Tuning the Redox Chemistry of a Cr/SiO2 Phillips Catalyst for Controlling Activity,Induction Period and Polymer Properties

The Cr/SiO₂ Phillips catalyst has taken a central role in ethylene polymerization ever since its discovery in 1953. This catalyst is unique compared to other ethylene polymerization catalysts, since it is active without the addition of a metal-alkyl co-catalyst. However, metal-alkyls can be added for scavenging poisons, enhancing the catalyst activity, reducing the induction period and altering polymer characteristics. Despite extensive research into the working state of the catalyst, still no consensus has been reached. Here, we show that by varying the type of metal-alkyl co-catalyst and its amount, the Cr redox chemistry can be tailored, resulting in distinct catalyst activities, induction periods, and polymer characteristics. We have used in-situ UV-Vis-NIR diffuse reflectance spectroscopy (DRS) for studying the Cr oxidation state during the reduction by tri-ethyl borane (TEB) or tri-ethyl aluminum (TEAl) and during subsequent ethylene polymerization. The results show that TEB primarily acts as a reductant and reduces Cr⁶⁺ with subsequent ethylene polymerization resulting in rapid polyethylene formation. TEAl generated two types of Cr²⁺ sites, inaccessible Cr³⁺ sites and active Cr⁴⁺ sites. Subsequent addition of ethylene also revealed an increased reducibility of residual Cr⁶⁺ sites and resulted in rapid polyethylene formation. Our results demonstrate the possibility of controlling the reduction chemistry by adding the proper amount and type of metal-alkyl for obtaining desired catalyst activities and tailored polyethylene characteristics.     

Performance of the Cr[CH(SiMe3)2]3/SiO2 catalyst for ethylene polymerization compared with the performance of the Phillips catalyst

The catalysis of a silica‐supported chromium system {Cr[CH(SiMe₃)₂]₃/SiO₂} was compared with a silica‐supported chromium oxide catalyst, the Phillips catalyst (CrO₃/SiO₂). This catalyst was prepared by the calcining of the typical silica support used for the Phillips catalyst at 600 °C and by the support of tris[bis(trimethylsilyl)methyl]chromium(III) {Cr[CH(SiMe₃)₂]₃} on the silica. In the slurry‐phase polymerization, this catalyst conducted the polymerization of ethylene at a high activity without organoaluminum compounds as cocatalysts or scavengers. The activity per Cr was about 6–7 times higher than that of the Phillips catalyst. Upon the introduction of hydrogen to the system, the molecular weight of polyethylene did not change with the Phillips catalyst, but it decreased with the Cr[CH(SiMe₃)₂]₃/SiO₂ catalyst. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 413–419, 2003     

Theoretical investigation of novel silsesquioxane-supported Phillips-type catalyst by density functional theory (DFT) method

In spite of great commercial importance of the Phillips CrO_x/SiO₂ catalyst and long term research efforts, the precise physicochemical nature of active sites and polymerization mechanisms still remains unclear. The difficulties in a clear mechanistic understanding of this catalyst mainly come from the complexity of the surface chemistry of the amorphous silica gel support. In this work, novel silsesquioxane-supported Phillips Cr catalysts are utilized as realistic models of the industrial catalyst for theoretical investigation using the density functional theory (DFT) method in order to elucidate the effects of surface chemistry of silica gel in terms of supporting of chromium compounds and fluorination of the silica surface on the catalytic properties of the Phillips catalyst. Both qualitative and quantitative aspects with respect to various electronic properties and thermodynamic characteristics of the model catalysts were achieved. The future prospects of a state-of-the-art catalyst design and mechanistic approaches for the heterogeneous SiO₂-supported Phillips catalyst has been demonstrated. The text was submitted by the authors in English.     

