Production of Long‐Chain Branched Polyolefins with Two Single‐Site Catalysts: Comparing CSTR and Semi‐Batch Performance

We developed a mathematical model to describe the solution polymerization of olefins with two single‐site catalysts in a series of two CSTRs. The model was used to simulate processes where semi‐crystalline macromonomers produced in the first reactor are incorporated as long chain branches onto amorphous (or lower crystallinity) chains in the second reactor (cross‐products). The simulation results show that CSTRs are more efficient to make chains with high LCB density and high weight percent of cross‐products. The model can also predict the polydispersity index, average chain lengths, and fractions of the different polymer populations, and help the polymer reactor engineer formulate new products with complex microstructures.

     

Synthesis and Characterization of Long‐Chain‐Branched Polyolefins with Metallocene Catalysts: Copolymerization of Ethylene with Poly(ethylene‐co‐propylene) Macromonomer

Poly(ethylene‐co‐propylene) macromonomer (EPM) was synthesized in a high‐temperature continuous stirred tank reactor (CSTR) with [C₅Me₄(SiMe₂N^tBu)]TiMe₂ (CGC‐Ti) as the catalyst system. PE samples with EPM long chain branching (LCB) were produced by semi‐batch copolymerization of ethylene and EPM with CGC‐Ti. The LCB frequencies were up to 21.8 EPM side chains per PE backbone. The effects of temperature and ethylene pressure on the degree of EPM grafting and catalyst activity were examined.

Incorporation of EPM into a growing PE chain forming an LCB polymer.     

Simulation of Polymerization and Long Chain Branch Formation in a Semi‐Batch Reactor Using Two Single‐Site Catalysts

We developed a mathematical model for the solution polymerization of olefins in a semi‐batch reactor with two single‐site catalysts. In the propylene polymerization case, our objective is to study the production of a thermoplastic elastomer using two catalysts, one capable of forming isotactic chains containing terminal vinyl bonds (macromonomers) and the other producing atactic chains while also being able to copolymerize macromonomers to form long chain branches. A similar thermoplastic elastomer can be produced by polymerizing ethylene and α‐olefin comonomers when the α‐olefin reactivity ratios of the two catalysts are significantly different.

     

MAO‐Free Activation of Metallocenes and other Single‐Site Catalysts for Ethylene Polymerization using Spherical Supports based on MgCl2

Summary: Supports of type MgCl₂/AlR_n(OEt)_3−n, obtained by reaction of AlR₃ with adducts of MgCl₂ and ethanol, have been shown to be effective for the immobilization and activation of [Cp₂TiCl₂] and other single‐site olefin polymerization catalysts without the use of methylaluminoxane or a borate activator. Polyethylene with a spherical particle morphology and narrow molecular weight distribution was obtained.

     

Mesoporous Silica Supported Multiple Single‐Site Catalysts and Polyethylene Reactor Blends with Tailor‐Made Trimodal and Ultra‐Broad Molecular Weight Distributions

A ternary blend of the bisiminopyridine chromium (III) (Cr‐ 1 ) with the bisiminopyridine iron (II) (Fe‐ 2 ) post‐metallocenes with the quinolylsilylcyclopentadienyl chromium (III) halfsandwich complex (Cr‐ 3 ) was supported on mesoporous silica to produce novel multiple single‐site catalysts and polyethylene reactor blends with tailor‐made molecular weight distributions (MWDs). The preferred cosupporting sequence of this ternary blend on MAO‐treated silica was Fe‐ 2 followed by Cr‐ 1 and Cr‐ 3 . Cosupporting does not impair the single‐site nature of the blend components producing polyethylene fractions with = 10⁴ g · mol⁻¹ on Cr‐ 1 , = 3 × 10⁵ g · mol⁻¹ on Fe‐ 2 , and = 3 × 10⁶ g · mol⁻¹ on Cr‐ 3 . As a function of the Fe‐ 2 /Cr‐ 1 /Cr‐ 2 mixing ratio it is possible to control the weight ratio of these three polyethylenes without affecting the individual average molecular weights and narrow polydispersities of the three polyethylene fractions. Tailor‐made polyethylene reactor blends with ultra‐broad MWD and polydispersities varying between 10 and 420 were obtained. When the molar ratio of Fe‐ 2 /Cr‐ 1 was constant, the ultra‐high molecular polyethylene (UHMWPE, > 10⁶ g · mol⁻¹) content was varied between 8 and 16 wt.‐% as a function of the Cr‐ 3 content without impairing the blend ratio of the other two polyethylene fractions and without sacrificing melt processability. When the molar ratio Fe‐ 2 /Cr‐ 3 was constant, it was possible to selectively increase the content of the low molecular weight fraction by additional cosupporting of Cr‐ 1 . Due to the intimate mixing of low and ultra‐high molecular weight polyethylenes (UHMPEs) produced on cosupported single‐site catalysts a wide range of melt processable polyethylene reactor blends was obtained.

