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     

Kinetic features of ethylene polymerization over supported catalysts [2,6‐bis(imino)pyridyl iron dichloride/magnesium dichloride] with AlR3 as an activator

The effects of polymerization temperature, polymerization time, ethylene and hydrogen concentration, and effect of comonomers (hexene‐1, propylene) on the activity of supported catalyst of composition LFeCl₂/MgCl₂‐Al(i‐Bu)₃ (L = 2,6‐bis[1‐(2,6‐dimethylphenylimino)ethyl] pyridyl) and polymer characteristics (molecular weight (MW), molecular‐weight distribution (MWD), molecular structure) have been studied. Effective activation energy of ethylene polymerization over LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a value typical of supported Ziegler–Natta catalysts (11.9 kcal/mol). The polymerization reaction is of the first order with respect to monomer at the ethylene concentration >0.2 mol/L. Addition of small amounts of hydrogen (9–17%) significantly increases the activity; however, further increase in hydrogen concentration decreases the activity. The IRS and DSC analysis of PE indicates that catalyst LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a very low copolymerizing ability toward propylene and hexene‐1. MW and MWD of PE produced over these catalysts depend on the polymerization time, ethylene and hexene‐1 concentration. The activation effect of hydrogen and other kinetic features of ethylene polymerization over supported catalysts based on the Fe (II) complexes are discussed. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 5057–5066, 2007     

Synthesis of polypropylene graft copolymers by the combination of a polypropylene copolymer containing pendant vinylbenzene groups and atom transfer radical polymerization

This article discusses a facile and inexpensive reaction process for preparing polypropylene‐based graft copolymers containing an isotactic polypropylene (i‐PP) main chain and several functional polymer side chains. The chemistry involves an i‐PP polymer precursor containing several pendant vinylbenzene groups, which is prepared through the Ziegler–Natta copolymerization of propylene and 1,4‐divinylbenzene mediated by an isospecific MgCl₂‐supported TiCl₄ catalyst. The selective monoenchainment of 1,4‐divinylbenzene comonomers results in pendant vinylbenzene groups quantitatively transformed into benzyl halides by hydrochlorination. In the presence of CuCl/pentamethyldiethylenetriamine, the in situ formed, multifunctional, polymeric atom transfer radical polymerization initiators carry out graft‐from polymerization through controlled radical polymerization. Some i‐PP‐based graft copolymers, including poly(propylene‐g‐methyl methacrylate) and poly(propylene‐g‐styrene), have been prepared with controlled compositions. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 429–437, 2005     

Multicenter nature of titanium‐based Ziegler–Natta catalysts: Comparison of ethylene and propylene polymerization reactions

This article discusses the similarities and differences between active centers in propylene and ethylene polymerization reactions over the same Ti‐based catalysts. These correlations were examined by comparing the polymerization kinetics of both monomers over two different Ti‐based catalyst systems, δ‐TiCl₃‐AlEt₃ and TiCl₄/DBP/MgCl₂‐AlEt₃/PhSi(OEt)₃, by comparing the molecular weight distributions of respective polymers, in consecutive ethylene/propylene and propylene/ethylene homopolymerization reactions, and by examining the IR spectra of “impact‐resistant” polypropylene (a mixture of isotactic polypropylene and an ethylene/propylene copolymer). The results of these experiments indicated that Ti‐based catalysts contain two families of active centers. The centers of the first family, which are relatively unstable kinetically, are capable of polymerizing and copolymerizing all olefins. This family includes from four to six populations of centers that differ in their stereospecificity, average molecular weights of polymer molecules they produce, and in the values of reactivity ratios in olefin copolymerization reactions. The centers of the second family (two populations of centers) efficiently polymerize only ethylene. They do not homopolymerize α‐olefins and, if used in ethylene/α‐olefin copolymerization reactions, incorporate α‐olefin molecules very poorly. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 1745–1758, 2003     

Isotactic Poly(propylene)/Monoalkylimidazolium‐Modified Montmorillonite Nanocomposites: Preparation by Intercalative Polymerization and Thermal Stability Study

Summary: Poly(propylene)/monoalkylimidazolium‐modified montmorillonite (PP/IMMT) nanocomposites were prepared by in situ intercalative polymerization of propylene with TiCl₄/MgCl₂/MMT catalyst. The PP synthesized possessed high isotacticity and molecular weight. Both wide‐angle X‐ray diffraction (XRD) and transmission electron microscopy (TEM) examinations evidenced the nanocomposite formation with exfoliated MMT homogeneously distributed in the PP matrix. A thermal stability study revealed that the nanocomposites possess good thermal stability.

