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     

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     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. II. Mechanism of the chain‐transfer reaction

Hydrogen is a very effective chain‐transfer agent in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts. However, measurements of the hydrogen concentration effect on the molecular weight of polypropylene prepared with a supported TiCl₄/dibutyl phthalate/MgCl₂ catalyst show a peculiar effect: hydrogen efficiency in the chain transfer significantly decreases with concentration, and at very high concentrations, hydrogen no longer affects the molecular weight of polypropylene. A detailed analysis of kinetic features of chain‐transfer reactions for different types of active centers in the catalyst suggests that chain transfer with hydrogen is not merely the hydrogenolysis reaction of the Ti? C bond in an active center but proceeds with the participation of a coordinated propylene molecule. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1899–1911, 2002     

Active center determinations on MgCl2‐supported fourth‐ and fifth‐generation Ziegler–Natta catalysts for propylene polymerization

Active center determinations on different Ziegler–Natta polypropylene catalysts, comprising MgCl₂, TiCl₄, and either a diether or a phthalate ester as internal donor, have been carried out by quenching propylene polymerization with tritiated ethanol, followed by radiochemical analysis of the resulting polymers. The purpose of this study was to determine the factors contributing to the high activities of the catalyst system MgCl₂/TiCl₄/diether—AlEt₃. Active center contents (C*) in the range 2–8% (of total Ti present) were measured and a strong correlation between catalyst activity and active center content was found, indicating that the high activity of the diether‐containing catalysts is due to an increased proportion of active centers rather than to a difference in propagation rate coefficients. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1635–1647, 2006     

Adsorption of TiCl4 and electron donor on defective MgCl2 surfaces and propylene polymerization over Ziegler-Natta catalyst: A DFT study

The formations of defective MgCl₂ surfaces, and subsequent adsorption of Ti species and electron donor, as well as propylene polymerization over the Ziegler-Natta catalyst have been investigated using density functional theory (DFT) method. Twelve possible support models of regular and defective MgCl₂ (110) and (100) surfaces were built. The individual adsorptions of titanium chlorides as mononuclear or dinuclear, and ethyl benzoate (EB) as electron donor, on these models were evaluated. The analysis of energies presented the cases of EB adsorption were generally more stable than titanium chlorides on both surfaces. Thus, EB as internal electron donor mainly prevented TiCl₄ from coordinating on the MgCl₂ surfaces where mostly non-stereospecific active sites could be formed. Exceptionally, A5 the site model with terminal Cl-vacancy on the MgCl₂ support, presented stronger adsorption of TiCl₄ than that of EB on (110) surface. Since the TiCl₄ and ethyl benzoate (EB) would compete to adsorb on the support surface, it seems reasonable to assume that TiCl₄ might predominately occupy this site, which can act as the most plausible active site for propylene polymerization. The first insertion of propylene monomer into the A5 active site model showed that it exhibited good regioselectivity but poor stereospecificity in the absence of electron donor.     

Supported titanium‐magnesium catalysts for ethylene polymerization: A comparative study of catalysts containing isolated and clustered titanium ions in different oxidation states

Supported titanium–magnesium catalysts (TMC) comprising isolated and clustered titanium ions in different oxidation states, which are obtained using titanium compounds of different composition (TiCl₄, TiCl₃?nDBE (DBE – dibutyl ether), [η⁶–BenzeneTiAl₂Cl₈]), were synthesized and tested in ethylene polymerization. The state of titanium ions was studied by the ESR method both for the procatalysts and after their interaction with triisobutilaluminum. For identification of ESR‐silent Ti³⁺ ions and Ti²⁺ ions, special procedures of additional catalyst treatment with pyridine, water, and chloropentafluorobenzene were used to obtain Ti³⁺ ions that are observable in ESR spectra. In distinction to numerous earlier works performed with the TiCl₄/MgCl₂ catalyst comprising after the interaction with AlR₃ the Ti³⁺ surface compounds both as isolated ions and clusters (ESR‐silent), this work considers the [η⁶–BenzeneTiAl₂Cl₈]/MgCl₂ catalyst (TMC‐3) comprising mainly the isolated Ti²⁺ ions and a new catalyst TMC‐4 obtained by treating the TMC‐3 with chloropentafluorobenzene. This catalyst comprises only the isolated Ti³⁺ ions both before and after the interaction with triisobutylaluminum. It was shown that in spite of sharp distinctions between the catalysts under consideration concerning titanium oxidation state and the ratio of isolated Ti³⁺ ions to clustered ones, all these catalysts produce polyethylenes with similar molecular weights and molecular‐weight distributions. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6362–6372, 2009     

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     

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.     