     

Long‐chain‐branched polyethene by the copolymerization of ethene and nonconjugated α,ω‐dienes

Ethene was copolymerized (1) with 1,5‐hexadiene with rac‐ethylenebis(indenyl)zirconium dichloride/methylaluminoxane (MAO) used as a catalyst and (2) with 1,7‐octadiene with bis(n‐butylcyclopentadienyl)zirconium dichloride/MAO and rac‐ethylenebis(indenyl)hafnium dichloride (Et[Ind]₂HfCl₂)/MAO used as catalysts at 80 °C in toluene. The copolymer microstructure and the influence of diene incorporation on the rheological properties were examined. Ethene and 1,5‐hexadiene formed a copolymer in which a major fraction of the 1,5‐hexadiene was incorporated into rings and a small fraction formed 1‐butenyl branches. The copolymerization of ethene with 1,7‐octadiene resulted in a higher selectivity toward branch formation. Some of the branches formed long‐chain‐branching (LCB) structures. The ring formation selectivity increased with decreasing ethene concentration in the polymerization reactor. Melt rheological properties of the diene copolymers resembled those of metallocene‐catalyzed LCB homopolyethenes and depended on the vinyl content, the catalyst, and the polymerization conditions. At high diene contents, all three catalysts produced crosslinked polyethene. This was especially pronounced with Et[Ind]₂HfCl₂, where only 0.2 mol % 1,7‐octadiene in the copolymer was required to achieve significantly modified rheological properties. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3805–3817, 2001     

Polymerization Kinetics and Microstructure of Ethylene/1‐Hexene Copolymers Made with Dual Metallocenes

Mathematical models are developed to describe the polymerization of ethylene and 1‐hexene with a constrained geometry catalyst (CGC‐Ti) and with bis(cyclopentadienyl)‐zirconium (IV) dichloride (Cp₂ZrCl₂). Particle swarm optimization is used to fit these models to homo‐ and copolymerization data. The models are also used to describe copolymerizations with mixtures of CGC‐Ti and Cp₂ZrCl₂ to make copolymers with inverse short chain branching distribution. Copolymer molecular weight and short chain branch distributions, as well as polymerization rates with the dual metallocene system, are measured to test whether they agreed with model predictions. The results show that the two metallocenes do not interact strongly when used as a mixture to make ethylene/1‐hexene copolymers.     

Ethylene (Co)Polymerization with Metallocene Catalysts Encapsulated in Gel‐Type Poly(styrene‐co‐divinylbenzene) Beads

Gel‐type poly(styrene‐co‐divinylbenzene) beads (PS bead) were used as a carrier to encapsulate metallocene catalysts through a simple swelling‐shrinking procedure. The catalytic species were homogeneously distributed in the PS bead particle. The catalyst exhibited high and stable ethylene polymerization and ethylene/1‐hexene copolymerization activity affording uniform spherical polymer particles (1 mm). Polymerization rate profiles exhibited slow initiation and stable increase in polymerization activity with time.     

Structural analysis of polyethene prepared with rac‐dimethylsilylbis(indenyl)zirconium dichloride/methylaluminoxane in a high‐temperature,continuously stirred tank reactor

A study of ethene solution polymerization with the rac‐dimethylsilylbis(indenyl)‐zirconium dichloride/methylaluminoxane catalyst system in a high‐temperature (140 °C), continuously stirred tank reactor system was carried out. ¹³C NMR, gel permeation chromatography, Fourier transform infrared, and rheological measurements were used for polymer analyses. Polyethylenes with low molecular weights (weight‐average molecular weight ≈ 35–55 kg/mol) and small amounts of methyl, ethyl, and long‐chain branching were produced. ¹³C NMR measurements showed that the long‐chain and methyl branches increased and that the ethyl branch contents decreased with decreasing monomer concentrations. At high monomer concentrations, the chain transfer to the coordinated monomer was concluded to be the predominant chain termination mechanism, whereas the chain transfer to aluminum was dominant at low monomer concentrations, which was evidenced by the fact that the selectivity of end groups was reduced to about 50%. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3292–3301, 2002     

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.     

Effect of cocatalyst on the chain microstructure of polyethylene made with CGC‐Ti/MAO/B(C6F5)3

This investigation studied the solution polymerization of ethylene in Isopar E in a semibatch reactor using CGC‐Ti as catalyst and methylalumoxane (MAO) and tris(pentaflourophenyl)borane [B(C₆F₅)₃] as cocatalysts. The effects of cocatalyst type and amount on the chain microstructure were investigated. ¹³C NMR and gel permeation chromatography were used to determine the long‐chain branching (LCB) content and molecular weight distribution (MWD), respectively, of the samples. It was observed that higher concentrations of MAO increased the LCB content and decreased the molecular weight of the polymer. On the other hand, increasing the amount of B(C₆F₅)₃ lowered the LCB content, increased the molecular weight, and broadened MWD significantly. We believe that this approach can be used as an efficient way to control the microstructure of polyolefins made with these catalytic systems. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3055–3061, 2004     

