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.     

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.     

Novel Preparation of Polyethylene from Nano‐extrusion Polymerization Inside the Nanochannels of MCM‐41/MgCl2/TiCl4 Catalysts

The MCM‐41 and SiO₂ supported TiCl₄ and TiCl₄/MgCl₂ catalysts with different molar ratios of Mg/Ti were synthesized and used for ethylene polymerization under atmospheric pressure. The nanochannels of MCM‐41 serve as nanoscale polymerization reactor and the polyethylene nanofibers were extruded during the reaction. The nanofibers were observed in SEM micrographs of resulting polyethylene. The effect of MgCl₂ on catalytic activity and thermal properties of resulting polyethylene is investigated too. In the presence of MgCl₂, the catalytic activity increased and more crystalline polyethylene with higher melting points were formed. However, no fibers could be observed in the polyethylene prepared by SiO₂ supported catalysts.     

Organometallic vanadium-based heterogeneous catalysts for ethylene polymerization. Study of the deactivation process

Slurry polymerizations of ethylene over vanadium catalysts (based on VCl₄ and VOCl₃) and their MgCl₂(THF)₂-supported equivalents were studied. Unsupported vanadium catalysts were found to be unstable while the vanadium active sites deposited on the MgCl₂(THF)₂ complex are stable. A sharply outlined correlation was found between the concentration of vanadium(III) and catalyst productivity. The high activity and stability of the vanadium catalyst when supported on the magnesium complex is attributed to the increase of resistance to reduction of active vanadium(III) to inactive vanadium(II) by an organoaluminium co-catalyst.     

Magnesium chloride supported high mileage catalysts for olefin polymerization. XXI. Isospecific and regiospecific vanadium catalyst for propylene polymerization

Several CW–V catalysts were prepared by supporting VCl₄ on Mg Cl₂ with ethyl benzoate and CH–V catalysts prepared by reacting MgCl₂.ROH, phthalic anhydride, and VCl₄. These vanadium catalysts, activated with TEA (triethyl aluminum)/MPT (methyl-p-toluate) produce mainly (88–96%) refluxing n-heptane insoluble isotactic PP. The active site has $ k_{p,i} = 1580 \left( M {\rm s} \right)^{ - 1}, k_{tr,i}^{\rm A} = 2 \times 10^{ - 3} {\rm s}^{ - 1} , k_{tr}^{\rm H} = 3.8 \times 10^{ - 2} \left( {\rm torr} \right)^{ - {1 \mathord{\left/ {\vphantom {1 2}} \right. \kern-\nulldelimiterspace} 2}} {\rm s}^{ - 1}$ for the isospecific ones and $ k_{p,a} = 58 \left( M {\rm s} \right)^{ - 1} ,k_{tr,a}^{\rm A} = 3 \times 10^{ - 3} {\rm s}^{ -1}$ for the nonspecific sites. Catalyst of VCl₃ supported on MgCl₂ has comparable productivity as the VCl₄/MgCl₂ catalyst but catalyst of VCl₂ supported on MgCl₂ exhibit only one-ninth of the productivity. Extensive comparison has been made between the CW–V and the CW–Ti systems which revealed striking similarities between their polymerization behaviors. MgCl₂ exerts profound influence on the stereochemical control of the vanadium ion on its activity for monomer coordination and insertion.     

Study of the compositional heterogeneity of ethylene–hexene-1 copolymers by thermal fractionation technique by means of differential scanning calorimetry