X‐ray diffraction patterns of PP/IMMT (MMT = 2.2 wt.‐%) nanocomposite before and after processing.     

Development of novel MgCl2 supported catalyst with trivalent titanocene complex of CP2TiCl2AlCl2 for propylene polymerization

Three kinds of MgCl₂‐supported trivalent titanocene catalyst (Cat. 1: Cp₂TiCl₂AlCl₂/MgCl₂, Cat. 2: CpCp*TiCl/MgCl₂, Cat. 3: Cp₂TiCl/MgCl₂) were prepared and tested for propylene polymerization. It was found that Cat. 1, combined with ordinary alkylaluminum as cocatalyst, produced PP containing 31.8 wt % of isotactic PP in fairly good yield. On the other hand, Cats. 2 and 3 hardly showed any activity. The effects of diisopropyldimethoxysilane (DIPDMS) on isospecificity of the Cat. 1 also were investigated. The isotactic index (I.I.) of PP was improved drastically by the addition of DIPDMS as external donor and reached the value as high as 98.4%, even in the absence of any internal donors. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3355–3359, 2000     

Supported titanium‐magnesium catalysts for ethylene polymerization: A comparative study of catalysts containing isolated and clustered titanium ions in different oxidation states

Supported titanium–magnesium catalysts (TMC) comprising isolated and clustered titanium ions in different oxidation states, which are obtained using titanium compounds of different composition (TiCl₄, TiCl₃?nDBE (DBE – dibutyl ether), [η⁶–BenzeneTiAl₂Cl₈]), were synthesized and tested in ethylene polymerization. The state of titanium ions was studied by the ESR method both for the procatalysts and after their interaction with triisobutilaluminum. For identification of ESR‐silent Ti³⁺ ions and Ti²⁺ ions, special procedures of additional catalyst treatment with pyridine, water, and chloropentafluorobenzene were used to obtain Ti³⁺ ions that are observable in ESR spectra. In distinction to numerous earlier works performed with the TiCl₄/MgCl₂ catalyst comprising after the interaction with AlR₃ the Ti³⁺ surface compounds both as isolated ions and clusters (ESR‐silent), this work considers the [η⁶–BenzeneTiAl₂Cl₈]/MgCl₂ catalyst (TMC‐3) comprising mainly the isolated Ti²⁺ ions and a new catalyst TMC‐4 obtained by treating the TMC‐3 with chloropentafluorobenzene. This catalyst comprises only the isolated Ti³⁺ ions both before and after the interaction with triisobutylaluminum. It was shown that in spite of sharp distinctions between the catalysts under consideration concerning titanium oxidation state and the ratio of isolated Ti³⁺ ions to clustered ones, all these catalysts produce polyethylenes with similar molecular weights and molecular‐weight distributions. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6362–6372, 2009     

A new route to atactic polypropylene: The second life of premetallocene homogeneous polymerization catalyst

Amorphous atactic polypropylene (PP) with an average molecular weight of 50,000–100,000 is produced by polymerizing propylene with a ternary Ti(Oiso‐Pr)₄ ‐ AlEt₂Cl/MgBu₂ catalyst at 30–50 °С. Main advantages of this catalyst compared with other catalysts capable of nearly exclusively producing atactic PP (such as some heterogeneous Ziegler‐Natta, metallocene and postmetallocene catalysts) are high activity, low cost and the ease of use: the catalyst is prepared in situ from three commercially available compounds readily soluble in aliphatic and aromatic hydrocarbons. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2124–2131     

