Peculiarities of Ethylene Polymerization Reactions with Heterogeneous Ziegler–Natta Catalysts: Kinetic Analysis

The previously developed kinetic scheme for olefin polymerization reactions with heterogeneous Ziegler–Natta catalysts states that the catalysts have several types of active centers which have different activities, different stabilities, produce different types of polymer materials, and respond differently to reaction conditions. In the case of ethylene polymerization reactions, each type of center exhibits an unusual chemical feature: a growing polymer chain containing one ethylene unit, Ti—C₂H₅, is unusually stable and can decompose with the formation of the Ti—H bond. This paper examines quantitative kinetic ramifications of this chemical mechanism. Modeling of the complex kinetics scheme described in the Scheme demonstrates that it correctly and quantitatively predicts three most significant peculiarities of ethylene polymerization reactions, the high reaction order with respect to the ethylene concentration, reversible poisoning with hydrogen, and activation in the presence of α‐olefins.     

Study of the composition and morphology of new modifications of titanium‐magnesium catalysts with improved properties in ethylene polymerization

Data on new modifications of supported titanium‐magnesium catalysts (TMCs) with improved performance in ethylene polymerization are reported. These catalysts possess a high and stable activity, an enhanced ability to regulate molecular weight of the polymer by hydrogen, a controllable particle size at a narrow particle size distribution, and the ability to produce the polymer with an increased bulk density. Various physicochemical methods were used to obtain data on the chemical composition of novel supports and catalysts, their phase composition and crystal structure as well as the pore structure. The results obtained were used to discuss possible correlations between composition and structure of TMCs and their catalytic properties. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 2545–2558     

Effect of the structure of titanium–magnesium catalysts on the morphology of polyethylene produced

The structure and formation of polyethylene (PE) particles on supported titanium–magnesium catalysts having different structural characteristics (sizes of microcrystallites, mesopores, and subparticles) were studied for the first time. Scanning electron microscopy was used to identify structural elements of the polymer particles formed over such catalysts and to reveal morphological changes in the growing polymer particles when the yield was increased from approximately 0.2 g PE/g catalyst to approximately 13 kg PE/g catalyst. A relationship was found between structural characteristics of the porous catalyst particles, morphology of the nascent polymer particles, and bulk density of the polymer powder. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2298–2308     

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     

Novel spherical Ziegler–Natta catalyst for polymerization and copolymerization. I. Spherical MgCl2 support

Spherical MgCl₂ adducts used as supports for a Ziegler–Natta catalyst for olefin polymerization were prepared by the general precipitation method. The influence of MgCl₂/EtOH (mol/mol) and the dispersion speeds on the particle size (PS) and particle size distribution (PSD) were investigated. It was found that the former played a trivial role in controlling the PS and PSD, and the latter was the key factor. In particular, the influence of ethanol on the crystal structure was further examined, with consideration given to the performance of the supported Ziegler–Natta catalyst. It was believed that the reactions between MgCl₂ and ethanol had a controlling effect on the destruction of the original anhydrous MgCl₂, which was the key point in the preparation of suitable supports for the latest generation Ziegler–Natta catalyst. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3112–3119, 2002     

Alternating,gradient, block,and block–gradient copolymers of ethylene and norbornene by Pd–Diimine‐Catalyzed “living” copolymerization

We demonstrate, in this article, the facile synthesis of a broad class of low‐polydispersity ethylene–norbornene (E–NB) copolymers having various controllable comonomer composition distributions, including gradient, alternating, diblock, triblock, and block–gradient, through “living”/quasiliving E–NB copolymerization facilitated with a single Pd – diimine catalyst ( 1 ). This synthesis benefits from two remarkable features of catalyst 1 , its high capability in NB incorporation and high versatility in rendering E–NB “living” copolymerization at various NB feed concentrations ([NB]₀) while under an ethylene pressure of 1 atm and at 15 °C. At higher [NB]₀ values between 0.42 and 0.64 M, E–NB copolymerization with 1 renders nearly perfect alternating copolymers. At lower [NB]₀ values (0.11–0.22 M), gradient copolymers yield due to gradual reduction in NB concentration, with the starting chain end containing primarily alternating segments and the finishing end being hyperbranched polyethylene segments. Through two‐stage or three‐stage “living” copolymerization with sequential NB feeding, diblock or triblock copolymers containing gradient block(s) have been designed. This work thus greatly expands the family of E–NB copolymers. All the copolymers have controllable molecular weight and relatively low polydispersity (with polydispersity index below 1.20). Most notably, some of the gradient and block–gradient copolymers have been found to exhibit the characteristic broad glass transitions as a result of their possession of broad composition distribution. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Evaluation of the Initial Stages of Gas‐Phase Ethylene Polymerizations with a SiO2‐Supported Ziegler–Natta Catalyst