Synthesis and Characterization of Chromium-Based Catalysts for Ethylene-1-hexene Copolymers Preparation via In-Situ Polymerization of Ethylene

The tandem catalysis system including the trimerization catalyst of CrCl₃/SNS (SNS = bis-(2-pentylsulfanyl-ethyl)-amine) (Cat 1) and the copolymerization catalyst Cat 2 of Cr/SiO₂ (Grace 643) has been prepared and used to the synthesis of branched polyethylene. The optimum polymerization conditions were found to be as follows: chromium concentration 0.2 wt %, ethylene pressure 23 bar, solvent hexane, polymerization temperature 90°C, co-catalyst triethylaluminum. The optimally prepared polyethylene was characterized thermally and morphologically. Appearance of α and γ hydrogens in ethylene-1-hexene copolymer confirms the presence of branches in polyethylene backbone.     

α-萘基丁二亚胺氯化镍/MAO制备双(宽)峰聚乙烯

合成了一种新型α 二亚胺镍配合物———α 萘基丁二亚胺氯化镍 ,此配合物作为催化剂在MAO的活化下催化乙烯聚合得到支化聚乙烯 ,聚合活性高达 7 18× 10 5gPE molNi·h ,1 3C NMR、FTIR测试结果表明制备的聚乙烯含有末端双键 ;GPC结果表明所制备的聚乙烯分子量呈双 (宽 )峰分布 ,其原因有两个 ,一是此催化剂能产生分子量较低的α 烯烃 ,在聚合过程中一部分α 烯烃会“就地”与乙烯原位共聚形成分子量较高的聚合物 ,二是此催化剂存在立体异构体 ,而不同异构体在MAO活化下形成的活性中心的配位环境不同 ,因而得到的聚乙烯的分子量也不同 .研究了聚合温度、聚合压力、铝镍摩尔比 (nAl nNi)对催化活性、聚乙烯分子量、支化度的影响 .聚乙烯的分子量随聚合温度的升高而下降 ,支化度增大 ,熔点则降低 .     

Various activation procedures of Phillips catalyst for ethylene polymerization

Nowadays, the Phillips CrO_x/SiO₂ catalyst is still attracting interest from both industrial and academic fields owing to its unique characteristics for HDPE production. Compared with other industrial catalysts for ethylene polymerization, the Phillips catalyst can be activated by ethylene monomer, CO or Al-alkyl cocatalyst after a simple calcination process (thermal activation). In this work, a brief review of our recent new understanding on various activation procedures, including thermal activation, monomer activation, and CO activation, on industrial Phillips catalyst was presented. A new initiation mechanism, ethylene metathesis mechanism, was proposed according to some experimental evidence during the induction period when ethylene monomer was used to activate the catalyst. Such an ethylene metathesis mechanism was also indirectly confirmed in CO-prereduced Phillips catalyst. The formation of short chain branches in polymer can be rationalized well by this newly proposed unique mechanism during ethylene homo-and copolymerization with hexene-1 using CO-prereduced Phillips catalyst in the presence of triethylaluminum cocatalyst.     

Polyethylene with Reverse Co‐monomer Incorporation: From an Industrial Serendipitous Discovery to Fundamental Understanding

A triethylaluminium(TEAl)‐modified Phillips ethylene polymerisation Cr/Ti/SiO₂ catalyst has been developed with two distinct active regions positioned respectively in the inner core and outer shell of the catalyst particle. DRIFTS, EPR, UV‐Vis‐NIR DRS, STXM, SEM‐EDX and GPC‐IR studies revealed that the catalyst produces simultaneously two different polymers, i.e., low molecular weight linear‐chain polyethylene in the Ti‐abundant catalyst particle shell and high molecular weight short‐chain branched polyethylene in the Ti‐scarce catalyst particle core. Co‐monomers for the short‐chain branched polymer were generated in situ within the TEAl‐impregnated confined space of the Ti‐scarce catalyst particle core in close proximity to the active sites that produced the high molecular weight polymer. These results demonstrate that the catalyst particle architecture directly affects polymer composition, offering the perspective of making high‐performance polyethylene from a single reactor system using this modified Phillips catalyst.     

