Alumina as support for metallocene catalyst in ethylene polymerization

Aluminas thermally and/or chemically treated were used as support for Cp₂ZrCl₂ and evaluated in ethylene polymerization at constant reaction conditions. Two different calcination temperatures were employed, and the metallocene was fixed either directly or after support pretreatment with MAO, TMA, or NaOH solutions. The obtained alumina‐supported catalysts showed activities comparable to the homogeneous precursor. It was noticed that the textural properties of the supports strongly influenced the catalyst performance. The direct fixation of the metallocene on alumina produced catalysts presenting lower activities in comparison to the ones obtained from the chemically treated supports. The chemical pretreatment of hydrated alumina with TMA originated catalysts whose activities were superior to those obtained by pretreatment with MAO. The pretreatment with NaOH produced the more active catalyst and generated branched polymer. The molecular weight of the PE produced by the supported catalysts was higher than the ones obtained with the homogeneous system. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 9–21, 2004     

Binary metallocene supported catalyst for propylene polymerization

The binary silica supported catalyst system comprising the Cp₂ZrCl₂ and SiMe₂(Ind)₂ZrCl₂ metallocene compounds was prepared with different immobilization methods and evaluated at different propylene polymerization conditions. The performance results of the homogeneous isolated catalysts and also the homogeneous catalyst mixture were also included for comparison. High activities were obtained with the supported systems and the molecular weight of the produced polypropylene was invariably higher than that obtained using the homogeneous precursor.     

Supported stereospecific metallocene binary catalyst for propylene polymerization

In this work, propylene was polymerized with isospecific and syndiospecific catalysts in homogeneous and heterogeneous systems. The binary metallocene system of both isospecific and syndiospecific catalysts in the heterogeneous system was also used. Besides the type of catalyst, parameters such as polymerization temperature and pressure were varied to achieve the better conditions for the polymerization. The objective of this work is to investigate the influence of these parameters on the characteristics of the produced polymer. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 2979–2986, 2002     

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     

Polypropylene fractions produced by binary metallocene catalysts

Because of the great economic interest in propylene‐based polymers and the possibility of designing materials with desired properties with metallocene catalyst mixtures, we investigated the characteristics of polypropylenes produced by mixtures of SiMe₂Ind₂ZrCl₂: dimethylsilane‐bis(indenyl) zirconocene ( 1 ) and Et(Flu)(Cp)ZrCl₂: ethylidene (fluorenyl cyclopentadienyl) zirconocene ( 2 ) in different proportions. The polymers were fractionated with solvents, and the fractions were characterized. We observed that the polymers produced by the different mixed systems showed lower weight‐average molecular weights and only slightly broader molecular weight distributions than polypropylenes synthesized by the individual catalysts. We concluded that catalyst 1 acted independently of catalyst 2 , producing polymers with the same isotacticity. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 1478–1485, 2003     

Ethylene polymerization with porous polystyrene spheres supported Cp2ZrCl2 catalyst

A catalyst with porous polystyrene beads supported Cp₂ZrCl₂ was prepared and tested for ethylene polymerization with methylaluminoxane as a cocatalyst. By comparison, the porous supported catalyst maintained higher activity and produced polyethylene with better morphology than its corresponding solid supported catalyst. The differences between activities of the catalysts and morphologies of the products were reasonably explained by the fragmentation processes of support as frequently observed with the inorganic supported Ziegler–Natta catalysts. Investigation into the distribution of polystyrene in the polyethylene revealed the fact that the porous polystyrene supported catalyst had undergone fragmentation during polymerization. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 3313–3319, 2003     

Copolymerization of propylene and methyl vinyl ketone with metallocene catalysts: Synthesis,properties, and thermal and photooxidation of modified polypropylene

The copolymers of propylene and methyl vinyl ketone are synthesized at 60°С by copolymerization in the propylene bulk in the presence of the polymethylaluminoxane-activated metallocene catalysts, namely, the isospecific С₂-symmetric metallocene catalyst rac-Me₂Si(2-Me-4-PhInd)₂ZrCl₂ and the syndiospecific Сs-symmetric metallocene catalyst Ph₂ССpFluZrCl₂, and characterized. It is shown that a noticeable insertion of methyl vinyl ketone into a polypropylene chain is possible during copolymerization initiated by the syndiospecific catalytic system, whereas in the case of the isospecific system, the insertion of methyl vinyl ketone is hindered. The thermal oxidation of the resulting polymers is studied. With the use of chemiluminescence, the accumulation of peroxy macroradicals under the action of daylight in samples based on isotactic and syndiotactic polypropylene is detected. It is found that even a low (0.2 mol %) content of methyl vinyl ketone endows polypropylene with the capability to undergo rapid and controlled degradation under natural conditions.     