The successive self-nucleation/annealing technique (SSA) by differential scanning calorimetry has been applied to study the heterogeneity of ethylene–hexene-1 copolymers produced with supported catalytic systems of different compositions: highly active supported Ziegler–Natta (Z–N) catalysts—a titanium–magnesium catalyst TiCl₄/MgCl₂ (TMC) and a vanadium–magnesium catalyst VCl₄/MgCl₂ (VMC), a supported zirconocene catalyst Me₂Si(Ind)₂ZrCl₂/SiO₂ (MAO), and a chromium-oxide catalyst CrO₃/SiO₂. Comparative data by SSA technique with the same temperature program were obtained for copolymers differed by MWD from narrow to very broad (Mw/Mn = 2.4–54) and short chain branching distribution from narrow (zirconocene catalyst) to very broad (TMC and chromium oxide catalysts). It is demonstrated that copolymers produced with the zirconocene catalyst have the narrowest melting range and do not contain thick lamellae. The widest lamella thickness distribution has been found for a copolymer produced with the chromium-oxide catalyst. Copolymers produced with the supported Z–N catalysts are ranked in the middle with a more narrow lamella thickness distribution for copolymer prepared with VMC as compared with the one produced with TMC. The SSA results are compared with the data on copolymer fractionation by TREF. It is shown that these methods give a good correlation for copolymers with narrow short-chain branching distribution produced with the supported zirconocene catalyst. In the case of copolymers produced with TMC, TREF yields a higher content of the high-branched fractions.     

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.     

The activation of MgCl2-supported ziegler-natta catalysts—II: Correlation between activity and structural disorder

The properties have been examined for Ziegler-Natta catalysts comprising TiCl₄ (Ti contents 2.0, 3.4 and 4.2%) supported on MgCl₂ activated by dry ball-milling up to 250 hr. The samples have been investigated by measurements of catalytic activity in polymerization, of surface area and of some structural parameters related to the crystal disorder introduced by ball-milling. It is shown that the TiCl₄ content affects the activation; a relationship has been found between the crystal disorder of the MgCl₂ support and the catalytic activity.     

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.     

Influence of support recrystallization techniques on catalyst performance in olefin polymerization

This paper is a comparative study of the performance of TiCl₄ catalysts supported on recrystallized MgCl₂ through different techniques for the polymerization of ethylene, propylene and ethylene-propylene copolymers. MgCl₂ was dissolved in 1-hexanol and recrystallized through solvent evaporation, quick cooling and precipitation with SiCl₄. The effect of the recrystallization conditions during the catalyst preparation on the chemical composition of catalysts was discussed with the help of IR spectroscopy. The variations of dealcoholation levels due to the different recrystallization techniques highly influenced the catalytic activity. The catalyst obtained through SiCl₄ recrystallization was not only the most active, but it also showed the highest isotacticity indexes for propylene polymerization.     

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     

State of various stereoregulating electron-donating compounds in titanium-magnesium catalysts for propylene polymerization: A diffuse reflectance IR spectroscopic study

Propylene polymerization on TiCl₄/donor/MgCl₂ (donor = ethyl benzoate, dibutyl phthalate, diisobutyl phthalate, diethyl 2,3-diisopropylsuccinate) supported catalysts is considered. The states of the donors in the catalysts have been investigated by diffuse reflectance IR spectroscopy. Data characterizing the distribution of the donors and the active component (TiCl₄) on the support surface have been obtained. Molecular weight distribution data for polypropylene are presented. The molecular weight distribution of polypropylene depends on the location of the donor and TiCl₄ molecules.     

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.     

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     

Copolymerization of ethylene and 1-hexene with TiCl4/MgCl2 catalysts modified by 2,6-diisopropylphenol

A supported TiCl4/MgCl2 catalyst without internal electron donor (O-cat) was prepared firstly. Then it was modified by 2,6-diisopropylphenol to make a novel modified catalyst (M-cat). These two catalysts were used to catalyze ethylene/1-hexene copolymerization and 1-hexene homopolymerization. The influence of cocatalyst and hydrogen on the catalytic behavior of these two catalysts was investigated. In ethylene/1-hexene copolymerization, the introduction of 2,6-iPr2C6H3O-groups did not deactivate the supported TiCl4/MgCl2 catalyst. Although the 1-hexene incorporation in ethylene/1-hexene copolymer prepared by M-cat was lower than that prepared by O-cat, the composition distribution of the former was narrower than that of the latter. Methylaluminoxane (MAO) was a more effective activator for M-cat than triisobutyl-aluminium (TIBA). MAO led to higher yield and more uniform chain structure. In 1-hexene homopolymerization, the presence of 2,6-iPr2C6H3O-groups lowered the propagation rate constants. Two types of active centers with a chemically bonded 2,6-iPr2C6H3O-group were proposed to explain the observed phenomena in M-cat.     