The very early stages of gas‐phase ethylene polymerization on an SiO₂‐supported Ziegler–Natta catalyst were studied with the help of a short‐stop reactor. The short‐stop‐reactor‐based technique was useful in studying nascent polymerization, providing insights at very short, controlled times into important phenomena regarding catalyst fragmentation and the activation and deactivation of catalyst sites that take place during the very early stages of the reaction. Experimental results indicate that the growth of the polymer chains occurs at unsteady conditions during the initial stages of the polymerization. Hydrogen has a strong influence on the initial kinetics, leading to a significant decrease of polymerization activity. Polymer crystallinity increases with the reaction time, probably due to the formation of long chains with a high degree of crystallinity.

     

Preparation of linear α‐olefins to high‐molecular weight polyethylenes using cationic α‐diimine nickel(II) complexes containing chloro‐substituted ligands

A series of α‐diimine nickel(II) complexes containing chloro‐substituted ligands, [(Ar)N?C(C₁₀H₆)C?N(Ar)]NiBr₂ ( 4a , Ar = 2,3‐C₆H₃Cl₂; 4b , Ar = 2,4‐C₆H₃Cl₂; 4c , Ar = 2,5‐C₆H₃Cl₂; 4d , Ar = 2,6‐C₆H₃Cl₂; 4e , Ar = 2,4,6‐C₆H₂Cl₃) and [(Ar)N?C(C₁₀H₆)C?N(Ar)]₂NiBr₂ ( 5a , Ar = 2,3‐C₆H₃Cl₂; 5b , Ar = 2,4‐C₆H₃Cl₂; 5c , Ar = 2,5‐C₆H₃Cl₂), have been synthesized and investigated as precatalysts for ethylene polymerization. In the presence of modified methylaluminoxane (MMAO) as a cocatalyst, these complexes are highly effective catalysts for the oligomerization or polymerization of ethylene under mild conditions. The catalyst activity and the properties of the products were strongly affected by the aryl‐substituents of the ligands used. Depending on the catalyst structure, it is possible to obtain the products ranging from linear α‐olefins to high‐molecular weight polyethylenes. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1964–1974, 2006     

Annealing of melt‐crystallized polyethylene and its influence on microstructure and mechanical properties: A comparative study on branched and linear polyethylenes

Annealing treatments have been performed on two melt‐crystallized polyethylenes (PE) with different topologies, namely highly branched and linear PE, to comparatively investigate the microstructural evolution and corresponding changes of mechanical property. It shows that annealing induced different degrees of variation in the lamellar rearrangement of the two PEs. Branched PE, which incorporates comonomers on the backbones, shows a more versatile annealing effect when compared with the linear counterpart. With respect to PEs, it is for the first time a connection was made between the annealing‐induced microstructural changes and an important but less understood property known as heat distortion temperature (HDT). It shows that at lower annealing temperatures, the improvement of HDT can be well correlated to the increased crystallinity induced by lamellar rearrangement for both PEs. However, for branched PE, the contribution of crystallinity is weakened at higher annealing temperatures and the dominant factor on HDT was replaced by the relaxation of lamellar structure. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 49: 1347–1359, 2011     

Propylene polymerization reactions with supported Ziegler–Natta catalysts: Observing polymer material produced by a single active center