The CrOx/SiO2/Si(100) catalyst – a surface science approach to supported olefin polymerization catalysis

Depositing catalytically active particles onto flat, thin and oxidic support forms an attractive way to make supported catalyst suitable for surface science characterization. Here we show how this approach has been applied to the Phillips (CrO_x/SiO₂) ethylene polymerization catalyst. The model catalyst shows a respectable polymerization activity after thermal activation in dry air (calcination). Combining the molecular information from X‐ray Photoelectron Spectroscopy (XPS) and Secondary Ion Mass Spectrometry (SIMS) we can draw a molecular level of the activated catalyst that features exclusively monochromate species, which are anchored to the silica support via ester bonds with the surface silanol groups. These surface chromates form the active polymerization site upon contact with ethylene. Upon increasing calcination temperature we observe a decrease in chromium coverage as some of the surface chromate desorbs from the silica surface. Nevertheless, we also find an increasing polymerization activity of the model catalyst. We attribute this increase in catalytic activity to the isolation of the supported chromium, which prevents dimerization of the coordinatively unsaturated active site. Diluting the amount of chromium to 200 Cr‐atoms/nm² of silica surface enables the visualisation of polyethylene produced by a single active site.     

Ethylene polymerization on a SiH4-modified Phillips catalyst: detection of in situ produced α-olefins by operando FT-IR spectroscopy

Ethylene polymerization on a model Cr(II)/SiO(2) Phillips catalyst modified with gas phase SiH(4) leads to a waxy product containing a bimodal MW distribution of α-olefins (M(w) < 3000 g mol(-1)) and a highly branched polyethylene, LLDPE (M(w) ≈ 10(5) g mol(-1), T(m) = 123 °C), contrary to the unmodified catalyst which gives a linear and more dense PE, HDPE (M(w) = 86,000 g mol(-1) (PDI = 7), T(m) = 134 °C). Pressure and temperature resolved FT-IR spectroscopy under operando conditions (T = 130-230 K) allows us to detect α-olefins, and in particular 1-hexene and 1-butene (characteristic IR absorption bands at 3581-3574, 1638 and 1598 cm(-1)) as intermediate species before their incorporation in the polymer chains. The polymerization rate is estimated, using time resolved FT-IR spectroscopy, to be 7 times higher on the SiH(4)-modified Phillips catalyst with respect to the unmodified one.     

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     

Supported metallocene catalysts prepared by impregnation of MAO modified silica by a metallocene/monomer solution

Silica supported (butylcyclopentadienyl)₂ZrCl₂/MAO catalysts were synthesized according to the “incipient wetness” method from a solution of metallocene in a liquid monomer. The monomer was allowed to polymerize yielding a catalyst containing polyhexene (PH), polystyrene (PS) or polyoctadiene (PO). One catalyst containing no polymer was also synthesized. The catalysts were used to polymerize ethene at 70°C and 4 bar total pressure. The measured average activities were 5 300 kg PE/(mol Zr · h) for (BuCp)₂ZrCl₂/MAO/PH/SiO₂, 8 600 kg PE/(mol Zr · h) for (BuCp)₂ZrCl₂/MAO/PS/SiO₂, 3 400 kg PE/(mol Zr · h) for (BuCp)₂ZrCl₂/MAO/PO/SiO₂ and 5 700 kg PE/(mol Zr · h) for (BuCp)₂ZrCl₂/MAO/SiO₂. The polyhexene, polystyrene or polyoctadiene in the catalyst forms a protective layer around the active sites. Even after exposure to air for five hours these catalysts retain some polymerization activity.     

Polymerization of ethylene with nickel α-diimine catalysts

Several nickel α-diimine compounds of the general formula (ArNC(R) C(R)NAr)NiX₂ (Ar = 2,6-alkyl substituted Ph, R = H or CH₃, X = Br or CH³) were tested in ethylene polymerization after activation with different co-catalysts, such as methylaluminoxane, Al(C₂H₅)₂Cl or other aluminium alkyls, and ionizing reagents like B(C₆F₅)₃, [CPh₃][B(C₆F₅)₄] or HBF₄. The performances of the different catalytic systems were compared with reference to polymer productivity and structure. The degree of branching of the obtained polyethylenes was shown to depend not only on the ligand environment at the Ni centre but also on the type of co-catalyst.     