Dialkylzinc Compounds as Chain Transfer Agents in Ethylene and Propylene Polymerizations Catalyzed by Metallocene Catalysts

Dialkylzinc compounds (ZnR₂) with the alkyl groups of different steric hindrance were used as chain transfer agents in ethylene and propylene polymerizations catalyzed by two conventional metallocene catalysts including rac-Et(Ind)₂ZrCl₂ and rac-Me₂Si[2-Me-4-Ph-Ind]₂ZrCl₂. In general, catalyst activities for ethylene polymerizations are barely affected by chain transfer agents, regardless of the R type; however, there are significant activity reductions in propylene polymerizations when the R in ZnR₂ is less hindered, and as R becomes bulkier, catalyst activities are gradually restored. ZnR₂ and metallocene catalyst active site tend to form a reversible and catalytically inactive complex, thus the geometry congested ZnR₂ would reduce complex formation tendency and hence decreased its negative effect on catalyst activities.     

Copolymerization of propylene with various higher α‐olefins using silica‐supported rac‐Me2Si(Ind)2ZrCl2

The copolymerization of propylene with 1‐hexene, 1‐octene, 1‐decene, and 1‐dodecene was carried out with silica‐supported rac‐Me₂Si(Ind)₂ZrCl₂ as a catalyst. The copolymerization activities of the homogeneous and supported catalysts and the microstructures of the resulting copolymers were compared. The activity of the supported catalyst was only one‐half to one‐eighth of that of the homogeneous catalyst, depending on the comonomer type. The supported catalyst copolymerized more comonomer into the polymer chain than the homogeneous catalyst at the same monomer feed ratio. Data of reactivity ratios showed that the depression in the activity of propylene instead of an enhancement in the activity of olefinic comonomer was responsible for this phenomenon. We also found that copolymerization with α‐olefins and supporting the metallocene on a carrier improved the stereoregularity and regioregularity of the copolymers. The melting temperature of all the copolymers decreased linearly with growing comonomer content, regardless of the comonomer type and catalyst system. Low mobility of the propagation chain in the supported catalyst was suggested as the reason for the different polymerization behaviors of the supported catalyst with the homogeneous system. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3294–3303, 2001     

Stereospecific polymerization of methacrylates by metallocene and related catalysts

Stereospecific—isospecific, syndiospecific, and diastereospecific—polymerizations of methacrylates using group 4 metallocene and related catalysts produce polymethacrylates with controlled stereo‐microstructures. The versatility and stereospecificity of these cat‐ alysts for methyl methacrylate polymerization were demonstrated not only in solution‐phase polymerization, but also in polymerizations on silica surfaces and inside silicate nanogalleries. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3395–3403, 2004     

Manganese‐based transition metal complexes as new catalysts for olefin polymerizations

Three manganese complexes, Mn(acac)₃ (acac = acetylacetonate), Cp₂Mn (Cp = cyclopentadienyl), and Mn(salen)Cl [salen = 1,2‐cyclohexanediamino‐N,N′‐bis(3,5‐dit‐butyl‐salicylidene)], were used for ethylene and propylene polymerizations. These complexes, in combination with an alkylaluminum cocatalyst such as methylaluminoxane (MAO) or diethyl aluminum chloride (AlEt₂Cl), could promote ethylene polymerizations that yielded extremely high molecular weight linear polymers, but were inactive for propylene polymerizations. The counterparts supported on MgCl₂ showed activities even for propylene polymerizations and had remarkably enhanced activities for ethylene polymerizations. In the presence of an electron donor such as ethylbenzoate, the MgCl₂‐supported manganese‐based catalysts yielded a highly isotactic polypropylene with a high molecular weight. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3733–3738, 2001     

Metallocene derivatives as active supports of zirconium‐based catalysts for ethene polymerization

Cyclopentadienyl magnesium chloride (MgClCp) and its functionalized derivatives represent original and interesting supporting materials to heterogenize metallocene catalysts for olefin polymerizations. The synthesis of MgClCp, its functionalization, and the preparation of a catalytic system in which the ZrCl₂(Flu)⁺ moiety is joined on the support through a cyclopentadienyl ligand are reported. This catalyst was tested in ethene polymerization, and both the catalytic activity and properties of the produced polymer were measured. Its performance was compared with that shown by the catalyst ZrCl₂CpFlu employed under the same conditions for both unsupported and conventional supports, such as MgCl₂. The results showed a remarkable improvement in terms of the activity and polymer properties with these heterogenized catalysts. Moreover, this system showed stability toward leaching processes and was characterized by good morphological control of the growing polymer. Finally, catalysts in which [HB(3,5‐Me₂pyrazolyl)₃]ZrCl and [HB(3,5‐Me₂pyrazolyl)₃]ZrClOtBu⁺ moieties were bonded to a functionalized MgClCp^? support were also synthesized and tested. The results showed that the proposed supports could be usefully used to heterogenize tailored metallocene homogeneous catalysts. In fact, new catalysts were prepared that combined the peculiar advantages of both heterogeneous and homogeneous catalysts and overcame the disadvantages of the latter, such as a lack of morphology and reactor fouling. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 4243–4248, 2001     