Propylene polymerization with catalysts containing divalent titanium

The behavior in propylene polymerization of divalent titanium compounds of type [η⁶-areneTiAl₂Cl₈], both as such and supported on activated MgCl₂, has been studied and compared to that of the simple catalyst MgCl₂/TiCl₄. Triethylaluminium was used as cocatalyst. The Ti–arene complexes were active both in the presence and in the absence of hydrogen, in contrast to earlier reports that divalent titanium species are active for ethylene but not for propylene polymerization. ¹³C-NMR analysis of low molecular weight polymer fractions indicated that the hydrogen activation effect observed for the MgCl₂-supported catalysts should be ascribed to reactivation of 2,1-inserted (“dormant”) sites via chain transfer, rather than to (re)generation of active trivalent Ti via oxidative addition of hydrogen to divalent species. Decay in activity during polymerization was observed with both catalysts, indicating that for MgCl₂/TiCl₄ catalysts decay is not necessarily due to overreduction of Ti to the divalent state during polymerization. In ethylene polymerization both catalysts exhibited an acceleration rather than a decay profile. It is suggested that the observed decay in activity during propylene polymerization may be due to the formation of clustered species that are too hindered for propylene but that allow ethylene polymerization. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 2645–2652, 1997     

Supported titanium-magnesium catalysts for propylene polymerization

The results of studies of the synthesis and properties of supported titanium-magnesium catalysts for propylene polymerization performed at the Boreskov Institute of Catalysis, Siberian Branch, Russian Academy of Sciences, are considered. The composition of the catalysts is TiCl₄/D₁/MgCl₂-AlEt₃/D₂, where D₁ and D₂ are stereoregulating donors. With the use of the procedure proposed for the synthesis of titanium-magnesium catalysts, the morphology of catalyst particles depends on the stage of the preparation of a Mg-containing support. The titanium-magnesium catalysts developed afforded polypropylene (PP) in a high yield; this PP was characterized by high isotacticity and excellent morphology. The controllable fragmentation of the catalyst by the polymer is of crucial importance for the retention of the morphology of titanium-magnesium catalyst particles in PP. The fragmentation of catalyst particles to microparticles occurred in the formation of more than 100 g of PP per gram of the catalyst. The surface complexes were studied by DRIFT and MAS NMR spectroscopy and chemical analysis. It was shown that the role of internal donors is to regulate the distribution of TiCl₄ on different MgCl₂ faces and, thereby, to influence the properties of PP. It was found that chlorine-containing complexes of aluminum compounds were formed on the catalyst surface by the interaction of the catalyst with AlEt₃; these complexes can block the major portion of titanium chloride. Data on the number of active sites and the rate constants of polymer chain propagation (k _p) at various sites indicate that donor D₁ increases the stereospecificity of the catalyst because of an increase in the fraction of highly stereospecific active sites, at which k _p is much higher than that at low-stereospecificity active sites. Donor D₂ enhances the role of D₁. Similar values of k _p at sites with the same stereospecificity in titanium-magnesium catalysts and TiCl₃ suggest that the role of the support mainly consists in an increase in the dispersity of titanium chloride.     

Synthesis of exfoliated isotactic polypropylene/functional alkyl-triphenylphosphonium-modified clay nanocomposites by in situ polymerization

Diphenyl (4-hydroxyphenyl) hexadecyl phosphonium bromide (POH) -modified montmorillonite (POHMMT) was used to prepare a novel TiCl₄/MgCl₂/POHMMT compound catalyst and exfoliated iPP/POHMMT nanocomposites were prepared by the in situ intercalative polymerization of propylene with the TiCl₄/MgCl₂/POHMMT compound catalyst. The POH surfactants don’t change the catalytic characteristic of the Z-N catalyst and the obtained PP presents high isotacticity, normal molecular weight and molecular weight distribution. The WAXD, SAXS and TEM results demonstrate the highly exfoliated iPP/POHMMT nanocomposites were produced by the in situ polymerization with this novel catalyst, while the intercalated iPP/Na⁺MMT nanocomposites were produced with the TiCl₄/MgCl₂/Na⁺MMT compound catalyst. Through this approach, in situ propylene polymerization can actually take place between the silicate layers and lead not only to PP with high isotacticity and molecular weight, but also to highly exfoliated PP nanocomposites.     

