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     

Exploring pathways to reduce the distribution of active sites in the Ziegler–Natta polymerization of propylene

Chemical treatments of classical supported Ziegler–Natta precatalysts were conducted by using additional bulky ligands to attempt to narrow and homogenize the active sites distribution in propylene polymerization. Additions of monodentate ligands such as bis(trimethylsilyl)amide, cyclopentadienyl derivates or triphenylsilanol were seen to slow down the polymerization without modifying the distribute properties of polypropylenes. In the case of multidentate ligands (porphines or biquinolines), in addition to the poisoning of active sites, an extraction of titanium from the catalyst surface is observed. A decrease of both melting point and isotacticity (II%) of polymers using these compounds suggest that the most isospecific titanium sites are first extracted from the MgCl₂‐surface. The narrowing of the molecular weight distribution confirms that the highly isospecific sites are the most active sites, producing the higher molecular weight polymers. Moreover, this study shows that the distributed properties of polymers are due to the chemical diversity of the active sites with various steric and electronic environments at the catalyst surface and not to mass transfer limitations. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 3941–3948, 2007     

Strong activation of MgCl2‐supported Ziegler‐Natta catalysts by treatments with BCl3: Evidence and application of the “cluster” model of active sites

Heterogeneous Ziegler‐Natta precatalysts (with phthalate as internal donor) were modified by treatments with BCl₃ (2 h in heptane; T = 20–90 °C; B/Ti = 0.1–5) before their use in the polymerization of propylene to modify the active sites distribution. If performed on previously “detitanated” precatalysts, the treatment leads to a strong increase of productivity (up to one order of magnitude) without drastic modifications of polypropylenes properties (tacticity, molecular weight distribution). In addition, these findings are in good agreement with the hypothesis of a “cluster” organization of active sites allowing to rationalize activation by BCl₃ by formation of heteronuclear B‐Ti clusters. The activation method was also applied to unmodified precatalysts and gave a significant gain of productivity. The simple and versatile activation process can also be performed under mild conditions (low T and low [BCl₃]). © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 5784–5791, 2009     

Propylene polymerization reactions with supported Ziegler–Natta catalysts: Observing polymer material produced by a single active center

Medium‐ and high‐resolution SEM analysis of several Ti‐based MgCl₂‐supported Ziegler–Natta catalysts and isotactic polypropylene produced with them is carried out. Each catalyst particle, 35–55 μ in size, produces one polymer particle with an average size of 1.5–2 mm, which replicates the shape of the catalyst particle. Polymer particles contain two distinct morphological features. The larger of them are globules with D_av ～400 nm; from 1 to 2 × 10¹¹ globules per particle. Each globule represents the combined polymer output of a single active center. The globules consist of ～2500 microglobules with an average size of ～20 nm. The microglobules contain several folded polymer molecules; they are the smallest thermodynamically stable macromolecular ensembles in propylene polymerization reactions. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 3832–3841     

Modifications of the active sites distribution in the Ziegler‐Natta polymerization of propylene using Lewis acids

Heterogeneous Ziegler‐Natta precatalysts (with phthalate as internal donor) were modified by treatments with various Lewis acids (MCl_n with M = Ga, Sn, Si, and Sb and n = 3, 4, or 5) before their use in the polymerization of propylene. If performed on previously “detitanated” precatalysts, treatments with SnCl₄ and SiCl₄ lead to a slight activation but especially to an increase of the tacticity whereas GaCl₃ and SbCl₅ treatments deactivate the catalyst. The modification method applied to conventional unmodified precatalysts gave similar trends. A significant increase of tacticity (and/or of T_m) and a narrowing of the molecular weight distribution were observed in the case of SnCl₄ and SiCl₄ treatments. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 2631–2635, 2010     

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     

Similarities and Differences of the Active Sites in Basic and Advanced MgCl2‐Supported Ziegler‐Natta Propylene Polymerization Catalysts

Though preparation procedures of heterogeneous Ziegler‐Natta catalysts for propylene polymerization are sophisticated, it is uncertain whether the nature of the active sites is similar or different for different preparation procedures. In this study, the effects of preparation procedures on the nature of the active sites were investigated by stopped‐flow polymerization in combination with microstructure analysis of polymers. Both basic and advanced types of catalysts showed the same two kinds of isospecific active site, which indicated little influence of the preparation method on the active site structure. On the contrary, the ratios of the two kinds of isospecific sites were not the same, resulting in variation of average polymer properties.

