Analysis of Ethylene/1‐Olefin Copolymers Made with Ziegler–Natta Catalysts by Deconvolution of Molecular Weight and Average Short Chain Branching Distributions

In this article a systematic method is proposed to deconvolute the time‐dependent molecular weight distributions (MWD) and average comonomer fraction profiles of ethylene/1‐olefin copolymers made with heterogeneous Ziegler–Natta catalysts. These distributions with a high‐temperature gel permeation chromatography equipped with an infrared detector at four different polymerization times have been measured and used this information to infer how the fractions of polymer made on each site type varied with polymerization time. The model estimates here the minimum number of active site types needed to describe these copolymers, the MWD of polymer populations made on each site type, and their average comonomer fractions. This method is useful to quantify the microstructure of olefin copolymers made with multiple site type catalysts using the least number of adjustable parameters.

     

Regulation of Molecular Weight Characteristics and Microtacticity of Polyhexene Produced over Highly Active Supported Titanium–Magnesium Catalysts

The data on the effect of polymerization temperature of 1‐hexene within the 30–70 °C range in the presence of a highly active supported titanium–magnesium catalyst on molecular weight characteristics and microtacticity of polyhexene, with cocatalyst composition being additionally varied (AlEt₃ or Al(i‐Bu)₃), in the absence and presence of an external stereoregulating electron‐donating compound and hydrogen, are reported. Polymerization conditions, making it possible to specifically regulate molecular weight and molecular weight distribution of polyhexene over a broad range ((M_w = 7 × 10⁴–2.2 × 10⁶ g mol⁻¹; M_w/M_n = 3.7–33) and regulate isotacticity of polyhexene (content of mmmm pentads from 56% to 96%), while retaining high catalyst activity, are determined.     

Preparation of Polyethylene/Graphene Nanocomposites with Octadecylamine‐Modified Graphene Oxide‐MgCl‐Supported Ziegler–Natta Catalyst

In this work, an octadecylamine‐modified graphene oxide (ODA‐GO)‐MgCl‐supported Ziegler–Natta catalyst was synthesized by reacting ODA‐GO with a Grignard reagent, followed by anchoring TiCl₄ to the structure. The effect of the ODA‐GO on the catalyst morphology and ethylene polymerization behavior was examined. The resultant polyethylene (PE)/ODA‐GO nanocomposites directly mirrored the catalyst morphology by forming a layered morphology, and the ODA‐GO fillers were well dispersed in the PE matrix and showed strong interfacial adhesion with it. The resultant PE/ODA‐GO nanocomposites exhibited better thermal stability and mechanical properties than neat PE, even with a small amount of ODA‐GO added. Thus, this work provides a facile approach to the production of high‐performance PE. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 855–860     

Preparation of linear α‐olefins to high‐molecular weight polyethylenes using cationic α‐diimine nickel(II) complexes containing chloro‐substituted ligands

A series of α‐diimine nickel(II) complexes containing chloro‐substituted ligands, [(Ar)N?C(C₁₀H₆)C?N(Ar)]NiBr₂ ( 4a , Ar = 2,3‐C₆H₃Cl₂; 4b , Ar = 2,4‐C₆H₃Cl₂; 4c , Ar = 2,5‐C₆H₃Cl₂; 4d , Ar = 2,6‐C₆H₃Cl₂; 4e , Ar = 2,4,6‐C₆H₂Cl₃) and [(Ar)N?C(C₁₀H₆)C?N(Ar)]₂NiBr₂ ( 5a , Ar = 2,3‐C₆H₃Cl₂; 5b , Ar = 2,4‐C₆H₃Cl₂; 5c , Ar = 2,5‐C₆H₃Cl₂), have been synthesized and investigated as precatalysts for ethylene polymerization. In the presence of modified methylaluminoxane (MMAO) as a cocatalyst, these complexes are highly effective catalysts for the oligomerization or polymerization of ethylene under mild conditions. The catalyst activity and the properties of the products were strongly affected by the aryl‐substituents of the ligands used. Depending on the catalyst structure, it is possible to obtain the products ranging from linear α‐olefins to high‐molecular weight polyethylenes. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1964–1974, 2006     

Evaluation of the Initial Stages of Gas‐Phase Ethylene Polymerizations with a SiO2‐Supported Ziegler–Natta Catalyst

The very early stages of gas‐phase ethylene polymerization on an SiO₂‐supported Ziegler–Natta catalyst were studied with the help of a short‐stop reactor. The short‐stop‐reactor‐based technique was useful in studying nascent polymerization, providing insights at very short, controlled times into important phenomena regarding catalyst fragmentation and the activation and deactivation of catalyst sites that take place during the very early stages of the reaction. Experimental results indicate that the growth of the polymer chains occurs at unsteady conditions during the initial stages of the polymerization. Hydrogen has a strong influence on the initial kinetics, leading to a significant decrease of polymerization activity. Polymer crystallinity increases with the reaction time, probably due to the formation of long chains with a high degree of crystallinity.

