Polymerization of ethylene over metallocenes confined inside the supercage of a NaY zeolite

Metallocene catalysts entrapped inside the supercages of NaY zeolite were prepared by reacting NaY with methylaluminoxane (MAO) or trimethylaluminium (TMA) and then with Cp₂ZrCl₂ (Cp: cyclopentadienyl) or Cp₂TiCl₂. NaY/MAO/Cp₂ZrCl₂ and NaY/MAO/Cp₂TiCl₂ catalysts could polymerize ethylene. The amount of additional MAO for the polymerization was lowered to a mole ratio of Al/Zr of 186. Molecular weights and melting points of polyethylene polymerized with NaY-supported catalysts were higher than those of polyethylene obtained with homogeneous metallocene catalysts. It could be confirmed by extraction experiments that the metallocene catalyst was confined securely inside the supercage of the NaY zeolite.     

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     

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.     

ESR study on styrene polymerization with CpTiCl3/MMAO: Effect of monomer addition on catalyst activity

An on-line electron spin resonance (ESR) technique was applied to investigate the syndiospecific polymerization of styrene activated by the catalyst system CpTiCl₃/MMAO. The measurements included trivalent titanocene concentration and monomer conversion. The activation procedure was found to have a dramatic effect on catalyst activity. Adding the reactants in the order of (MMAO + CpTiCl₃) + St gave a much higher trivalent titanocene concentration and catalyst activity than the order of (MMAO + St) + CpTiCl₃. The catalyst deactivation behaviors in the temperature range of 25–70°C were followed as a function of time during polymerization. At high Al/Ti ratios (500–1000), the decay rates of trivalent titanocene in the presence of styrene were much faster than those of the pure catalyst system. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3385–3390, 1999     

A novel zirconocene/ultradispersed diamond black powder supported catalytic system for ethylene polymerization

A novel carrier of ultradispersed diamond black powder (UDDBP) was used to support metallocene catalyst. Al₂O₃ was also used as carrier in order to compare with UDDBP. Supported catalysts for ethylene polymerization were synthesized by two different reaction methods. One way was direct immobilization of the metallocene on the support, the other was adsorption of MAO onto the support followed by addition of the metallocene. Four supported catalysts Cp₂ZrCl₂/UDDBP, Cp₂ZrCl₂/Al₂O₃, Cp₂ZrCl₂/MAO/UDDBP and Cp₂ZrCl₂/Al₂O₃/MAO were obtained. The content of the zirconium in the supported catalyst was determined by UV spectroscopy. The activity of the ethylene polymerization catalyzed by supported catalyst was investigated. The influence of Al/Zr molar ratio and polymerization temperature on the activity was discussed. The polymerization rate was also observed.     

Metallocene/mao polymerization catalysts supported on cyclodextrin

By treating cyclodextrin(CD) with methylaluminoxane (MAO such as PMAO or MMAO) or trimethylaluminium (TMA) followed by Cp₂ZrCl₂, CD/PMAO/Cp₂ZrCl₂, CD/MMAO/Cp₂ZrCl₂ and CD/TMA/Cp₂ZrCl₂ catalysts were prepared. The catalysts were analyzed by ¹³C-CP/MAS NMR spectrometer and ICP to examine the structure of catalyst and content of Zr and Al. Ethylene polymerization was conducted with MAO or TMA as cocatalyst. Styrene polymerization was also carried out with α-CD/MMAO/Cp*TiCl₃ and α-CD/TMA/Cp*TiCl₃ catalysts. While the ordinary trialkylaluminium such as TMA as well as MAO can be used as cocatalyst for ethylene polymerization, only MAO could initiate the styrene polymerization with α-CD supported catalysts.     