New organic supports for metallocene catalysts applied in olefin polymerizations

Nano-sized latex particles as organic supports for metallocenes applied in olefin polymerizations are introduced. The particles are functionalized with nucleophilic surfaces such as polyethylenoxide (PEO), polypropyleneoxide (PPO) or pyridine units allowing an immobilization of the metallocene catalysts via a non-covalent immobilization process. The latices are obtained by emulsion or miniemulsion polymerization with styrene, divinylbenzene as the crosslinker, and either PEO or PPO functionalized styrene or 4-vinylpyridine for surface functionalization. The supported catalysts, e.g. [Me₂Si(2MeBenzInd)₂ZrCl₂/MAO] on PPO containing latices or Cp₂ZrMe₂/([Ph₃C][B(C₆F₅)₄]) on pyridine functionalized materials were tested in ethylene polymerizations. Remarkably, high activities and excellent product morphologies were obtained. The influence of the degree of surface functionalization on activity and productivity was investigated. Furthermore, the fragmentation of the catalyst was studied by electron microscopy using bismuth-labeled latex particles or by fluorescence and confocal fluorescence microscopy using dye-labeled supports. Finally, a self-immobilizing catalyst/monomer system is presented. It is demonstrated that by using PEO-functionalized olefins, the metallocenes were immobilized on the monomers. Subjecting these mixtures to an ethylene copolymerization, again high activities and productivities as well as polyolefin beads with high bulk densities are observed, indicating that an extra supporting process for controlling the product size and shape of the polyolefins is not necessary for these monomers.     

Ethylene polymerization and ethylene/1-hexene copolymerization using homogeneous and heterogeneous unbridged bisindenyl zirconocene catalysts

Unbridged bis-substituted-indenyl zirconocene complexes, [(2,4-Me₂Ind)₂ZrCl₂, Met-1; (2,4,6-Me₃Ind)₂ZrCl₂, Met-2], were supported on silica and montmorillonite carriers (resulting in silica-supported catalysts MS-1 and MS-2, and montmorillonite-supported catalyst MT-1). Ethylene polymerization by homogeneous and heterogeneous catalysts showed high activity, affording polyethylenes with high molecular weight. The catalytic activity and the molecular weight of the polymer were improved using the heterogeneous systems. The activities for the ethylene/1-hexene copolymerization by heterogeneous systems were lower than those using homogeneous systems, however, the comonomer was incorporated efficiently into polymer in both the homo- and the heterogeneous systems, and moreover, the microstructure of the copolymer derived from the heterogeneous catalysts showed different characteristics from those resulting from the homogeneous systems. The r_Er_H values of the heterogeneous catalysts (1.82 for MS-1 and 0.70 for MS-2), are quite different from those of their homogeneous analogues (1.25 for Met-1 and 1.26 for Met-2).     

Dialkylzinc Compounds as Chain Transfer Agents in Ethylene and Propylene Polymerizations Catalyzed by Metallocene Catalysts

Dialkylzinc compounds (ZnR₂) with the alkyl groups of different steric hindrance were used as chain transfer agents in ethylene and propylene polymerizations catalyzed by two conventional metallocene catalysts including rac-Et(Ind)₂ZrCl₂ and rac-Me₂Si[2-Me-4-Ph-Ind]₂ZrCl₂. In general, catalyst activities for ethylene polymerizations are barely affected by chain transfer agents, regardless of the R type; however, there are significant activity reductions in propylene polymerizations when the R in ZnR₂ is less hindered, and as R becomes bulkier, catalyst activities are gradually restored. ZnR₂ and metallocene catalyst active sites tend to form a reversible and catalytically inactive complex, thus, the geometry congested ZnR₂ would reduce complex formation tendency and hence, decrease its negative effect on catalyst activities.     