     

Morphology and Thermal Characteristics of Polyethylene Nanocomposites Made Using Montmorillonite‐Supported Cp2ZrCl2 and Ni‐Diimine Precatalysts

Bis(cyclopentadienyl)‐zirconium dichloride (Cp₂ZrCl₂) and (1,4‐bis(2,6‐diisopropylphenyl)‐acenaphthenediimine) dichloronickel (Ni‐diimine) were supported on montmorillonite (MMT) pretreated with triisobutylaluminum and 10‐undecence‐1‐ol to produce in situ polyethylene–clay nanocomposites in a gas‐phase reactor. The development of the nanocomposite morphology was investigated with transmission electron microscopy (TEM), scanning electron microscopy (SEM), and X‐ray diffraction (XRD) analysis. During polymerization, the MMT layers were partially exfoliated by the growing polymer chains, starting from the openings of the clay galleries, but intercalation and exfoliation occurred only to a certain extent. The thermal properties of the nanocomposites we also analyzed by differential scanning calorimetry (DSC).

     

Synthesis of Bimodal Polyethylene Using Ziegler‐Natta Catalysts by Multiple H2 Concentration Switching in a Single Slurry Reactor

A simple, inexpensive and powerful method for synthesizing bimodal PE using Ziegler‐Natta catalysis by multiple switching of the H₂ concentration in a single slurry reactor is reported. The effects of polymerization type, hydrogen concentration, reaction time distribution and switching times on the MWD are investigated. The results show that the MWD produced by forcibly removing the gas during the switching process are much broader than those of PEs produced by directed replacement. In addition, the former can prominently enhance the value of compared to conventional methods, showing an increase from 7 to 27. The MWDs obtained are bimodal for H₂ concentrations ranging from 63 to 75 vol.‐% and have different shapes under different conditions.

     

Comparing Long‐Chain Branching Mechanisms for Ethylene Polymerization with Metallocenes and Other Single‐Site Catalysts: What Simulated Microstructures Can Teach Us

Three different long‐chain branch (LCB) formation mechanisms for ethylene polymerization with metallocenes in solution polymerization semi‐batch and continuous stirred‐tank reactors are modeled to predict the microstructure of the resulting polymer. The three mechanisms are terminal branching, C–H bond activation, and intramolecular random incorporation. Selected polymerization parameters are varied to observe how each mechanism affects polymer microstructure. Increasing the ethylene concentration during semi‐batch polymerization reduces the LCB frequency of polymers made with the terminal branching and intramolecular mechanisms, but has no effect on those made with the C–H bond activation mechanism, which disagrees with most previous data published in the literature. The intramolecular mechanism predicts that LCB frequencies hardly depend on polymerization time or ethylene conversion, which also disagrees with the published experimental data for these systems. For continuous polymerization reactors, experimental data relating polydispersity to LCB frequency can be well described with the terminal branching mechanism, but both C–H bond activation and intramolecular models fail to describe this experimental relationship. Therefore, detailed simulations confirm that the terminal branching mechanism is indeed the most likely mechanism for LCB formation when ethylene is polymerized with single‐site coordination catalysts such as metallocenes in solution polymerization reactors.     

Polyethylene Made with Combinations of Single‐Site‐Type Catalysts: Monte Carlo Simulation of Long‐Chain Branch Formation

The formation of long‐chain branches (LCBs) during ethylene polymerization with a combination of catalysts was studied by Monte Carlo simulation. The model describes polymerization with a non‐branching catalyst that produces linear macromonomers, and a branching catalyst that produces linear and branched macromonomers. The LCBs are formed when the branching catalyst incorporates a macromonomer. The discussion is based on the three types of chain topology obtained during the synthesis: linear, comb‐branched, or hyperbranched. Simulation results show how the chain length distribution and the number of LCBs change according to the ratio between the two catalysts present in the reactor. The ratio hyperbranched/comb‐branched is defined to evaluate the system composition and the contribution of each catalyst.     

Effects of Alterations to Ziegler–Natta Catalysts on Kinetics and Comonomer (1‐Butene) Incorporation

Various MgCl₂‐supported Ziegler–Natta (ZN) catalysts are synthesized with the intention to influence polymerization performance and 1‐butene incorporation in an ethylene copolymer. Modifications are introduced during different steps in the synthesis process, namely support preparation, titanation, and catalyst workup. While multiple different effects are observed upon modification, heat treatment during titanation shows the greatest impact. Increasing the heat‐treatment temperature increases polymerization activity. More importantly, the 1‐butene distribution can be shifted toward a more homogeneous profile. The amount of 1‐butene incorporated is similar to both for short‐ and for very long‐chain molecules. This behavior has so far been known only from metallocene‐based polyethylene and suggests that active sites are distributed more homogeneously in the ZN catalyst.

