course of the simulations, which makes dissociation the dominating event on a 20-ps timescale. The CPMD simulations thus support the validity of the assumption, fundamental to statistical propagation models, that each insertion is independent of the preceding insertions. Using insertion barriers from static density functional calculations, the statistical model predicts the polypropene microstructure in good agreement with experiment at low polymerization temperatures for the catalysts {iPr(3-R-CpFlu)}ZrCl2 (R=H, iPr, tBu). The predictions become less accurate at higher temperatures, probably due to the onset of the competing back-skip reaction, which is not included in the model.     

Polymer‐supported half‐titanocene catalysts for the syndiospecific polymerization of styrene

Monocyclopendienyltitanium trichloride (CpTiCl₃) was supported on polymer carriers with different hydroxyl contents, and the supported catalysts were used for styrene polymerization. The supported catalysts exhibited high activity even at low Al/Ti ratios and increased the molecular weight of the products, indicating that polymer carriers could stabilize the active sites. The polymers prepared with unsupported and supported catalysts were extracted with boiling n‐butanone and characterized by carbon nuclear magnetic resonance (¹³C NMR) and differential scanning calorimetry. The polymers obtained by supported catalysts had a high fraction of boiling n‐butanone‐insoluble part and high melting temperatures, but ¹³C NMR results showed that syndiotacticity decreased compared with that of polymers prepared with an unsupported catalyst. ESR study on the supported catalysts confirmed that the active sites supported on the carrier dropped into the solution and formed active sites the same as those in the unsupported system when they reacted with methylaluminoxane. ¹³C NMR analysis showed that the polymerization mechanism of the supported active sites was an active‐site controlled mechanism instead of a chain‐end controlled mechanism of the unsupported active sites. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 127–135, 2000