Ziegler–Natta catalysts on silica for ethylene polymerization

The amount of dibutylmagnesium (DBM) or triethylaluminum (TEAL) that reacted with silica at 55–60°C depended on the silica calcining temperature. Lower silica calcining temperatures resulted in more Mg or Al fixed to the silica surface, indicating greater amounts of DBM or TEAL reacting with the silica. The amount of the metal alkyls butyl(octyl) magnesium ethoxide, ethylaluminum dichloride, tri-n-hexylaluminum, and diethyl(ethyldimethylsilanolato) aluminum that reacted with 600°C calcined silica was also determined. The metal alkyl can react with the silica at two sites, a surface hydroxyl group and a siloxane group. The silica surface hydroxyl groups can be chemically converted to trimethylsilyl groups so that only the siloxane groups are available for attack. After the metal alkyl was reacted with silica, the resulting intermediate was treated with titanium tetrachloride to yield an ethylene polymerization catalyst in the presence of TEAL. When no metal alkyl was employed, titanium tetrachloride reacted only with the silica surface hydroxyl groups to yield a weakly active ethylene polymerization catalyst.     

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     

Ethylene–styrene thermoplastic copolymers prepared with supported Ziegler–Natta catalysts

The magnesium chloride supported Ziegler–Natta catalysts are able to copolymerize ethylene and styrene in conditions of high activity. Different parameters, including catalyst type, monomer ratio, temperature and Lewis bases, allow variation of the activity and reactivity ratio. The incorporation of styrene in the copolymer remains always rather limited in moles. The products obtained contain less than 20% styrene in weight, and seem very similar in structure to linear low-density polyethylenes (LLDPE) obtained with the same catalyst: the melting temperature is only about 5°C lower than that of pure polyethylene. The polymer can be fractionated by solvents in a similar manner to LLDPE, and contains a styrene-enriched fraction, but homopolystyrene production has never been observed.     

Layer-lattices in Ziegler–Natta catalysts

Some layered inorganic compounds of interest in old and new polymerization processes by Ziegler-Natta stereospecific catalysis have been studied. The results are reported of an investigation concerning the crystallographic disorder phenomena in α-TiCl₃, VCl₃, FeCl₃, ball-milled α-MgCl₂, β-MgCl₂, and in a new catalytic system produced according to some recent trends in the field. Best fits are reported of the experimental x-ray diffraction patterns with patterns calculated for a theoretical model that accounts for structural disorder; the different fits indicate that disorder phenomena due to stacking faults are rather frequent in the examined compounds. The catalytic systems are more and more dispersed, and the maximum of dispersion in heterogeneous systems is reached for the recently proposed formulations.     

Control of composition in ethylene copolymerizations using magnesium chloride supported Ziegler–Natta catalysts

Incorporation of a sterically hindered phenol (2,6-di-tert-butyl-4-methylphenol) during the preparation of MgCl₂-supported titanium catalysts coupled with the use of an aluminum alkyl activator modified with the same phenol and an electron donor such as ethyl benzoate allows the systematic modification of the reactivity ratios of ethylene and 1-olefin copolymerizations. The polymers obtained tend to be largely random with a tendency toward alternating at high comonomer incorporation. Very low density LLDPE copolymers have been prepared in stable slurry polymerizations. The same catalysts allow the preparation of copolymers with dienes.     

Reduced titanium dioxide as support for Ziegler–Natta catalysts

Titanium tetrachloride heterogenized on reduced TiO₂ has been studied as a catalyst for ethylene polymerization. The catalyst has good storage stability and exhibits good activity for ethylene polymerization. The polymer chains grow linearly during ca. 1 h, giving an average molecular weight of up to 2.5 × 10⁶ which indicates that practically no β-elimination occurs. The activity of the catalyst at 50°C, based on Ti(III), is 7.6 × 10⁶ PE/mol Ti h bar and based on the quantity of polyethylene formed it is 1.25 × 10⁶ g PE/mol Ti h bar. The molecular weight of the polymer can be controlled with the addition of hydrogen, under 0.5 bar hydrogen, polyethylene with a molecular weight of 411,000 and a relatively low polydispersity index of 2.2 is obtained. The catalyst shows good thermal stability; the Arrhenius activation energy is 31.8 kJ/mol for the polymerization. The catalyst is also active for propylene polymerization, giving 3 × 10⁶ g PP/mol Ti h bar with the high isotacticity of 93%. © 1994 John Wiley & Sons, Inc.     

New Ziegler–Natta polymerization catalysts and new polymers

Models for the explanation of the stereospecific behaviour of Ziegler-Natta catalysts, homogeneous and heterogeneous, are discussed. Structural data on new types of stereoregular polymers, obtained with homogeneous catalysts, are reported.     