Superactive and stereospecific catalysts. II. Kinetics of propylene polymerizations

The kinetics of propylene polymerization by superactive CH-catalyst prepared from toluene solution of MgCl₂ · EH/PA/TiCl₄–TEA/PES was investigated. The results are compared with CW-catalyst prepared from crystalline MgCl₂/EB/PC/TEA/TiCl₄–TEA/MPT (abbreviations given in the text). The former is four times more active than the latter and produces more isotactic polypropylene. The CH-catalyst has 25% of the Ti as isospecific sites as compared to 6.7% for the CW-catalysts. These sites have the same rate constant of propagation so that the higher polymerization activity of the CH-catalyst is attributable simply to a greater number of active sites. Differences in the kinetics of deactivation and of chain transfer for the two catalysts are described.     

Ethylene polymerization using novel titanium catalytic precursors bearing N,N‐dialkylcarbamato ligands

Polymerization catalysts based on N,N‐dialkylcarbamato complexes of titanium(IV) appear particularly interesting, because these novel catalytic precursors are rather cheap and easy to synthesize and handle. This contribution reports ethylene polymerization behavior of titanium(IV) complexes of general formula Ti(O₂CNR₂)₄ R = Me ( I ) and Et ( II ) and TiCl₂(O₂CNMe₂)₂ ( III ). These precursors in conjunction with methylaluminoxane resulted active catalysts for the polymerization of ethylene, affording high‐density polyethylene with limited branch content. The influence of the polymerization parameters was studied with particular reference to the type of catalyst components, solvent, temperature, monomer concentration, and Al/Ti ratio. The nature of the solvent appears crucial for catalytic performances: when toluene was replaced by chlorobenzene, a significant increase of the productivity was ascertained. The obtained polymers were characterized by DSC, size exclusion chromatography, FTIR, and NMR techniques. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011     

Titanium (IV) chloride complexes with salen ligands supported on magnesium carrier: Synthesis and use in ethylene polymerization

The magnesium support with the formula MgCl₂(THF)_0.32(Et₂AlCl)_0.36 was used for immobilization of salen complexes of titanium [Ti(salen)Cl₂, Ti(salen(OMe)₂)Cl₂]. The effects of the catalyst composition (i.e. type of titanium complex and type of activator), polymerization temperature, polymerization time, and the effect of comonomer (1‐octene) on the activity of the obtained supported catalysts, on the polymer characteristics (molecular weight, molecular weight distribution, melting point), and on the polymer morphology were studied. The findings were compared to those obtained for corresponding unsupported systems. Catalysts immobilization results in considerable changes in catalysts activity and in properties of resultant polymers. The studied supported catalysts are highly active in ethylene polymerization, their activity increases with increasing temperature and lasts at least 2 hours. Their copolymerizing ability towards 1‐octene is rather low. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6693–6703, 2009     

Hydrogen Effects for Propylene Polymerization with Ultra Low TiCl3 Loading MgCl2-Supported Catalyst

Hydrogen effects for propylene polymerization were investigated with ultra low TiCl₃ loading MgCl₂-supported catalysts in which the electric states of Ti species can be almost uniform. Hydrogen did not affect the catalyst activity, while the efficiency of hydrogen as a chain transfer agent was found to depend on the Ti content of the catalyst and the stereospecificity of the polymerization sites: Hydrogen was effective for isospecific sites independent of Ti contents, but inert for aspecific sites only at the extremely low Ti content. These results were explained within the island model, where isospecific sites may be located in the islands with other Ti species in their surroundings acting, as a steric hindrance for isospecific polymerization and as hydrogen dissociation sites after deactivation. Most of the aspecific sites should be isolated only at the extremely low Ti content. These isolated sites have no other Ti species in their surroundings, i.e. no hydrogen dissociation sites, and are inert to hydrogen.     

Kinetic study of gas phase olefin polymerization with a TiCl4/MgCl2 catalyst I. Effect of polymerization conditions

This study focuses on the kinetics of ethylene/propylene (homo/co) polymerization reactions using a high activity TiCl₄/MgCl₂/AlEt₃ catalyst. The reactor system is a gas phase reactor equipped with an on-line composition control scheme. As such, important kinetic data such as the instantaneous reaction rate of each monomer is readily obtained. In the investigation, experiments are performed to study the effects of comonomer composition variations, temperature variations, hydrogen concentration variations, and variations in the Al/Ti ratio. It is observed that the ethylene and propylene instantaneous reaction rates show a rather peculiar pattern with the appearance of a second peak. Our work linked the existence of this peak to the Al/Ti ratio used. A theory based on the oxidation state change is proposed. This theory is also used to explain the effects of temperature changes and hydrogen concentration changes on the system. A variety of analytical techniques are employed to study the polymer properties and evidence is provided to support the existence of polymer partial melting at relatively high reaction temperatures. The resulting diffusion limitation is believed to be partially responsible for the observed activity decrease at such elevated temperatures. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35 : 2063–2074, 1997     

Propylene Polymerization Performance of Isolated and Aggregated Ti Species Studied Using a Well‐Designed TiCl3/MgCl2 Ziegler‐Natta Model Catalyst

In propylene polymerization with MgCl₂‐supported Ziegler‐Natta catalysts, it is known that the reduction of TiCl₄ with alkylaluminum generates Ti³⁺ active species, and at the same time, leads to the growth of TiCl_x aggregates. In this study, the aggregation states of the Ti species were controlled by altering the Ti content in a TiCl₃/MgCl₂ model catalyst prepared from a TiCl₃ · 3C₅H₅N complex. It is discovered that all the Ti species become isolated mononuclear with a highly aspecific feature below 0.1 wt.‐% of the Ti content, and that the isolated aspecific Ti species are more efficiently converted into highly isospecific ones by the addition of donors than active sites in aggregated Ti species.