Copolymerization of ethylene with 1‐hexene over metallocene catalyst supported on complex of magnesium chloride with tetrahydrofuran

The study of ethylene/1‐hexene copolymerization with the zirconocene catalyst, bis(cyclopentadienyl)zirconium dichloride (Cp₂ZrCl₂)/methylaluminoxane (MAO), anchored on a MgCl₂(THF)₂ support was carried out. The influence of 1‐hexene concentration in the feed on catalyst productivity and comonomer reactivity as well as other properties was investigated. Additionally, the effect of support modification by the organoaluminum compounds [(MAO, trimethlaluminum (AlMe₃), or diethylaluminum chloride (Et₂AlCl)] on the behavior of the MgCl₂(THF)₂/Cp₂ZrCl₂/MAO catalyst in the copolymerization process and on the properties of the copolymers was explored. Immobilization of the Cp₂ZrCl₂ compound on the complex magnesium support MgCl₂(THF)₂ resulted in an effective system for the copolymerization of ethylene with 1‐hexene. The modification of the support as well as the kind of organoaluminum compound used as a modifier influenced the activity of the examined catalyst system. Additionally, the profitable influence of immobilization of the homogeneous catalyst as well as modification of the support applied on the molecular weight and molecular weight distribution of the copolymers was established. Finally, with the successive self‐nucleation/annealing procedure, the copolymers obtained over both homogeneous and heterogeneous metallocene catalysts were heterogeneous with respect to their chemical composition. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 2512–2519, 2004     

Random propene/4‐methyl‐1‐pentene copolymers synthesized with C2 symmetric highly isospecific metallocenes

Propene (P)/4‐methyl‐1‐pentene (Y) copolymers in a wide range of composition were prepared with isospecific single center catalysts, rac‐Et(IndH₄)₂ZrCl₂ ( EBTHI ), rac‐Me₂Si(2‐Me‐BenzInd)₂ZrCl₂ ( MBI ), and rac‐CH₂(3‐^tBuInd)₂ZrCl₂ ( TBI ). ¹³C NMR analysis of copolymers and statistical elaboration of microstructural data at triad level were performed. Unprecedented and surprising results are here reported. Random P/Y copolymers were prepared with the most isospecific catalyst, TBI , that is known to prepare ethene/propene and ethene/4‐methyl‐1‐pentene copolymers with long homosequences of both comonomers, whereas longer homosequences of both comonomers were observed in copolymers from the less enantioselective metallocenes EBTHI and MBI . These findings, which are against what is acknowledged in the field, can pave the way for the preparation on a large scale of random propene‐based copolymers. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2575–2585     

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 Influence of Bridge Type on the Activity of Supported Metallocene Catalysts in Ethylene Polymerization简

Ethylene polymerization was carried out by immobilization of rac-ethylenebis(1-indenyl)zirconium dichloride(Et(Ind)2 ZrCl2) and rac-dimethylsilylbis(1-indenyl)zirconium dichloride(Me2 Si(Ind)2 ZrCl2) preactivated with methylaluminoxane(MAO) on calcinated silica at different temperatures. Polymerizations of ethylene were conducted at different temperatures to find the optimized polymerization temperature for maximum activity of the catalyst. The Me2 Si bridge catalyst showed higher activity at the lower polymerization temperature compared to the Et bridge catalyst. The highest catalytic activities were obtained at temperatures about 50 °C and 70 °C for Me2 Si(Ind)2 ZrCl2 /MAO and Et(Ind)2 ZrCl2 /MAO catalysts systems, respectively. Inductively coupled plasma-atomic emission spectroscopy results and polymerization activity results confirmed that the best temperature for calcinating silica was about 450 °C for both catalysts systems. The melting points of the produced polyethylene were about 130 °C, which could be attributed to the linear structure of HDPE.     

Preparation and application of a novel core–shell‐particle‐supported zirconocene catalyst

The use of functional groups bearing silica/poly(styrene‐co‐4‐vinylpyridine) core–shell particles as a support for a zirconocene catalyst in ethylene polymerization was studied. Several factors affecting the behavior of the supported catalyst and the properties of the resulting polymer, such as time, temperature, Al/N (molar ratio), and Al/Zr (molar ratio), were examined. The conditions of the supported catalyst preparation were more important than those of the ethylene polymerization. The state of the supported catalyst itself played a decisive role in both the catalytic behavior of the supported catalyst and the properties of polyethylene (PE). IR and X‐ray photoelectron spectroscopy were used to follow the formation of the supports. The formation of cationic active species is hypothesized, and the performance of the core–shell‐particle‐supported zirconocene catalyst is discussed as well. The bulk density of the PE formed was higher than that of the polymer obtained from homogeneous and polymer‐supported Cp₂ZrCl₂/methylaluminoxane catalyst systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2085–2092, 2001