Experimental and Computational Approaches on the Isospecific Role of Monoester-Type Internal Electron Donor for TiCl4/MgCl2 Ziegler-Natta Catalysts

In this work, a combination of experimental and computational approaches on the isospecific role of monoester-type internal electron donors (ED) such as phenylpropionate (PhP), ethylheptanoate (EH), methylbenzoate (MB), ethylbenzoate (EB) for TiCl₄/ED/MgCl₂ Ziegler-Natta catalysts had been performed. The propylene polymerization results revealed that the isospecificity of catalysts increases in the following order: PhP < EH < MB < EB. The subsequent molecular modeling on the electronic properties of the donors and two kinds of cluster model catalysts: TiCl₄/ED/MgCl₂ and TiCl₄/ED/(MgCl₂)₄ based on density functional theory (DFT) method was carried out. Two kinds of ED coordination on MgCl₂ clusters through either O or  O within the monoester-type ED had been disclosed. A perfect correlation between the dipole moment of ED, the coordination bond length of O … Mg, the competitive coordination from  O with Mg ion and the isospecificity of the catalysts had been established.     

MgCl2·6H2O-BASED ZIRCONOCENE CATALYST FOR ETHYLENE POLYERIZATION

Several supported zirconocene catalysts were prepared by using MgCl_2·6H_2O as a precursor forproducing an active support. Such catalysts combined with methylaluminoxane (MAO) obtained by reactingMgCl_2·6H_2O with AlMe_3 show good activity for ethylene polymerization similar to that of anhydrousMgCl_2 supported zirconocene catalyst.     

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     

Homogeneous and supported catalysts based on bis(imino)pyridyl Iron(II) complexes for ethylene polymerization

Data on ethylene polymerization on homogeneous and supported catalysts based on 2,6-bis(imino)pyridyl Fe(II) complexes activated by trialkylaluminums are considered (activity, the molecular-weight characteristics of polymers, the number of active sites, and the propagation rate constants). Unlike homogeneous systems, the supported catalysts prepared with the use of various carriers (SiO₂, Al₂O₃, and MgCl₂) exhibited high stability and activity at 70–80°C and produced high-molecular-weight polyethylene with a broad molecular-weight distribution (MWD). The molecular weights and MWDs of polymers and the propagation rate constant depended on the nature of the carrier only slightly. The reasons for an unusual effect of an increase in the activity of the supported catalysts in ethylene polymerization in the presence of hydrogen are discussed.     

Kinetics of polymerization of 1-octene with Mgcl2-supported Ticl4 catalysts

A number of TiCl₄ catalysts supported on MgCl₂ which was activated by the recrystallization method using different alcohols were prepared with ethyl benzoate or dibutyl phthalate as the internal electron donor. All the catalysts were characterized by BET, x-ray diffraction, and hydrolysis–GC analysis. Kinetics of polymerization of 1-octene was studied with three of the above catalysts (having different internal electron donors) activated by AlEt₃. The rate of polymerization increased linearly with increasing temperature, and catalyst and monomer concentrations. From the Arrhenius plot, the overall activation energies of polymerization were determined and the dependence of rate on the AlEt₃ concentration could be explained by the Langmuir-Hinshelwood mechanism. ¹³C-NMR was used to study the effect of internal electron donors on the % isotacticity of poly(1-octene). The catalytic activities of all the catalysts were compared in 1-octene polymerization. © 1994 John Wiley & Sons, Inc.