A Self-Supporting Strategy for Gas-Phase and Slurry-Phase Ethylene Polymerization using Late-Transition-Metal Catalysts

The polyolefin industry is dominated by gas-phase and slurry-phase polymerization using heterogeneous catalysts. In contrast, academic research is focused on homogeneous systems, especially for late-transition-metal catalysts. The heterogenization of homogeneous catalysts is a general strategy to provide catalyst solutions for existing industrial polyolefin synthesis. Herein, we report an alternative, potentially general strategy for using homogeneous late-transition-metal catalysts in gas-phase and slurry-phase polymerization. In this self-supporting strategy, catalysts with moderate chain-walking capabilities produced porous polymer supports during gas-phase ethylene polymerization. Chain walking, in which the metal center can move up and down the polymer chain during polymerization, ensures that the metal center can travel along the polymer chain to find suitable sites for ethylene enchainment. This strategy enables simple heterogenization of catalysts on solid supports for slurry-phase polymerization. Most importantly, various branched ultra-high-molecular-weight polyethylenes can be prepared under various polymerization conditions with proper catalyst selection.     

Ultrahigh Branching of Main‐Chain‐Functionalized Polyethylenes by Inverted Insertion Selectivity

Branched polyolefin microstructures resulting from so‐called “chain walking” are a fascinating feature of late transition metal catalysts; however, to date it has not been demonstrated how desirable branched polyolefin microstructures can be generated thereby. We demonstrate how highly branched polyethylenes with methyl branches (220 Me/1000 C) exclusively and very high molecular weights (ca. 10⁶ g mol^?1), reaching the branch density and microstructure of commercial ethylene–propylene elastomers, can be generated from ethylene alone. At the same time, polar groups on the main chain can be generated by in‐chain incorporation of methyl acrylate. Key to this strategy is a novel rigid environment in an α‐diimine Pd^II catalyst with a steric constraint that allows for excessive chain walking and branching, but restricts branch formation to methyl branches, hinders chain transfer to afford a living polymerization, and inverts the regioselectivity of acrylate insertion to a 1,2‐mode.     

Ultrahigh Branching of Main-Chain-Functionalized Polyethylenes by Inverted Insertion Selectivity

Branched polyolefin microstructures resulting from so-called “chain walking” are a fascinating feature of late transition metal catalysts; however, to date it has not been demonstrated how desirable branched polyolefin microstructures can be generated thereby. We demonstrate how highly branched polyethylenes with methyl branches (220 Me/1000 C) exclusively and very high molecular weights (ca. 10⁶ g mol⁻¹), reaching the branch density and microstructure of commercial ethylene–propylene elastomers, can be generated from ethylene alone. At the same time, polar groups on the main chain can be generated by in-chain incorporation of methyl acrylate. Key to this strategy is a novel rigid environment in an α-diimine Pd^II catalyst with a steric constraint that allows for excessive chain walking and branching, but restricts branch formation to methyl branches, hinders chain transfer to afford a living polymerization, and inverts the regioselectivity of acrylate insertion to a 1,2-mode.     

Advances in late transition metal catalysts for olefin polymerization/oligomerizarion

In this review article, we have consolidated our recent studies on late transition metal catalysts (mainly Fe, Co) for olefin polymerization/oligomerization. A series of bisiminopyridyl Co(II) and Fe(II) complexes were synthesized. These catalysts when activated with MAO in aromatic or aliphatic hydrocarbon solvents, oligomerize or polymerize ethylene to α-olefins or high molecular weight polymers with exceptionally high activities and selectivities. The electronic and steric effects of allyloxy and benzyloxy substituted bisiminopyridyl Fe(II) and Co(II) complexes were also investigated. The influence of catalyst structure and temperature on the polymerization activity, thermal properties and molecular weight were discussed. The effects of heterogenization of these catalysts on silica and modified SBA-15 were analyzed. The polymerization of polar monomers such as vinyl ethers and methyl methacrylate was tested and no specific trends in activity and polymer molecular weight with changes in steric bulkiness around the metal center were observed with the same catalyst system.     

Gas‐Phase Olefin Polymerization in the Presence of Supported and Self‐Supported Ziegler‐Natta Catalysts

The RPPFM is employed to describe the gas‐phase catalytic polymerization of ethylene in the presence of supported or self‐supported Z‐N catalysts. Numerical simulations are carried out to analyze the effect of the catalyst type on the polymerization rate, particle overheating and the average molecular polymer properties of the polyolefin. It is shown that non‐porous, self‐supported Ziegler‐Natta catalysts exhibit higher particle growth rates and lower particle overheating. The average molecular weight of polyethylene produced by both catalysts is almost identical. Depending on particle size and polymer crystallinity, the average monomer solubility and the effective monomer diffusivity can significantly vary.