Controlling molecular weight distributions of polyethylene by combining soluble metallocene/MAO catalysts

A critical look at the possibility of controlling the molecular weight distribution (MWD) of polyolefins by combining metallocene/methylalumoxane (MAO) catalysts is offered. Catalysts investigated were bis(cyclopentadienyl)zirconium dichloride (Cp₂ZrCl₂), its titanium and hafnium analogues (Cp₂TiCl₂ and Cp₂HfCl₂), as well as rac-ethylenebis(indenyl)zirconium dichloride (Et(Ind)₂ZrCl₂). As observed by other researchers, the MWD of polyethylene can be manipulated by combining soluble catalysts, which on their own produce polymer with narrow MWD but with different average molecular weights. Combined in slurry polymerization reactors, the catalysts in consideration produce ethylene homopolymer just as they would independently. Unimodal or bimodal MWDs can be obtained. This effect can be mimicked by blending polymers produced by the individual catalysts. We demonstrate how a variability in catalyst activity translates into a variability in MWD when mixing soluble catalysts in polymerization. Such a variability in MWD must be considered when setting goals for MWD control. We introduce a more quantitative approach to controlling the MWD using this method. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 831–840, 1998     

Unusual features of ethylene copolymerization reactions with binary metallocene catalysts

Ethylene/1-hexene copolymers produced with MAO-activated binary metallocene catalysts, such as combinations Cp₂ZrCl₂ + (Me₅Cp)₂ZrCl₂, (Ind-H₄)₂ZrCl₂ + (Me₅Cp)₂ZrCl₂, Cp₂ZrCl₂ + Cp₂TiCl₂, etc., contain three types of components. Two of the components can be attributed to active centers derived from each individual metallocene complex, and one or two materials are produced with different types of active center. Some of the binary catalysts generate the three components in comparable proportions, whereas other catalysts produce copolymers with one dominant component, which does not resemble the copolymers produced with the individual complexes. A mechanism is proposed for the formation of the “new” copolymer materials.     

Metallocene–methylaluminoxane catalysts for olefin polymerizations. III. Reduction of η5-cyclopentadienyl trichlorides of titanium and zirconium

The reactions occurring between the components of metallocene and methylaluminoxane (MAO) catalyst leading to the reduction of the former were studied by electron paramagnetic resonance (EPR). At low Al/Zr ratios, C_pZrCl₃ (C_p = η⁵-cyclopentadienyl) was reduced to simple trivalent Zr species (g = 1.998, a(⁹¹Zr) = 12.3 G) without other superhyperfine splittings. At higher Al/Zr ratios the reactions proceed further to form two CpZr(III) hydrides (g = 1.991, a(H) = 5.5 G; and g = 2.00, a(H) = 3 G). Two CpTi(III) hydrides were also produced by the reaction of MAO with CpTiCl₃ (g = 1.989, a(H) = 7.4 G, a(Ti) = 8 G; and, g = 1.995, a(H) = 4.5 G, a(Ti) = 8 G). In the case of Cp^*TiCl₃ (Cp^* = η⁵-pentamethyl cyclopentadienyl) initially a multitude of paramagnetic species were formed. After long reaction time the final products show EPR features consistent with two η³: η⁴-(1,2,3-trimethyl-4,5-dimethylene cyclopentadienyl)hydrido Ti(III) species: the abundant one with g = 1.999, (H, sextet) = 9.5 G, a(Ti) = 9.5 G, and a weaker one of g = 1.975, a(H) = 4.8 G. All the five protons of these species and as well as those in the Cp hydrido complexes of Ti and Zr undergo facile H? D exchanges with D₂. MAO is important in the formation of these hydrides because they are not formed by trimethyl aluminum reduction. The presence of tetrahydrofuran suppresses the hydride formation. The possible structures for the hydrido species and reactions producing them are discussed.     

Combined polymerization catalysis of nickel complex and zirconocene for branched polyethylene

The polymerization behavior of 2-(2′-pyridyl) quinoxaline nickel dibromide/Cp₂ZrCl₂/MAO system was investigated in three ways: the Ni catalyst was added first, followed by addition of Zr catalyst (method I); the Ni and Zr catalysts were added simultaneously (method II); and the Zr catalyst was added first, followed by addition of Ni catalyst (method III). Results of GC-MS, GPC,¹³C NMR and DSC investigations indicated that the properties of resulting polyethylene were greatly varied by changing feeding orders of the two catalysts. Decreasing Ni/Zr molar ratio or increasing polymerization temperature gave corresponding polyethylenes with less branches and higher melting point. Compared to the procedure using Cp₂ZrCl₂ catalyst only, the activity of Zr catalyst in those combined system decreased because of the competition of ethylene between the [Ni−C] and [Zr−C] active centers. In addition, other zirconocenes were also employed as copolymerization catalysts in the combined system with nickel complex. compared to Cp₂ZrCl₂ case, the ethyl-bridged Zr catalyst performed better for polymerization of ethylene while the Si-bridged Zr catalyst showed better copolymerization ability.     