     

Novel spherical Ziegler–Natta catalyst for polymerization and copolymerization. I. Spherical MgCl2 support

Spherical MgCl₂ adducts used as supports for a Ziegler–Natta catalyst for olefin polymerization were prepared by the general precipitation method. The influence of MgCl₂/EtOH (mol/mol) and the dispersion speeds on the particle size (PS) and particle size distribution (PSD) were investigated. It was found that the former played a trivial role in controlling the PS and PSD, and the latter was the key factor. In particular, the influence of ethanol on the crystal structure was further examined, with consideration given to the performance of the supported Ziegler–Natta catalyst. It was believed that the reactions between MgCl₂ and ethanol had a controlling effect on the destruction of the original anhydrous MgCl₂, which was the key point in the preparation of suitable supports for the latest generation Ziegler–Natta catalyst. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3112–3119, 2002     

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     

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     

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.

     

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. II. Ethylene polymerization reactions in the presence of deuterium

Ethylene polymerization reactions with many Ziegler–Natta catalysts exhibit several features which differentiate them from polymerization reactions of α-olefins: a relatively low ethylene reactivity, higher polymerization rates in the presence of α-olefins, a high reaction order with respect to ethylene concentration, and strong reversible rate depression in the presence of hydrogen. A detailed kinetic analysis of ethylene polymerization reactions (see ref. 1 ) provided the basis for a new reaction scheme which explains all these features by postulating 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. This mechanism predicts that the β-agostically stabilized Ti C₂H₅ groups can decompose in the β-hydride elimination reaction with expulsion of ethylene and the formation of a Ti H bond even in the absence of hydrogen in the reaction medium. If D₂ is used as a chain transfer agent instead of H₂, the mechanism predicts the formation of deuterated ethylene molecules, which copolymerize with protioethylene. To prove this prediction, several ethylene homopolymerization reactions were carried out with a supported Ziegler–Natta titanium-based catalyst in the presence of large amounts of D₂. Analysis of gaseous reaction products and polymers confirmed the formation of several types of deuterated ethylene molecules and protio/deuterioethylene copolymers, respectively. In contrast, a metallocene catalyst, Cp₂ZrCl₂ MAO, does not exhibit these kinetic features. In the presence of deuterium, it produces only DCH₂ CH₂ (CH₂ CH₂)_x CH₂ CH₂D molecules. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4273–4280, 1999     

Effects of external donors and hydrogen concentration on oligomer formation and chain end distribution in propylene polymerization with Ziegler‐Natta catalysts

The effect of type and concentration of external donor and hydrogen concentration on oligomer formation and chain end distribution were studied. Bulk polymerization of propylene was carried out with two different Ziegler‐Natta catalysts at 70 °C, one a novel self‐supported catalyst (A) and the other a conventional MgCl₂‐supported catalyst (B) with triethyl aluminum as cocatalyst. The external donors used were dicyclopentyl dimethoxy silane (DCP) and cyclohexylmethyl dimethoxy silane (CHM). The oligomer amount was shown to be strongly dependent on the molecular weight of the polymer. Catalyst A gave approximately 50 % lower oligomer content than catalyst B due to narrower molecular weight distribution in case of catalyst A. More n‐Bu‐terminated chain ends were found for catalyst A indicating more frequent 2,1 insertions. Catalyst A also gave more vinylidene‐terminated oligomers, suggesting that chain transfer to monomer, responsible for the vinylidene chain ends, was a more important chain termination mechanism for this catalyst, especially at low hydrogen concentration. Low site selectivity, due to low external donor concentration or use of a weak external donor (CHM), was also found to increase formation of vinylidene‐terminated oligomers. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 351–358, 2010     

Ethylene polymerization reactions with Ziegler–Natta catalysts. III. Chain-end structures and polymerization mechanism

Ethylene polymerization reactions with many Ziegler–Natta catalysts exhibit a number of features that differentiate them from polymerization reactions of α olefins: (1) a relatively low ethylene reactivity, (2) markedly higher polymerization rates in the presence of α olefins, (3) a high reaction order with respect to ethylene concentration, and (4) a strong reversible rate depression in the presence of hydrogen. A detailed kinetic analysis of ethylene polymerization reactions¹ provided the basis for a new kinetic scheme that postulates the equilibrium formation of Ti C₂H₅ species with the H atom in the methyl group β-agostically coordinated to the Ti atom in an active center. This mechanism predicts several new features of ethylene polymerization reactions, one being that chain initiation via insertion of any α-olefin molecule into the Ti H bond should proceed with an increased probability compared to that via ethylene insertion into the same bond. As a result, a significant fraction of ethylene/α-olefin copolymer chains should contain α-olefin units as the starting units. This article provides experimental data supporting this prediction on the basis of both a detailed structural analysis of co-oligomers formed in ethylene/1-pentene and ethylene/4-methyl-1-pentene copolymerization reactions and a spectroscopic analysis of chain ends in the copolymers. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4281–4294, 1999     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. I. Chemical mechanism of catalyst activation