     

Ethylene polymerization using crosslinked polystyrene as support for zirconocene dichloride/methylaluminoxane

In this paper we report on a zirconocene dichloride/methylaluminoxane catalyst system supported on a crosslinked polystyrene in order to provide ethylene polymerization catalysts for gas phase or slurry processes. Our novel approach uses the Diels‐Alder reaction of cyclopentadiene functions as the final, cross‐linking synthetic step. This provides polymer supported zirconocene catalysts with a homogeneous distribution of active sites. The catalysts were shown to be highly active and to form spherical beads as proven by scanning electron microscopy.     

Reversibly Crosslinked Networks of Nanoparticles in Metallocene‐Catalyzed Olefin Polymerization

A hierarchic build‐up of functional nano‐ and microparticles allows the generation of smart organic supports for metallocene catalysts. Latices, well defined in size and surface structure, are made by emulsion polymerization using poly(ethylene oxide)‐containing surfactants. Micron‐sized catalyst beads are formed by reversible loading/crosslinking with a metallocene/methylaluminoxane complex. As a result of the network fragmentation during ethylene polymerization, the catalysts achieve very high productivities, hard polyethylene particles and homogeneous distributions of nanometer‐sized fragments in the product.     

Preparation and characterization of SBA‐15 supported iron(II)‐bisimine pyridine catalyst for ethylene polymerization

2,6‐Diacetylpyridinebis (2,6‐diisopropylani) iron dichloride, a late‐transition metal catalyst for olefin polymerization, was supported on SBA‐15 successfully and the property of the supported catalyst was carefully studied. Ethylene polymerization was systematically investigated in the presence of MAO under various conditions employing this type of catalyst system. In general, after support, a decrease in the catalytic activity was observed and higher molecular weight and fibrous morphology of polyethylene were obtained. The “extrusion polymerization” phenomenon was observed in ethylene polymerization by using the supported catalyst system. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4830–4837, 2004     

Synthesis of Hyperbranched Polyethylene Amphiphiles by Chain Walking Polymerization in Tandem with RAFT Polymerization and Supramolecular Self‐Assembly Vesicles

A novel polymerization methodology for efficient synthesis of hyperbranched polyethylene amphiphiles by chain walking polymerization (CWP) followed by RAFT polymerization has been developed. Hyperbranched polyethylene with hydroxyl ends (HBPE‐OHs) is first synthesized via chain walking copolymerization of ethylene with 2‐hydroxyethyl acrylate with Pd‐α‐diimine catalyst. The hydroxyl groups of hyperbranched polyethylene are then converted into thiocarbonyl thio moieties by an esterification reaction with trithiocarbonate 3‐benzylsulfanylthiocarbonyl sulfanylpropionic acid (BSPA). The hyperbranched polyethylene with thiocarbonyl thio moiety ends (HBPE‐BSPAs) is used as a macro‐RAFT agent for the synthesis of hyperbranched polyethylene amphiphiles, HBPE‐PDMAEMAs, by RAFT polymerization of N,N‐dimethylaminoethyl methacrylate (DMAEMA). The resultant HBPE‐PDMAEMAs can self‐assemble to form supramolecular polymer vesicles in aqueous solution. A preliminary investigation on thermo‐ and pH‐responsive behaviors of the polymer is also reported.     

Silica‐Supported Pentamethylcyclopentadienyl Ytterbium(II) and Samarium(II) Sites: Ultrahigh Molecular Weight Polyethylene without Co‐Catalyst

Designing highly active supported ethylene polymerization catalysts that do not require a co‐catalyst to generate electrophilic metal alkyl species is still a challenge despite its industrial relevance. Described herein is the synthesis and characterization of well‐defined silica‐supported cyclopentadienyl Ln^II sites (Ln=Yb and Sm) of general formula [(≡SiO)LnCp*]. These well‐defined surface species are highly activite towards ethylene polymerization in the absence of added co‐catalyst. Initiation is proposed to occur by single electron transfer.     