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 with acrylonitrile promoted by novel nonmetallocene catalysts with phenoxy‐imine ligands

A series of novel nonmetallocene catalysts with phenoxy‐imine ligands was synthesized by the treatment of phthaldialdehyde, substituted phenol with TiCl₄, ZrCl₄, and YCl₃ in THF. The structures and properties of the catalysts were characterized by ¹H NMR and elemental analysis. These catalysts were used for copolymerization of ethylene with acrylonitrile after activated by methylaluminoxane (MAO). The effects of copolymerization temperature, Al/M (M = Ti, Zr, and Y) ratio in mole, concentrations of catalyst and comonomer on the polymerization behaviors were investigated in detail. These results revealed that these catalysts were favorable for copolymerization of ethylene with acrylonitrile. Cat. 3 was the most favorable one for the copolymerization of ethylene with acrylonitrile, and the catalytic activity was up to 2.19 × 10⁴ g PE/mol.Ti.h under the conditions: polymerization temperature of 50 °C, Al/Ti molar ratio of 300, catalyst concentration of 1.0 × 10^–4 mol/L, and toluene as solvent. The resultant polymer was characterized by FTIR, cross‐polarization magic angle spinning, ¹³C NMR, WAXD, GPC, and DSC. The results confirmed that the obtained copolymer featured high‐weight–average molecular weight, narrow molecular weight distribution about 1.61–1.95, and high‐acrylonitrile incorporation up to 2.29 mol %. Melting temperature of the copolymer depended on the content of acrylonitrile incorporation within the copolymer chain. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

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     

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     

Preparation of functionalized montmorillonites and their application in supported zirconocene catalysts for ethylene polymerization

Ethylene polymerization was carried out with zirconocene catalysts supported on montmorillonite (or functionalized montmorillonite). The functionalized montmorillonite was from simple ion exchange of [CH₃O₂CCH₂NH₃]⁺ (MeGlyH⁺) ions with interlamellar cations of layered montmorillonites. The functionalized montmorillonites [high‐purity montmorillonite (MMT)‐MeGlyH⁺] had larger interlayer spacing (12.69 Å) than montmorillonites without treatment (9.65 Å). The zirconocene catalyst system [Cp₂ZrCl₂/methylaluminoxane (MAO)/MMT‐MeGlyH⁺] had much higher Zr loading and higher activities than those of other zirconocene catalyst systems (Cp₂ZrCl₂/MMT, Cp₂ZrCl₂/MMT‐MeGlyH⁺, Cp₂ZrCl₂/MAO/MMT, [Cp₂ZrCl]⁺[BF₄]/MMT, [Cp₂ZrCl]⁺[BF₄]^?/MMT‐MeGlyH⁺, [Cp₂ZrCl]⁺[BF₄]^?/MAO/MMT‐MeGlyH⁺, and [Cp₂ZrCl]⁺[BF₄]^?/MAO/MMT). The polyethylenes with good bulk density were obtained from the catalyst systems, particularly (Cp₂ZrCl₂/MAO/MMT‐MeGlyH⁺). MeGlyH⁺ and MAO seemed to play important roles for preparation of the supported zirconocenes and polymerization of ethylene. The difference in Zr loading and catalytic activity among the supported zirconocene catalysts is discussed. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1892–1898, 2002     

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.     