The hydrogen activation effect in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts is usually explained by hydrogenolysis of dormant active centers formed after secondary insertion of a propylene molecule into the growing polymer chain. This article proposes a different mechanism for the hydrogen activation effect due to hydrogenolysis of the Ti? iso‐C₃H₇ group. This group can be formed in two reactions: (1) after secondary propylene insertion into the Ti? H bond (which is generated after β‐hydrogen elimination in the growing polymer chain or after chain transfer with hydrogen), and (2) in the chain transfer with propylene if a propylene molecule is coordinated to the Ti atom in the secondary orientation. The Ti? CH(CH₃)₂ species is relatively stable, possibly because of the β‐agostic interaction between the H atom of one of its CH₃ groups and the Ti atom. The validity of this mechanism was demonstrated in a gas chromatography study of oligomers formed in ethylene/α‐olefin copolymerization reactions with δ‐TiCl₃/AlEt₃ and TiCl₄/dibutyl phthalate/MgCl₂–AlEt₃ catalysts. A quantitative analysis of gas chromatography data for ethylene/propylene co‐oligomers showed that the probability of secondary propylene insertion into the Ti? H bond was only 3–4 times lower than the probability of primary insertion. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1353–1365, 2002     

Polymerization of propylene by metallocene and Ziegler–Natta mixed catalytic systems. Study of polypropylene properties

Propylene was polymerized with metallocene and Ziegler–Natta mixed-catalytic systems to obtain reactor blends of metallocene and Ziegler–Natta-derived propylene homopolymers. The two catalytic systems are able to act jointly, providing individual polymers with different melting and crystallization temperatures. Compatibility between the components of the mixed-catalytic systems and the influence of the components on the polymerization process and on the properties of the reactor blends were studied. Thermal, mechanical, viscoelastic, rheological, and optical properties of the blends were tested and compared with those of conventional polypropylene grades. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 3063–3072, 1998     

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.     

The “comonomer effect” in ethylene/α‐olefin copolymerization using homogeneous and silica‐supported Cp2ZrCl2/MAO catalyst systems: Some insights from the kinetics of polymerization,active center studies,and polymerization temperature

Homogeneous and silica‐supported Cp₂ZrCl₂/methylaluminoxane (MAO) catalyst systems have been used for the copolymerization of ethylene with 1‐butene, 1‐hexene, 4‐methylpentene‐1 (4‐MP‐1), and 1‐octene in order to compare the “comonomer effect” obtained with a homogeneous metallocene‐based catalyst system with that obtained using a heterogenized form of the same metallocene‐based catalyst system. The results obtained indicated that at 70 °C there was general rate depression with the homogeneous catalyst system whereas rate enhancement occurred in all copolymerizations carried out with the silica‐supported catalyst system. Rate enhancement was observed for both the homogeneous and the silica‐supported catalyst systems when ethylene/4‐MP‐1 copolymerization was carried out at 50 °C. Active center studies during ethylene/4‐MP‐1 copolymerization indicated that the rate depression during copolymerization using the homogeneous catalyst system at 70 °C was due to a reduction in the active center concentration. However, the increase in polymerization rate when the silica‐supported catalyst system was used at the same temperature resulted from an increase in the propagation rate coefficient. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 267–277, 2008     

Liquid‐phase polymerization of propylene with a highly active Ziegler–Natta catalyst. Influence of hydrogen,cocatalyst, and electron donor on the reaction kinetics

This paper presents an experimental kinetic study of the polymerization of propylene in liquid monomer with a high activity catalyst. The influences of the concentration of hydrogen and the molar ratios of the catalyst, cocatalyst, and electron donor on the activation period, the maximum activity, the yield, and the decay behavior have been investigated at a temperature of 42°C using a relatively simple kinetic model. On the basis of the experimental data, the reaction rate has been modeled as a function of the hydrogen concentration, the molar ratio of cocatalyst and titanium, and the molar ratio of the electron donor and the cocatalyst. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 219–232, 1999