Organic nanoparticles as fragmentable support for Ziegler–Natta catalysts

A fragmentable support material for Ziegler–Natta catalysts is presented based on micrometer‐sized aggregates of polystyrene nanoparticles. Hydroxyl anchoring groups are introduced by copolymerization of hydroxymethylstyrene in emulsion process to immobilize the catalysts. The catalytic activity in ethylene slurry polymerizations is found to be directly correlated to the hydroxyl group content of the supports. Furthermore, the fragmentation behavior of dye‐labeled support aggregates into the initial nanoparticles is demonstrated using laser scanning confocal fluorescence microscopy as a nondestructive method. These supported catalysts fulfill two important design criteria, high fragmentability and high catalyst loading, and produce high‐density polyethylene with medium molecular weight distributions (MWDs = 3–4). These values lie between those obtained using single‐site metallocene‐based (narrow MWD < 3) or inorganic supported multi‐site Ziegler–Natta‐based (broad MWD = 4–12) polymerizations without the need of blending. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 15–22     

Crown ethers as ligands for stereospecific polymerization by Ziegler–Natta catalysts

Some new TiCl₄/Crown ether complexes were synthesized and used as polymerization catalysts with AlEt₃ or AlEt₂Cl as cocatalyst for the stereospecific polymerization of 1,3-butadiene. As with most of the nucleophilic ligands the addition of crown ethers to Ziegler–Natta catalytic systems results in a decrease of the polymer conversion. But the Al/Ti molar ratio appears to be less critical for the complexed systems than for the uncomplexed ones. The presence of the crown ether in the surroundings of the catalytic sites presumably protects them from an excess of the organoaluminum cocatalyst. The side groups of the crown ether do not influence the microstructure of the polybutadiene obtained but they change the activity of the catalytic systems. Thus, the electron-donating effect of the macrocyclic ligands seems to be less important than the sterical effect due to the rigidity and to the hole size of the crown ether.     

Reactivity of 4-vinylpyridine in the presence of Ziegler–Natta catalysts

The homopolymerization of both free and aluminum alkyls complexed 4-vinylpyridine (4VP) in the presence of Ziegler-Natta catalysts, based on TiCl₃“ARA” and aluminum or zinc alkyls, has been performed. The copolymerization of free or complexed 4VP with chiral α-olefins or styrene (St), using the same catalysts, has also been investigated. Spectroscopic and solubility data of the polymers obtained are consistent with the presence in the above-mentioned catalysts of several species having different reactivity and stereochemistry. Data, based on fractionation and composition of the resulting polymeric products, are reported supporting a polymerization mechanism different from that connected with a free radical initiation.     

Polymerization of propylene by mixed Ziegler–Natta and metallocene catalysts

The polymerization of propylene using a mixture of racemic metallocenes and Ziegler–Natta catalysts was investigated. The polypropylene was obtained as a mixture of a fine powder and beads, with the powder being absorbed partially on the beads. The relative amount of the powder can be controlled by the concentration of the metallocene. The compatibility between the components of the mixed catalytic systems and the effect of the components on the rate of polymerization and on the properties of the new polymers were studied. The metallocene system dramatically affects the melt viscosity, isotacticity and molecular weight of the polymers. The two catalytic systems are able to act jointly, producing different polymers, for which separate melting and crystallization temperatures are obtained. © 1998 John Wiley & Sons, Ltd.     

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     

High activity magnesium chloride supported catalysts for olefin polymerization. XXIX. Molecular basis of hydrogen activation of magnesium chloride supported Ziegler–Natta catalysts

Hydrogen (pH₂ = 72 torr) increases the rate of propylene polymerization by a MgCl₂/ethyl benzoate/p-cresol/AlEt₃/TiCl₄-AlEt₃/methyl-p-toluate catalyst (CW-catalyst) by two-to three-fold which corresponds closely with the increase in the number of active sites as counted by radiolabeling with tritiated methanol. The oxidation states of titanium in decene polymerizations by the CW-catalyst were determined as a function of time of polymerization (t_p). In the absence of H₂, all [Ti⁺ⁿ] for n = 2, 3, 4 remain constant during a batch polymerization. In the presence of H₂ and within 5 min of t_p, [Ti⁺²] decreases by an amount, corresponding to 15% of the total titanium and [Ti⁺³] increases by the same amount, while [Ti⁺⁴] is not changed. Therefore, three-fourths of the H₂ activation result from oxidative addition processes. The remaining one-fourth of the H₂ activation may be attributed to the activation of previously deactivated Ti⁺³ ions by hydrogenolysis. Monomer converts some of the EPR silent Ti⁺³ sites to EPR observable species resulting in their activation.     