Medium‐ and high‐resolution SEM analysis of several Ti‐based MgCl₂‐supported Ziegler–Natta catalysts and isotactic polypropylene produced with them is carried out. Each catalyst particle, 35–55 μ in size, produces one polymer particle with an average size of 1.5–2 mm, which replicates the shape of the catalyst particle. Polymer particles contain two distinct morphological features. The larger of them are globules with D_av ～400 nm; from 1 to 2 × 10¹¹ globules per particle. Each globule represents the combined polymer output of a single active center. The globules consist of ～2500 microglobules with an average size of ～20 nm. The microglobules contain several folded polymer molecules; they are the smallest thermodynamically stable macromolecular ensembles in propylene polymerization reactions. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 3832–3841     

Synthesis and properties of super high molecular weight polyhexene-1

TiCl₄–alkylaluminium systems have been fixed on graphite and other inorganic supports and used in hexene-1 polymerization. Kinetic studies show a decreasing polymerization rate from high initial values. High conversions (up to 99%) are reached, although retardation by a diffusion process is observed above 60%. The polymers have high molecular weights (up to 10⁷) and high isotacticity (up to 98.5% from ¹³C NMR analysis). The effects of the nature of the components (carrier, alkylaluminium), and their concentration on the polymerization kinetics and the molecular structure of the polymer are discussed. The linear chain has one alkyl group (the alkylaluminium) and one unsaturation as the chain ends. Despite the high tacticity, the polymers are amorphous and rubber-like.     

Half‐titanocene complexes bearing dianionic 6‐benzimidazolylpyridyl‐2‐carboximidate ligands: Synthesis,characterization, and their ethylene polymerization

6‐Benzimidazolylpyridyl‐2‐carboximidic half‐titanocene complexes, Cp′TiLCl (Cp′ = C₅H₅, MeC₅H₄, C₅Me₅, L = 6‐benzimidazolylpyridine‐2‐carboxylimidic, C1–C13 ), were synthesized and characterized along with single‐crystal X‐ray diffraction. The half‐titanocene chlorides containing substituted cyclopentadienyl groups, especially pentamethylcyclopentadienyl groups were more stable, while those without substituents on the cyclopentadienyl groups were easily transformed into their dimeric oxo‐bridged complexes, (CpTiL)₂O ( C14 and C15 ). In the presence of excessive amounts of methylaluminoxane (MAO) or modified methylaluminoxane (MMAO), all half‐titanocene complexes showed high catalytic activities for ethylene polymerization. The substituents on the Cp groups affected the catalytic behaviors of the complexes significantly, with less substituents favoring increased activities and higher molecular weights of the resultant polyethylenes. Effects of reaction conditions on catalytic behaviors were systematically investigated with catalytic systems of mononuclear C1 and dimeric C14 . With C1 /MAO, large MAO amount significantly increases the catalytic activity, while the temperature only has a slight effect on the productivity. In the case of C14 /MAO catalytic system, temperature above 60 °C and Al/Ti value higher than 5000 were necessary to observe good catalytic activities. In both systems, higher reaction temperature and low cocatalyst amount gave the polyethylenes with higher molecular weights. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 3396–3410, 2008     

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     

New tethered ansa‐bridged zirconium catalysts: Insights into the “self‐immobilization” mechanism

New ω‐alkenyl‐substituted ansa‐bridged bisindenyl zirconium complexes are prepared and tested as self‐immobilized catalysts for ethene polymerization. But, even at very high concentration of the tethered complexes and low pressure of ethene, there is no evidence of their insertion into the polyethene chain. A “cross polymerization” test, performed by copolymerizing the tethered complexes with ethene using rac‐Me₂Si(2‐MeBenzInd)₂ZrCl₂ ( MBI ), does not lead to their incorporation into the polyethene chain. However, the corresponding ligand proves to be a suitable comonomer for ethene, and, through copolymerization promoted by MBI, innovative poly(ethene‐co‐2,2′‐bis[(1H‐inden‐3′‐yl)‐hex‐5‐ene) copolymers are prepared and characterized by ¹³C NMR. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Liquid‐phase polymerization of propylene with a highly active Ziegler–Natta catalyst. Influence of hydrogen,cocatalyst, and electron donor on the reaction kinetics