Methyl branching in polyethylene from homopolymerization of ethylene with N‐arylcyano‐β‐diketiminate methallyl nickel‐B(C6F5)3

N‐Arylcyano‐β‐diketiminate methallyl nickel complexes activated with B(C₆F₅)₃ were used in the polymerization of ethylene. The microstructure analysis of obtained polyethylene (PE) was done by differential scanning calorimetry and ¹³C nuclear magnetic resonance (NMR). The branched polymer structures produced by these catalysts were attributed to one step isomerization mechanism of the catalyst along the polymer chain. The ortho or para position of the cyano group with co‐ordinated B(C₆F₅)₃ in both methallyl nickel catalysts influenced the polymer molecular weight, branching, and consequently melting and crystallization temperatures. NMR spectroscopic studies showed predominantly the formation of methyl branches in the obtained PE. Catalysts under study gave linear low‐density PEs with good crystallinities at temperatures of reaction between 50 °C and 70 °C at moderate pressures (12.3 atm). A propylene–ethylene copolymer produced by the metallocene catalyst had the same concentration of branches as the PE synthesized from methallyl nickel/B(C₆F₅)₃. Comparing the two polyolefins with the same degree of branching, it was observed that the polymer obtained with the nickel catalyst proved to be twice more crystalline and had greater T_m. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 452–458     

Influence of Pore Structure and Metal-Node Geometry on the Polymerization of Ethylene over Cr-Based Metal–Organic Frameworks

Metal–organic frameworks (MOFs) have received increasing interest as solid single-site catalysts, owing to their tunable pore architecture and metal node geometry. The ability to exploit these modulators makes them prominent candidates for producing polyethylene (PE) materials with narrow dispersity index (Ð) values. Here a study is presented in which the ethylene polymerization properties, with Et₂AlCl as activator, of three renowned Cr-based MOFs, MIL-101(Cr)-NDC (NDC=2,6-dicarboxynapthalene), MIL-53(Cr) and HKUST-1(Cr), are systematically investigated. Ethylene polymerization reactions revealed varying catalytic activities, with MIL-101(Cr)-NDC and MIL-53(Cr) being significantly more active than HKUST-1(Cr). Analysis of the PE products revealed large Ð values, demonstrating that polymerization occurs over a multitude of active Cr centers rather than a singular type of Cr site. Spectroscopic experiments, in the form of powder X-ray diffraction (pXRD), UV/Vis-NIR diffuse reflectance spectroscopy (DRS) and CO probe molecule Fourier transform infrared (FTIR) spectroscopy corroborated these findings, indicating that indeed for each MOF unique active sites are generated, however without alteration of the original oxidation state. Furthermore, the pXRD experiments indicated that one major prerequisite for catalytic activity was the degree of MOF activation by the Et₂AlCl co-catalyst, with the more active materials portraying a larger degree of activation.     

The influence of porosity on the Phillips Cr/silica catalyst 2. Polyethylene elasticity

The Phillips Cr/silica catalyst produces low levels of long chain branching (LCB) in polyethylene, which have a powerful influence on industrial molding behavior. Although many catalyst and reactor variables determine the degree of LCB, perhaps the most significant of these is the morphology of the silica support. In this study many different types of silicas were converted into Cr/silica catalysts, which were tested in ethylene polymerization, and the resultant polymer elasticity was then determined. In some experiments, the surface area of the catalyst seemed to correlate quite well with polymer elasticity. In other tests, however, no connection with surface area was evident but the pore volume was quite influential. Together, all these studies suggest that it is the degree of structural reinforcement of the silica matrix, rather than any one physical measurement of porosity, that influences elasticity. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 845–865, 2009     

Characterization of the changes in the initial morphology for MgCl2-supported Ziegler-Natta polymerization catalysts