Vapor synthesis of high-activity catalysts for olefin polymerization

Vaporization of MgCl₂ and other metal halides results in monomeric gas-phase species. Cocondensation of these species with organic diluents such as heptane yields highly activated solids which are precursors to MgCl₂ supported “high-mileage” catalysts for olefin polymerization. These catalysts, prepared by treatment with TiCl₄ followed by standard activation with aluminum alkyls display high activity for ethylene and propylene polymerization. MgCl₂ can also be evaporated into neat TiCl₄ to give a related catalyst. The concentration of MgCl₂ in the diluent affects catalyst properties as does the nature of the diluent. TiCl₃, 3TiCl₃ · AlCl₃, VCl₃ and other metal halides are subject to similar activation.     

In‐Situ and Ex‐Situ Microscopic Study of Gas Phase Propylene Polymerization over a High Activity TiCl4‐MgCl2 Heterogeneous Ziegler‐Natta Catalyst

In‐situ gas phase poly(propylene) (PP) formation over a high activity TiCl₄‐MgCl₂‐supported Ziegler‐Natta catalyst has been studied by video microscopy combined with ex‐situ light microscopy, SEM, high‐resolution TEM, and STEM/PEELS/EDX for the first time. In‐situ observation revealed rapid formation of poly(propylene) beads 9–10 μm in size (< 1/30 s) as well as growth of significant amounts of polymer within local regions. Catalyst particles containing 2–5 nm‐sized MgCl₂ crystalline domains are subjected to transformations during catalysis that form PP/catalyst aggregated structures of 30–50 μm in size.     

Copolymerization of ethylene–1-Hexene over a thermally pretreated MgCl2/THF/TiCl4 bimetallic catalyst

MgCl₂/THF/TiCl₄ (TT-0) were thermally pretreated at 80°C for 5 min (TT-1) and 60 min (TT-2), and at 108°C for 5 min (TT-3) and 60 min (TT-4). These thermally pretreated catalysts showed comonomer enhancement effects in the ethylene-1-hexene copolymerization, while TT-0 catalyst did not. Comonomer enhancement effect of thermally pretreated catalysts could come from the generation of new active sites and change of its nature after heat treatment. 1-Hexene content in copolymer obtained with TT-1 was higher than those of TT-4 and TT-0. The morphology of homopolyethylene (PE) obtained with TT-1, 2, 3, and 4 was more regular and homogeneous than that of TT-0. This result could be due to the generation of active sites and change of its nature after thermal treatment of bimetallic catalyst. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 2769–2776, 1997     

Synthesis of polypropylene-co-p-methylstyrene copolymers by metallocene and Ziegler–Natta catalysts

This paper discusses the copolymerization reaction of propylene and p-methylstyrene (p-MS) via four of the best-known isospecific catalysts, including two homogeneous metallocene catalysts, namely, {SiMe₂[2-Me-4-Ph(Ind)]₂}ZrCl₂ and Et(Ind)₂ZrCl₂, and two heterogeneous Ziegler–Natta catalysts, namely, MgCl₂/TiCl₄/electron donor (ED)/AlEt₃ and TiCl₃. AA/Et₂AlCl. By comparing the experimental results, metallocene catalysts show no advantage over Ziegler–Natta catalysts. The combination of steric jamming during the consective insertion of 2,1-inserted p-MS and 1,2-inserted propylene (k₂₁ reaction) and the lack of p-MS homopolymerization (k₂₂ reaction) in the metallocene coordination mechanism drastically reduces catalyst activity and polymer molecular weight. On the other hand, the Ziegler–Natta heterogeneous catalyst proceeding with 1,2-specific insertion manner for both monomers shows no retardation because of the p-MS comonomer. Specifically, the supported MgCl₂/TiCl₄/ED/AlEt₃ catalyst, which contains an internal ED, produces copolymers with high molecular weight, high melting point, and no p-MS homopolymer. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2795–2802, 1999     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. II. Mechanism of the chain‐transfer reaction

Hydrogen is a very effective chain‐transfer agent in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts. However, measurements of the hydrogen concentration effect on the molecular weight of polypropylene prepared with a supported TiCl₄/dibutyl phthalate/MgCl₂ catalyst show a peculiar effect: hydrogen efficiency in the chain transfer significantly decreases with concentration, and at very high concentrations, hydrogen no longer affects the molecular weight of polypropylene. A detailed analysis of kinetic features of chain‐transfer reactions for different types of active centers in the catalyst suggests that chain transfer with hydrogen is not merely the hydrogenolysis reaction of the Ti? C bond in an active center but proceeds with the participation of a coordinated propylene molecule. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1899–1911, 2002     