Multi‐center nature of heterogeneous Ziegler–Natta catalysts: TREF confirmation

A new approach to detailed Tref analysis of ethylene/α‐olefin copolymers prepared with multi‐center polymerization catalysts is developed. It is based on resolution of complex Tref curves into elemental components described with the Lorentz distribution function. This approach was applied to the study of a series of ethylene/1‐butene copolymers prepared with a supported Ti‐based catalyst. The analysis showed that the copolymers, which, on average, contain from 6.5 to 3.5 mol % of 1‐butene, consist of seven discrete components with different compositions, ranging from a completely amorphous material with a 1‐butene content of > 15–20 mol %, to two highly crystalline components with 1‐butene contents < 1 mol %. A comparison of these Tref results with the data on the molecular weight distribution of the copolymers (based on resolution of their GPC curves) shows that Tref and GPC data provide complimentary information on the properties of active centers in the catalysts in terms of the molecular weights of the material they produce and their ability to copolymerize α‐olefins with ethylene. Tref analysis of copolymers produced at different reaction times showed that the active centers responsible for the formation of various Tref components differ in the rates of their formation and in stability. The centers that produce copolymer molecules with a high 1‐butene content are formed rapidly but decay rapidly as well whereas the centers producing copolymer molecules with a low 1‐butene content are formed more slowly but are more stable. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 4351–4362, 2005     

Some contributions to the characterization of active sites in Mg-supported Ziegler–Natta catalysts

The contribution of different MgO supports to the coordination polymerization of ethylene was studied by x-ray diffractometry and infrared (IR) and electron spin resonance (ESR) spectroscopy of the supports and their products after treatment with TiCl₄. It was concluded that TiCl₄ was bonded on the surface OH groups of MgO mainly in inactive form, whereas the majority of the active sites was associated with the coordinatively unsaturated O^2? ions.     

Polymer-supported Ziegler–Natta catalyst for the polymerization of isoprene

A polymer-supported Ziegler–Natta catalyst, polystyrene-TiCl₄AlEt₂Cl (PS–TiCl₄AlEt₂Cl), was synthesized by reaction of polystyrene–TiCl₄ complex (PS–TiCl₄) with AlEt₂Cl. This catalyst showed the same, or lightly greater catalytic activity to the unsupported Ziegler–Natta catalyst for polymerization of isoprene. It also has much greater storability, and can be reused and regenerated. Its overall catalytic yield for isoprene polymerization is ca. 20 kg polyisoprene/gTi. The polymerization rate depends on catalyst titanium concentration, mole ratio of Al/Ti, monomer concentration, and temperature. The kinetic equation of this polymerization is: R_p = k[M]^0.30[Ti]^0.41[Al]^1.28, and the apparent activation energy ΔE_act = 14.5 kJ/Mol, and the frequency factor A_p = 33 L/(mol s). The mechanism of the isoprene polymerization catalyzed by the polymer-supported catalyst is also described. © 1993 John Wiley & Sons, Inc.     

Application of Monte Carlo simulation method to polymerization kinetics over Ziegler–Natta catalysts

In the current work, the Monte Carlo simulation method was applied to ethylene polymerization over Ziegler–Natta catalysts. As expected, polymerization over each center of a Ziegler–Natta catalyst leads to a polymer having a Schultz–Flory molecular weight distribution. Notwithstanding, the total molecular weight distribution obtained by all catalyst centers together is at least twice as broad as that of each center. As another interesting finding, the introduction of hydrogen to the reaction deactivates the catalyst active centers and thereby reduces the catalyst activity. Nevertheless, it does not mainly affect the polymerization kinetics. In addition, the polymer molecular weight falls as hydrogen is added to the reaction since it acts as a strong transfer agent. The same effect is seen when cocatalyst concentration increases. Hydrogen also widens the polymer molecular weight distribution. © 2008 Wiley Periodicals, Inc. Int J Chem Kinet 41: 45–56, 2009     

Polymerization of ethylene at high temperature by vanadium-based heterogeneous Ziegler–Natta catalysts. I. Study of the deactivation process

Kinetics of the polymerization of ethylene initiated by heterogeneous vanadium-based Ziegler-Natta catalysts (VCI₃-1/3 AICI₃) have been studied at high temperature (160°C, 5 bars) and compared with a titanium-based system. For the V catalyst, the dependence of the polymerization activity versus time, with the nature and the concentration of the associated aluminum alkyl, has been investigated. Kinetic results have also been correlated with the oxidation state of vanadium in the polymerization conditions. Despite the relatively high initial activity a low productivity is obtained; it can be attributed to a very fast deactivation of the active sites due to the reduction of vanadium III into vanadium II. The effect of the nature of the alkyl aluminum component of the catalytic system on the reduction process is shown. A kinetic model for the polymerization is proposed. © 1993 John Wiley & Sons, Inc.     

Polymer-supported Ziegler–Natta catalysts. I. A preliminary study of catalyst synthesis

Polymer-supported Ziegler–Natta catalysts based on various polymer carriers were synthesized by different methods, including (1) loading TiCl₄ directly onto the polymer supports; (2) loading TiCl₄ onto the polymer supports modified by magnesium chloride (MgCl₂); (3) loading TiCl₄ onto the polymer supports modified by Grignard reagent (RMgCl); and (4) loading TiCl₄ onto the polymer supports modified by magnesium alkyls (MgR₂). The activity and kinetic features of the catalysts for ethylene polymerization were examined. Among the combinations tested, the best was found to be TiCl₄/n-Bu₂Mg.Et₃Al/poly(ethylene-co-acrylic acid) (92:8), which produced a catalyst of very high activity for ethylene polymerization. © 1994 John Wiley & Sons, Inc.