Recently considerable detail has become available on the initial morphology and the morphological changes that occur for silica based Cr catalysts for ethylene polymerization. These catalysts are produced as a dry powder and may be employed either in gas phase or in slurry processes. MgCl₂-supported Ziegler-Natta polymerization catalysts are often prepared and employed as slurries. They usually are never dried and thus few studies have employed the spectra of physical techniques common to the characterization of pore structure. In the current study, we have carefully removed the solvent for both ball-milled and precipitated MgCl₂-supported catalysts. These catalysts are characterized by physical sorption, mercury porosimetry, and electron microscopy both as prepared and during the initial stages of polymerization (to ～ 100 g of polymer/g of catalyst). We find that the initial catalyst may be represented by a complex agglomerate of small crystallites as contrasted with the branched pore network found in Cr/silica catalysts. As a result, it is concluded that the initial fragmentation of the MgCl₂ based systems is more uniform as contrasted with the progressive fragmentation of the silica-based system. This fragmentation mechanism facilitates the retention of greater polymer/catalyst surface during the initial stages of the polymerization. © 1992 John Wiley & Sons, Inc.     

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.

     

Synthesis of polyethylene with bimodal molecular weight distribution by supported iron‐based catalyst

Through immobilization of two iron‐based complexes, [((2,6‐MePh)N = C(Me))₂C₅H₃N]FeCl₂ ( 1 ) and [((2,6‐iPrPh)N = C(Me))₂C₅H₃N]FeCl₂ ( 2 ), on SiO₂ pretreated with tetraethylaluminoxane (TEAO), two supported iron‐based catalysts, 1 /TEAO/SiO₂ ( 3 ) and 2 /TEAO/SiO₂ ( 4 ), were prepared. These two supported catalysts 3 and 4 could be used to catalyze ethylene polymerization with moderate polymerization activity and prepare linear high‐density polyethylene with bimodal molecular weight distribution (MWD). It was demonstrated that immobilization of catalyst could significantly improve molecular weight (MW) of high‐MW fraction of the resultant polyethylene, as well as maintain bimodal MWD of polyethylene produced by the corresponding homogeneous catalysts. Such bimodal MWD of polyethylene produced by supported iron‐based catalysts could be well tailored by varying polymerization conditions, such as ethylene pressure and molar ratio of Al to Fe. It has been proven that TEAO is an efficient activator for both homogeneous and heterogeneous iron‐based catalysts for producing polyethylene with bimodal MWD. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 5662–5669, 2004     

Influence of the aluminum alkyl co-catalyst type in Ziegler-Natta ethene polymerization on the formation of active sites, polymerization rate, and molecular weight

The influence of the concentration of the co-catalysts triethylaluminium (TEAL), tri-iso-butylaluminium (TIBAL), tri-n-octylaluminium on the polymerization rate for standard Ziegler-Natta catalyst systems was studied. By comparing the influence of monomeric TIBAL with TEAL co-catalyst on the polymerization activity, the effect of TEAL dimerization was described. The use of the Eley-Ridealadsorption model instead of Langmuir-Hinselwood model is proposed for the absorption of monomeric aluminiumalkyl species and for the formation of active centers C*. It is further proposed that steric hindrance from different co-catalysts, which results in a higher molecular weight (MW) of polymers, is caused by active centers with reduced space for chain transfer reactions.     

SUPPORTED ZIEGLER-NATTA CATALYSTS FOR ETHYLENE SLURRY POLYMERIZATION AND CONTROL OF MOLECULAR WEIGHT DISTRIBUTION OF POLYETHYLENE

The effect of chemical composition of highly active supported Ziegler-Natta catalysts with controlled morphology on the MWD of PE has been studied.It was shown the variation of transition metal compound in the MgCl_2-supported catalyst affect of MWD of PE produced in broad range:Vanadium-magnesium catalyst(VMC)produce PE with broad and bimodal MWD(M_w/M_n=14-21).MWD of PE,produced over titanium-magnesium catalyst(TMC)is narrow or medium depending on Ti content in the catalyst(M_w/M_n=3.1-4.8).The oxidati...