Benzosuberyl Substituents as a “Sandwich-like” Function in Olefin Polymerization Catalysis

For the rational design of metal catalyst in olefin polymerization catalysis, various strategies were applied to suppress the chain transfer by bulking up the axial positions of the metal center, among which the "sandwich" type turned out to be an efficient category in achieving high molecular weight polyolefin. In the α-diimine system, the "sandwich" type catalysts were built using the typical 8-aryl-naphthyl framework. In this contribution, by introducing the rotationally restrained benzosuberyl substituent into the ortho-position of N-aryl rings, a new class of "sandwich-like" α-diimine nickel catalysts was constructed and fully identified. The rotationally restrained benzosuberyl substituents played a "sandwich-like" function by capping the nickel center from two axial sites. Compared to the nickel catalyst Ni1 bearing freely rotated benzhydryl substituent, Ni2 featuring benzosuberyl substituent enabled the increase(8 times) of polymer molecular weights from 8 kDa to 65 kDa in the polymerization of ethylene. By further increasing the steric bulk of another ortho-site of the N-aryl ring, the polymer molecular weight even reached an ultrahigh level of 833 kDa(M_w=1857 kDa) using the optimized Ni3. Notably, these nickel catalysts could also mediate the copolymerization of ethylene with methyl 10-undecenoate, with Ni3 giving the highest copolymer molecular weight(88 kDa) and the highest incorporation of comonmer(2.0 mol%), along with high activity of up to 10~5 g·mol~(-1)·h~(-1).     

Olefin Polymerization Catalyzed by Double‐Decker Dipalladium Complexes: Low Branched Poly(α‐Olefin)s by Selective Insertion of the Monomer Molecule

Dipalladium complexes of a cyclic bis(diimine) ligand with a double‐decker structure catalyze polymerization of ethylene and α‐olefins and copolymerization of ethylene with 1‐hexene. The polymerization of 1‐hexene yields a polymer that is mainly composed of the hexamethylene unit formed by 2,1‐insertion of the monomer into the palladium–carbon bond, followed by chain‐walking (6,1‐insertion). The polymerization of 4‐methyl‐1‐pentene proceeds by 2,1‐insertion with a selectivity of 92–97 %, and affords the polymer with methyl and 2‐methylhexyl branches. 2,1‐Insertion occurs selectively in all of the polymerization reactions of α‐olefins catalyzed by the dipalladium complexes. Ethylene polymerization with the catalyst at 100 °C lasts over 24 h, whereas the monopalladium–diimine catalyst loses its activity within 8 h at 60 °C. Polyethylene obtained by the dipalladium catalyst is less‐branched and has a higher molecular weight compared to that of the monopalladium catalyst under the same conditions. Copolymerization of ethylene with 1‐hexene affords solid products with melting points and molecular weights that vary depending on the polymerization time, suggesting formation of a block and/or gradient copolymer.     

过渡金属乙烯齐聚与聚合催化剂研究进展

综述了近年来过渡金属配合物催化乙烯齐聚与聚合的最新进展;介绍了乙烯齐聚或聚合的反应时间、反应温度、乙烯压力、助催化剂用量等反应条件及配体上不同取代基对前过渡金属(铬,锆,钛,钒)和后过渡金属(铁,钴,镍,铜)配合物的催化活性和齐聚或聚合产物的影响;分别以钛和镍配合物催化剂为例,介绍了前过渡金属和后过渡金属催化乙烯齐聚或聚合的机理。     

Preparation and application of a novel core–shell‐particle‐supported zirconocene catalyst

The use of functional groups bearing silica/poly(styrene‐co‐4‐vinylpyridine) core–shell particles as a support for a zirconocene catalyst in ethylene polymerization was studied. Several factors affecting the behavior of the supported catalyst and the properties of the resulting polymer, such as time, temperature, Al/N (molar ratio), and Al/Zr (molar ratio), were examined. The conditions of the supported catalyst preparation were more important than those of the ethylene polymerization. The state of the supported catalyst itself played a decisive role in both the catalytic behavior of the supported catalyst and the properties of polyethylene (PE). IR and X‐ray photoelectron spectroscopy were used to follow the formation of the supports. The formation of cationic active species is hypothesized, and the performance of the core–shell‐particle‐supported zirconocene catalyst is discussed as well. The bulk density of the PE formed was higher than that of the polymer obtained from homogeneous and polymer‐supported Cp₂ZrCl₂/methylaluminoxane catalyst systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2085–2092, 2001     

Influence of Polyethylene Glycol Unit on Palladium‐ and Nickel‐Catalyzed Ethylene Polymerization and Copolymerization

The transition‐metal‐catalyzed copolymerization of olefins with polar functionalized co‐monomers represents a major challenge in the field of olefin polymerization. It is extremely difficult to simultaneously achieve improvements in catalytic activity, polar monomer incorporation, and copolymer molecular weight through ligand modifications. Herein we introduce a polyethylene glycol unit to some phosphine‐sulfonate palladium and nickel catalysts, and its influence on ethylene polymerization and copolymerization is investigated. In ethylene polymerization, this strategy leads to enhanced activity, catalyst stability, and increased polyethylene molecular weight. In ethylene copolymerization with polar monomers, improvements in all copolymerization parameters are realized. This effect is most significant for polar monomers with hydrogen‐bond‐donating abilities.     