     

Estimation of Apparent Kinetic Constants of Individual Site Types for the Polymerization of Ethylene and α‐olefins with Ziegler–Natta Catalysts

This article proposes a method to quantify the polymerization kinetics of ethylene and α‐olefins with commercial TiCl₄/MgCl₂ Ziegler–Natta catalysts. The method determines the leading apparent polymerization kinetic constants for each active site in a Ziegler–Natta catalyst by simultaneously fitting the instantaneous polymerization rate, cumulative polymer yield, and polymer molecular weight distribution measured at different times during a series of semi‐batch polymerization experiments. This approach quantifies the behavior of olefin polymerization with multisite catalysts using the least number of adjustable parameters needed to consistently model polymerization kinetics and polymer microstructural data.

     

Melting behavior of polyethylene/α‐olefin copolymers: Narrow composition distribution copolymers and fractions from Ziegler–Natta and single‐site catalyst products

The melting temperature and heat of fusion were measured for an extensive series of compositionally uniform copolymers of ethylene with butene‐1, hexene‐1, and octene‐1. Fractions and whole polymers that exhibited minimal interchain compositional heterogeneity were from commercial copolymers made with either Ziegler–Natta (ZN) or single‐site metallocene catalysts. The present results do not support recent claims that ZN and corresponding metallocene catalyst copolymers melt at significantly different temperatures, nor the implication that comonomer incorporation is “blocky” in ZN copolymers. In five of the six comonomer/catalyst systems the dependencies of the melting temperature on comonomer type and amount were scarcely distinguishable. This common behavior is the same as that for a model random copolymer, so we conclude that most ethylene/α‐olefin copolymers have random distributions of ethylene sequences. The exception in the present study is a metallocene ethylene/butene‐1 copolymer that melts at lower temperatures and apparently has perceptibly alternating sequence distributions. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3416–3427, 2004     

Ethylene polymerization with FI complexes having novel phenoxy‐imine ligands: Effect of metal type and complex immobilization

A series of bis(phenoxy‐imine) vanadium and zirconium complexes with different types of R³ substituents at the nitrogen atom, where R³ = phenyl, naphthyl, or anthryl, was synthesized and investigated in ethylene polymerization. Moreover, the catalytic performance was verified for three supported catalysts, which had been obtained by immobilization of bis[N‐(salicylidene)‐1‐naphthylaminato]M(IV) dichloride complexes (M = V, Zr, or Ti) on the magnesium carrier MgCl₂(THF)₂/Et₂AlCl. Catalytic performance of both supported and homogeneous catalysts was verified in conjunction with methylaluminoxane (MAO) or with alkylaluminium compounds (Et_nAlCl_3?n, n = 1–3). The activity of FI vanadium and zirconium complexes was observed to decline for the growing size of R³, whereas the average molecular weight (MW) of the polymers was growing for larger substituent. Moreover, vanadium complexes exhibited the highest activity with EtAlCl₂, whereas zirconium ones showed the best activity with MAO. All immobilized systems were most active in conjunction with MAO, and their activities were higher than those for their homogeneous counterparts, and they gave polymers with higher average MWs. That effect was in particular evident for the titanium catalyst. The vanadium complex 3 was also a good precursor for ethylene/1‐octene copolymerization; however, its immobilization reduced its potential for incorporation of a comonomer into a polyethylene chain. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011     

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.     

Peculiarities of Ethylene Polymerization Reactions with Heterogeneous Ziegler–Natta Catalysts: Kinetic Analysis

The previously developed kinetic scheme for olefin polymerization reactions with heterogeneous Ziegler–Natta catalysts states that the catalysts have several types of active centers which have different activities, different stabilities, produce different types of polymer materials, and respond differently to reaction conditions. In the case of ethylene polymerization reactions, each type of center exhibits an unusual chemical feature: a growing polymer chain containing one ethylene unit, Ti—C₂H₅, is unusually stable and can decompose with the formation of the Ti—H bond. This paper examines quantitative kinetic ramifications of this chemical mechanism. Modeling of the complex kinetics scheme described in the Scheme demonstrates that it correctly and quantitatively predicts three most significant peculiarities of ethylene polymerization reactions, the high reaction order with respect to the ethylene concentration, reversible poisoning with hydrogen, and activation in the presence of α‐olefins.     