     

Olefin polymerization with Me4Cp–Amido complexes with electron‐withdrawing groups

A series of Me₄Cp–amido complexes {[η⁵:η¹‐(Me₄C₅)SiMe₂NR]TiCl₂; R = t‐Bu, 1 ; C₆H₅, 2 ; C₆F₅, 3 ; SO₂Ph, 4 ; or SO₂Me, 5 } were prepared and investigated for olefin polymerization in the presence of methylaluminoxane (MAO). X‐ray crystallography of complexes 3 and 4 revealed very long Ti N bonds relative to the bonds of 1 . These complexes were employed for ethylene–styrene copolymerizations, styrene homopolymerizations, and propylene homopolymerizations in the presence of MAO. The productivities of the catalysts derived from 3 – 5 were much lower than the productivity of the catalyst derived from 1 for the propylene polymerizations and ethylene–styrene copolymerizations, whereas the styrene polymerization activities were much higher for the catalysts derived from 3 – 5 than for the catalyst derived from 1 . The polymerization behavior of the catalysts derived from the metallocenes 3 – 5 were more reminiscent of monocyclopentadienyl titanocene Cp′TiX₃/MAO catalysts than of CpATiX₂/MAO catalysts such as 1 containing alkylamido ligands. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 4649–4660, 2000     

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.     

Kinetics of propylene and ethylene polymerization reactions with heterogeneous ziegler-natta catalysts: Recent results

The article discusses recent results of kinetic analysis of propylene and ethylene polymerization reactions with several types of Ti-based catalysts. All these catalysts, after activation with organoaluminum cocatalysts, contain from two to four types of highly isospecific centers (which produce the bulk of the crystalline fraction of polypropylene) as well as several centers of reduced isospecificity. The following subjects are discussed: the distribution of active centers with respect to isospecificity, the effect of hydrogen on polymerization rates of propylene and ethylene, and similarities and differences between active centers in propylene and ethylene polymerization reactions over the same catalysts. Ti-based catalysts contain two families of active centers. The centers of the first family are capable of polymerizing and copolymerizing all α-olefins and ethylene. The centers of the second family efficiently polymerize only ethylene. Differences in the kinetic effects of hydrogen and α-olefins on polymerization reactions of ethylene and propylene can be rationalized using a single assumption that active centers with alkyl groups containing methyl groups in the β-position with respect to the Ti atom, Ti-CH(CH₃)R, are unusually unreactive in olefin insertion reactions. In the case of ethylene polymerization reactions, such an alkyl group is the ethyl group (in the Ti-C₂H₅ moiety) and, in the case of propylene polymerization reactions, it is predominantly the isopropyl group in the Ti-CH(CH₃)₂ moiety. Published in Russian in Vysokomolekulyarnye Soedineniya, Ser. A, 2008, Vol. 50, No. 11, pp. 1911–1934. The text was submitted by the authors in English.     

Characterization of Ziegler–Natta catalyst by ESCA

The surface composition of TiCl₃-based Ziegler—Natta catalysts prepared by various methods was analyzed by ESCA to correlate the total amount of surface titanium with the catalyst activity in propylene polymerization. The ESCA peak ratio (Ti 2P_3/2/Cl 2P) of the catalysts was measured to estimate the surface composition. The titanium index defined as the product of the (Ti/Cl peak ratio and surface area) was closely correlated with the catalyst activity in polymerization. This indicates that surface titanium concentration and surface area determine the catalyst activity. It was also found that removal of surface aluminum and chlorine at the catalyst preparation stage results in concentration of titanium at the surface and an increase in surface area.     

Recent data on the number of active centers and propagation rate constants in olefin polymerization with supported ZN catalysts

Data on the number of active centers (Cp) and propagation rate constants (Kp) have been obtained by means of polymerization quenching with ¹⁴CO of propylene and ethylene polymerization with supported titanium-magnesium catalysts (TMC) with different composition. In the case of propylene polymerization the Cp and Kp values have been measured separately for isospecific, aspecific and low stereospecific centers. Effects of MgCl₂ support, internal and external donors are discussed on the basis of data obtained. Data on the strong effect of diffusion limitation at ethylene polymerization with number of TMC have been obtained and a set of methods have been used to exclude this effect. Data on Cp and Kp values at ethylene polymerization with low stereospecific and highly stereospecific catalysts are presented.