Development of an Integrated Framework for Multiscale,Multiphase Modeling of Industrial Slurry‐Phase Reactors for Polyethylene Production

A framework based on the Monte Carlo/random‐pore polymeric flow model is proposed to simulate both single‐particle and continuous slurry reactor industrial polymerizations. The Sanchez–Lacombe equation of state describes the distributions of components in the different phases of these systems. The developed process model is applied to describe heterogeneously catalyzed polymerizations of ethylene in n‐hexane diluent with or without 1‐hexene as a comonomer, but the proposed methodology is applicable to any ethylene/1‐olefin copolymerization in slurry reactors. In addition to the effects of catalyst particle size and reactor residence time distributions, the proposed hybrid model is used to investigate the impact of several catalyst characteristics under different process conditions on polymer yield and microstructure. Particular attention is paid to the catalyst fragmentation process and active center distribution through the particle. These simulations demonstrate the versatility and thoroughness of combining Monte Carlo simulation with single‐particle models to analyze and predict the behavior of commercial polyolefin reactors.     

Stereospecific Olefin Polymerization with Chiral Metallocene Catalysts

Current studies on novel, metallocenebased catalysts for the polymerization of α-olefins have far-reaching implications for the development of new materials as well as for the understanding of basic reaction mechanisms responsible for the growth of a polymer chain at a catalyst center and the control of its stereoregularity. In contrast to heterogeneous Ziegler–Natta catalysts, polymerization by a homogeneous, metallocene-based catalyst occurs principally at a single type of metal center with a defined coordination environment. This makes it possible to correlate metallocene structures with polymer properties such as molecular weight, stereochemical microstructure, crystallization behavior, and mechanical properties. Homogeneous catalyst systems now afford efficient control of regio- and stereoregularities, molecular weights and molecular weight distributions, and comonomer incorporation. By providing a means for the homo- and copolymerization of cyclic olefins, the cyclopolymerization of dienes, and access even to functionalized polyolefins, these catalysts greatly expand the range and versatility of technically feasible types of polyolefin materials. For corrigendum see DOI: 10.1002/anie.199513681     

A New Type of Polymer-Supported Metallocene Catalyst for Ethylene Polymerization

Although homogeneous metallocene catalysts show some specific characteristics, such as single site, extremely high catalytic activity, high ability to incorporate monomers, narrow molecular weight and comonomer distribution, and excellent control of stereoregularity, but they also suffer some drawbacks, a very large amount of MAO requirement, inability to be used in slurry or gas phase processes, and poor control of polymer morphology. Therefore, it is necessary to modify the catalysts for the…     

Outer-Shell Self-Supported Nickel Catalysts for the Synthesis of Polyolefin Composites

In situ heterogeneous olefin polymerization has attracted much attention for the synthesis of polyolefin composites. However, the complicated syntheses of specially designed catalysts or the detrimental effects of interactions between catalyst and solid supports pose great challenges. In this contribution, an outer-shell self-supporting strategy was designed to heterogenize nickel catalysts on different fillers via precipitation homopolymerization of ionic cluster type polar monomer. These catalysts demonstrated high activity, good product morphology control, and stable performances in ethylene polymerization and copolymerization. Moreover, various polyolefin composites with great mechanical and customized properties can be efficiently synthesized.     

Fabrication of Nanofillers into a Granular “Nanosupport” for Ziegler‐Natta Catalysts: Towards Scalable in situ Preparation of Polyolefin Nanocomposites

This communication reports a strategy for scale‐up of an in situ polymerization technique for polyolefin‐based nanocomposites preparation, taking layered silicate (clay) and multi‐walled carbon nanotubes (MWCNTs) as examples of nanofillers. The strategy is realized by transforming the nanofillers into granular “nanosupports” for Ziegler‐Natta catalysts. With a catalyst to polymer replication effect on particle morphology, the in situ prepared nanocomposites are of controlled granular particle morphology. With the polymer particle morphology controlled, the in situ polymerization technique becomes suitable for industrial olefin polymerization processes for mass production of polyolefin nanocomposites.