Zirconium‐chelate and mono‐η‐ cyclopentadienyl zirconium‐chelate/ methylalumoxane systems as soluble Ziegler–Natta olefin polymerization catalysts

Zirconium‐chelate and mono‐η‐cyclopentadienyl zirconium‐chelate complexes were tested as ethene and propene polymerization catalysts in combination with methylalumoxane (MAO) as a co‐catalyst: in particular (acac) _nZrCl_4−n (1a–c) (acac = acetylacetonato), (dbm) _nZrCl_4−n (2a–2c) (dbm = dibenzoylmethanato = 1,3‐diphenylpropanedionato) (n = 2–4) and (dbm)₂ZrCl₂(thf) (3) (thf = tetrahydrofuran), (η‐C₅H₅)[H₂B (C₃H₃N₂)₂]ZrCl₂ (4), (η‐C₅H₅)[HB (C₃H₃N₂)₃] ZrCl₂ (5) and (η‐C₅H₅)[(Me₃SiN)₂ CPh]ZrCl₂ (6). Polymerization productivities comparable with the (η‐C₅H₅)₂ZrCl₂ reference system were observed towards ethene for all of the above complexes. In addition, compound 6 showed some minor polymerization activity towards propene. Ethylalumoxane or isobutylalumoxane did not exhibit a co‐catalytic activity for these chelate complexes; in combination with MAO these higher alumoxanes were even found to be deactivating ⁹¹Zr NMR data are reported for 1b, 1c, 4 and 5. Copyright © 2000 John Wiley & Sons, Ltd.     

Amorphous Polyethylene by Tandem Action of Cobalt and Titanium Single‐Site Catalysts

Summary: A variety of branched polyethylenes, spanning from semicrystalline LLDPE to completely amorphous, rubbery PE, was obtained from ethylene by homogeneous tandem catalysis using combinations of CoCl₂(N) ( 1 ) (N = [1‐(6‐benzo[b]thiophen‐2‐yl‐pyridin‐2‐yl)‐ethylidlene)‐(2,6‐diisopropyl‐phenyl)‐amine) and [(η⁵‐C₅Me₄)SiMe₂(tBuN)]TiCl₂ ( 2 ) in the presence of MAO at 30 °C. The productivity reached a maximum of 4 570 kg PE (mol Ti · h)⁻¹ at χ_Co = 0.50, yielding a rubbery material with d₂₅ = 0.868 g · cm⁻³ and T_g = −55 °C.

Conversion of ethylene into branched polyethylene using Co^II iminopyridyl complex CoCl₂(N) ( 1 ) and TiCl₂[(η⁵‐C₅Me₄)SiMe₂(tBuN)] ( 2 ).     

Mimicking Ziegler‐Natta Catalysts in Homogeneous Phase, 1. C2‐Symmetric Octahedral Zr(IV) Complexes with Tetradentate [ONNO]‐Type Ligands

Results of propene polymerization in the presence of two known octahedral C₂‐symmetric Zr complexes bearing tetradentate [ONNO]‐type ligands are reported for the first time. Depending on the steric hindrance at the active metal, isotactic site‐controlled or weakly syndiotactic chain‐end‐controlled polymers were obtained, in both cases via highly regioselective 1,2 (primary) monomer insertion. In this respect, the complexes mimic the behavior of the active Ti species on the surface of the heterogeneous Ziegler‐Natta catalysts of which they might represent good structural models.     

Ethylene polymerization reactions with Ziegler–Natta catalysts. I. Ethylene polymerization kinetics and kinetic mechanism

Kinetics of ethylene homopolymerization reactions and ethylene/1-hexene copolymerization reactions using a supported Ziegler–Natta catalyst was carried out over a broad range of reaction conditions. The kinetic data were analyzed using a concept of multicenter catalysis with different centers that respond differently to changes in reaction parameters. The catalyst contains five types of active centers that differ in the molecular weights of material they produce and in their copolymerization ability. In ethylene homopolymerization reactions, each active center has a high reaction order with respect to ethylene concentration, close to the second order. In ethylene/α-olefin copolymerization reactions, the centers that have poor copolymerization ability retain this high reaction order, whereas the centers that have good copolymerization ability change the reaction order to the first order. Hydrogen depresses activity of each type of center in the homopolymerization reactions in a reversible manner; however, the centers that copolymerize ethylene and α-olefins well are not depressed if an α-olefin is present in the reaction medium. Introduction of an α-olefin significantly increases activity of those centers, which are effective in copolymerizing it with ethylene but does not affect the centers that copolymerize ethylene and α-olefins poorly. To explain these kinetic features, a new reaction scheme is proposed. It is based on a hypothesis that the Ti—C₂H₅ bond in active centers has low reactivity due to the equilibrium formation of a Ti—C₂H₅ species with the H atom in the methyl group β-agostically coordinated to the Ti atom in an active center. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4255–4272, 1999