Synthesis of tailor‐made polyethylene through the control of polymerization conditions using selectively combined metallocene catalysts in a supported system

Tailoring of the molecular weight distribution (MWD) in ethylene polymerization was attempted by selectively combining different types of metallocene catalysts onto a single support. The catalyst produced by supporting Et[Ind]₂ZrCl₂ and Cp₂HfCl₂ onto a single MAO pretreated silica support was able to produce polymers with unimodal or bimodal MWD's. This approach permits the synthesis of polyethylene with different MWD's using the same catalyst as a function of the polymerization conditions. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 331–339, 1999     

Polymerization of methyl methacrylate using a metallocene catalyst system

Methyl methacrylate was polymerized with Cp₂YCl(THF) or IVB group metallocene compounds (i.e., Cp₂ZrCl₂ and Cp₂HfCl₂, etc.), in the presence of a Lewis acid like Zn(C₂H₅)₂. The Lewis acid was complexed with methyl methacrylate, which avoided the metallocene compounds being poisoned with a functional group. A living polymerization was promoted through the use of metallocene/MAO/Zn(C₂H₅)₂, which gave tactic poly(methyl methacrylate) with a high molecular weight. The polymer yield increases with polymerization time, which indicates that the propagation rate is zero in order in the concentration of the monomer. The polymer yield increases also with the concentration of Cp₂YCl(THF), which indicates the yttrocene to be the real catalyst. When the polymerization temperature exceeds room temperature, the poly(methyl methacrylate) cannot be synthesized by the Cp₂YCl(THF) catalyst. When the reaction temperature reachs −60 °C, the poly(methyl methacrylate) is high syndiotatic and molecular weight by the Cp₂YCl(THF)/MAO catalyst system. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1184–1194, 2000     

Polymerization of 1-vinylcyclohexene in the presence of group 4 metallocenes – MAO catalysts

1-Vinylcyclohexene was polymerized in the presence of several homogeneous catalytic systems consisting of methylaluminoxane and group 4 metallocenes such as CpTiCl₃, [isopropyl(cyclopentadienyl)(1-fluorenyl)]ZrCl₂,rac-[ethylenebis(1-indenyl)] ZrCl₂, (CH₃)₂Si(Cp)₂ZrCl₂, CpZrCl₃. The structure of the polymers depends on the catalyst. In fact, with CpTiCl₃, [isopropyl(cyclopentadienyl)(1-fluorenyl)]ZrCl₂ and rac-[ethylenebis-(1-indenyl)]ZrCl₂ the polymers are chemo-, regio- and stereoregular with 1,4 cis, 1,4 trans and 1,2 isotactic structure, respectively.     

Surface chemistry of selected supported metallocene catalysts studied by DR‐FTIR,CPMAS NMR,and XPS techniques

Two supported metallocene catalysts (CS 1: PQ 3030/MAO/Cp₂ZrCl₂ and CS 2: PQ 3030‐BuGeCl₃/MAO/Cp₂ ZrCl₂) were prepared by sequentially loading MAO and Cp₂ZrCl₂ on partially dehydroxylated silica PQ 3030. In catalyst CS 2, ⁿBuGeCl₃ was used to functionalize the silica. These catalysts were characterized by DR‐FTIR spectroscopy, CPMAS NMR spectroscopy, and XPS. Their catalytic performance was evaluated by polymerizing ethylene using the MAO cocatalyst and characterizing the resulting polymers by GPC. Both catalysts produced two metallocenium cations (Cation 1: [Cp₂ZrCl]⁺ and Cation 2: [Cp₂ZrMe]⁺) with comparable equilibrium concentrations and showed varying solid‐state electronic environments. The modified supports (PQ 3030/MAO and PQ 3030‐BuGeCl₃/MAO) acted as weakly coordinating polyanions and stabilized the above cations. BuGeCl₃ did not affect the solid‐state electronic environment. However, it increased the surface cocatalyst to catalyst molar ratio (Al:Zr), acted as a spacer, increased catalyst activity, and enhanced chain‐transfer reactions. The separately fed MAO cocatalyst shifted the equilibrium between Cation 1 and Cation 2 toward the right. Consequently, more Cation 2 was generated, which acted as the effective and active single‐site catalytic species producing monomodal PDI. Copyright © 2006 John Wiley & Sons, Ltd.