This paper presents an experimental kinetic study of the polymerization of propylene in liquid monomer with a high activity catalyst. The influences of the concentration of hydrogen and the molar ratios of the catalyst, cocatalyst, and electron donor on the activation period, the maximum activity, the yield, and the decay behavior have been investigated at a temperature of 42°C using a relatively simple kinetic model. On the basis of the experimental data, the reaction rate has been modeled as a function of the hydrogen concentration, the molar ratio of cocatalyst and titanium, and the molar ratio of the electron donor and the cocatalyst. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 219–232, 1999     

Nascent particle sizes and degrees of entanglement are responsible for the significant differences in impact strength of ultrahigh molecular weight polyethylene

The physical properties of ultrahigh molecular weight polyethylene (UHMWPE) are generally highly dependent on its molecular weight. However, in our study, it was found that two UHMWPE samples of similar molecular weight, SLL‐5 and GUR 4150, have significantly different impact strengths, with the Charpy impact strength of GUR 4150 being almost 3.4 times that of SLL‐5. To reveal the reasons, the structure–property relations of these UHMWPE materials were investigated. Morphologies of the nascent particles and impact fracture surfaces, the melting behavior, rheological behavior, and three‐phase (crystalline, amorphous, and interphase) contents were characterized by scanning electron microscopy, differential scanning calorimetry, advanced rotary rheometer, and Raman spectroscopy, respectively. It was observed that no significant differences in the crystal structures of SLL‐5 and GUR 4150, but GUR 4150 had smaller nascent particles sizes and a lower degree of entanglement when compared with those of SLL‐5. Accordingly, a mechanism to clarify the significant difference in the impact strengths of GUR 4150 and SLL‐5 was developed. More importantly, this work may be useful for improving the preparation technologies and industrial applications of UHMWPE. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2019 , 57, 632–641     

In situ polymerization of ethylene using metallocene catalysts: Effect of clay pretreatment on the properties of highly filled polyethylene nanocomposites

Highly filled polyethylene (PE)‐based nanocomposites were obtained by insitu polymerization technique. An organically modified montmorillonite, Cloisite® 15A (C15A), was previously treated with methylaluminoxane (MAO) to form a supported cocatalyst (C15A/MAO) before being contacted with a zirconocene catalyst. The main features of C15A/MAO intermediates were studied by elemental analysis, TGA, TGA‐FTIR, WAXD, and TEM. MAO reacts with the clay, replaces most of the organic surfactant within the clay galleries and destroys the typical crystrallographic order of the nanoclay. The catalytic activity in the presence of C15A/MAO is higher than in ethylene polymerization without any inorganic filler and increases with MAO supportation time. This indicates that part of the polymer chains grows within the clay galleries, separates them, and makes it possible to tune the final morphology of the composites. The polymerization results and the influence of C15A pretreatment and polymerization conditions on thermal and morphological properties of the hybrid PE/C15A nanocomposites are presented. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5390–5403, 2008     

Chlorotitanium (IV) tetradentate Schiff‐base complex immobilized on inorganic supports: Support type and other factors having effect on ethylene polymerization activity

A titanium complex with [O,N,N,O]‐type tetradentate Schiff base (LTiCl₂), never used before in polymerization of olefins, was immobilized on silica‐ and magnesium‐type carriers, and it was used in ethylene polymerization. The conducted research revealed that the catalytic properties of the complex LTiCl₂ supported on those carriers were different for both the catalytic systems studied, and simultaneously they turned out different from those of the unsupported system. The supported catalysts require the use of Me₃Al, Et₃Al, or MAO as the activator to be able to offer high catalytic activities, whereas Et₂AlCl is needed for the nonsupported catalyst. This finding, together with considerable changes in polymerization yields and in properties of polymers versus composition of the catalytic system, suggest that there are different types of active sites in the studied catalysts. The catalyst anchored on the carrier produced in the reaction of MgCl₂·3.4EtOH with Et₂AlCl is definitely the most active one within the support systems tested. Its activity remarkably increases with the increasing reaction temperature. Moreover, that catalyst does not undergo deactivation over the studied period of time, irrespective of the type of the activator used and of the process temperature. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 4811–4821, 2009