A Novel SiO2‐Supported Fluorine Modified Chromium–Vanadium Bimetallic Catalyst for Ethylene Polymerization and Ethylene/1‐Hexene Copolymerization

Phillips catalyst is one of the most significant industrial ethylene polymerization catalysts. Chemical modifications have been carried out to tune the Phillips catalyst performance and improve the polyethylene properties. After the modification of the catalyst by fluorine, the polyethylene product with higher molecular weight (MW) and narrower molecular weight distribution (MWD) is suitable for producing automobile fuel tanks. Vanadium containing Phillips catalyst enhances α‐olefin incorporation and MW regulation. In present work, fluorine modified and unmodified chromium–vanadium (Cr–V) bimetallic catalysts are prepared and explored. Compared with the fluorine‐free catalyst, the activities of F‐modified bimetallic catalysts slightly decrease with the increasing MW of the product and the hydrogen response increases slightly. Due to the synergistic effect of the chromium, vanadium and fluorine on the silica gel support, the short‐chain branch distribution (SCBD) of copolymers from F‐modified Cr–V bimetallic catalyst (Cr–V–F)⁶⁰⁰ is more beneficial than that of Cr–V bimetallic catalyst (Cr–V)⁶⁰⁰ and F‐modified Cr–V bimetallic catalyst (Cr–V–F)⁵⁰⁰. The fluorination of Cr–V bimetallic catalysts has not only preserved the high polyethylene activity of bimetallic active sites but also produced the advantage of the high MW ability from fluorine.

     

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.

     

Hyperbranched Polyethylenes and Functionalized Polymers by Chain Walking Polymerization with Pd‐Diimine Catalysis

Chain walking polymerization (CWP) with Pd‐diimine catalysis represents a novel concept for the synthesis of hyperbranched polyethylenes (HBPEs) and functionalized polymers from ethylene stocks. This article summarizes recent developments in this research area. The properties of HBPEs have recently been studied and their application as lubricant viscosity additives, polymer processing aids, and polymers for the functionalization and solubilization of carbon nanotubes in organic solvents have been explored, with some outstanding features having been discovered. Using the CWP strategy, we have also synthesized a range of functionalized HBPEs covalently tethered with a variety of functional groups, including POSS nanoparticles, ATRP‐initiating sites, methacryloyl and acryloyl double bonds, and backbone‐incorporated functionalized ring units.

     

Ethylene/1‐octene copolymerization studies with in situ supported metallocene catalysts: Effect of polymerization parameters on the catalyst activity and polymer microstructure

Ethylene and 1‐octene copolymerizations were carried out with an in situ supported rac‐[dimethylsilylbis(methylbenzoindenyl)] zirconium dichloride catalyst. In a previous study, it was found that some in situ supported metallocenes produced polyethylene/α‐olefin copolymers with broad and bimodal short chain branching distributions and narrow molecular weight distributions. The ability to produce polyolefins with multimodal microstructural distributions in a single metallocene and a single reactor is attractive for producing polymers with balanced properties with simpler reactor technology. In this study, a factorial experimental design was carried out to examine the effects of the polymerization temperature and ethylene pressure, the presence of hydrogen and an alkylaluminum activator, and the level of the comonomer in the feed on the catalyst activity, short chain branching distribution, and molecular weight distribution of the polymer. The temperature had the most remarkable effect on the polymer microstructure. At high 1‐octene levels, the short chain branching distribution of the copolymer broadened significantly with decreasing temperature. Several factor interactions, including the hydrogen and alkylaluminum concentrations, were also observed, demonstrating the sensitivity of the catalyst to the polymerization conditions. For this catalyst system, the responses to the polymerization conditions are not easily predicted from typical polymerization mechanisms, and several two‐factor interactions seem to play an important role. Given the multiple‐site nature of the catalyst, it has been shown that predicting the polymerization activity and the resulting microstructure of the polymer is a challenging task. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 4426–4451, 2002     

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.     

Tuning the Reactivity of N,O,O,O‐Non‐Metallocene Catalysts for α‐Olefin Polymerization: Issues Related to Ligand Symmetry and Derivatization

Summary: Titanium‐based precatalysts, bearing C₃ or pseudo‐C_s symmetric aminotriol ligands, upon activation with methylaluminoxane, polymerize hex‐1‐ene to give polymers of high molecular weight, i.e., 50 000 and 600 000, respectively, with low dispersity, 1.2–1.4, and high isotacticity, 85–60%, depending on the overall symmetry of the precatalysts, but when one arm of the aminotriol ligands is methylated to yield C₂ or meso aminodiol ligands, their corresponding titanium catalysts gave higher‐molecular‐weight polyhexenes, 300 000 to 250 000, with lower dispersities, 1.07–1.11, which possibly suggests living polymerization, with activities 200–500 times greater than that of the parent C₃ and pseudo‐C_s catalysts.

     

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