Polymerization of olefins catalyzed by a dichloride complex of titanium with a dioxolane dicarbonate ligand: The promoting effect of LiCl and MgCl2

The polymerizations of propylene and ethylene with two postmetallocene catalysts [(4R,5R)-2,2-dimethyl-α,α,α′,α′-tetra(perfluorophenyl)-1,3-dioxolane-4,5-dimethanol]TiCl₂ · MgCl₂ and [(4R,5R)-2,2-dimethyl-α,α,α′,α′-tetra-(perfluorophenyl-1,3-dioxolane-4,5-dimethanol]TiCl₂· (LiCl)₂ are studied. The first catalyst shows higher activity in both reactions and forms a lower molecular mass PP. This PP is characterized by a wide molecular-mass distribution that can be described by a set of five or six Flory components with different average molecular masses. Along with heterogeneity with respect to kinetic parameters, there is heterogeneity with respect to stereospecificity. Some of the sites form a high-molecular-mass highly isotactic polymer whose melting point is ≥150°C, whereas other sites produce syndiotactic and atactic PPs. For the most isospecific sites, a stereocontrol mechanism similar to the mechanism typical for metallocene catalysts with C ₁-symmetry is advanced. The catalysts under study are composed of the [(4R,5R)-2,2-dimethyl-α,α,α′,α′-tetra(perfluorophenyl)-1,3-dioxolane-4,5-dimethanol]TiCl₂ complex supported on LiCl and MgCl₂, respectively.     

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.     

Methyl branching in polyethylene from homopolymerization of ethylene with N‐arylcyano‐β‐diketiminate methallyl nickel‐B(C6F5)3

N‐Arylcyano‐β‐diketiminate methallyl nickel complexes activated with B(C₆F₅)₃ were used in the polymerization of ethylene. The microstructure analysis of obtained polyethylene (PE) was done by differential scanning calorimetry and ¹³C nuclear magnetic resonance (NMR). The branched polymer structures produced by these catalysts were attributed to one step isomerization mechanism of the catalyst along the polymer chain. The ortho or para position of the cyano group with co‐ordinated B(C₆F₅)₃ in both methallyl nickel catalysts influenced the polymer molecular weight, branching, and consequently melting and crystallization temperatures. NMR spectroscopic studies showed predominantly the formation of methyl branches in the obtained PE. Catalysts under study gave linear low‐density PEs with good crystallinities at temperatures of reaction between 50 °C and 70 °C at moderate pressures (12.3 atm). A propylene–ethylene copolymer produced by the metallocene catalyst had the same concentration of branches as the PE synthesized from methallyl nickel/B(C₆F₅)₃. Comparing the two polyolefins with the same degree of branching, it was observed that the polymer obtained with the nickel catalyst proved to be twice more crystalline and had greater T_m. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 452–458     

Copolymerization of styrene and conjugated dienes with half‐sandwich titanium(IV) catalysts: The effect of the ligand structure on the monomer reactivity,monomer sequence distribution,and insertion mode of dienes

The copolymerization of styrene and 1,3‐butadiene (Bd) or isoprene (Ip) was carried out with half‐sandwich titanium(IV) Cp′TiCl₃ catalysts (where Cp′ is cyclopentadienyl 1 , indenyl 2 , or pentamethylcyclopentadienyl 3 ) with methylaluminoxane as a cocatalyst. For the copolymerization with Bd, catalyst 3 gave the copolymers containing the highest amount of Bd among the catalysts used. The resulting copolymers were composed of a styrene–Bd multiblock sequence. High melting points were observed in the copolymers prepared with catalyst 1 . The structures of hydrogenated poly(styrene‐co‐Bd) were studied by ¹³C NMR spectroscopy, and the long styrene sequence length was detected in the copolymers prepared with catalyst 1 . For styrene/Ip copolymerization, random copolymers were obtained. Among the used catalysts, catalyst 1 gave the copolymers containing the highest amount of Ip. The copolymers prepared with catalyst 1 showed a steep melting point depression with increasing Ip content because of the high ratio of 1,4‐inserted Ip units and/or the low molecular weights of the copolymers. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 939–946, 2003