Magnesium chloride supported high-mileage catalysts for olefin polymerization. I. Chemical composition and oxidation states of titanium

The chemical composition of a MgCl₂-supported, high-mileage catalyst has been determined at every stage of its preparation. Ball milling of MgCl₂ with ethyl benzoate (EB) resulted in the incorporation of 95% of the EB present to give MgCl₂·EB_0.15. A mild reaction with a half-mole equivalent of p-cresol (PC) at 50°C for 1 h resulted in near quantitative retention of p-cresol by the support. The composition is now approximately MgCl₂·EB_0.15P?_0.5. Addition of an amount of AlEt₃ corresponding to half-mole equivalent of p-cresol liberated one mole of ethane per mole of p-cresol, thus signaling quantitative reaction between the two components. The support contains on the average one ethyl group per Al. Further reaction with TiCl₄ resulted in the incorporation of titanium of approximately 8, 38, and 54% in the oxidation states of +2, +3, and +4, respectively. The ratio of Al to Ti in the catalyst lies in the range of 0.5–1.0. Only 19% of all the Ti⁺³ species in the catalyst can be observed by electron paramagnetic resonance (EPR); these are attributable to isolated Ti⁺³ complexes. The remaining EPR silent Ti⁺³ species are believed to be bridged to another Ti⁺³ by Cl ligands. The total Cl content is equal to the sum of 2 × Mg + 3 × Al + 3.5 × Ti. Most of the p-cresol moiety apparently disappeared from the support, leaving much of ethyl benzoate in the catalyst. Activation with AlEt₃/methyl-p-toluate complex reduces 90% of the Ti⁺⁴ in the catalyst to lower oxidation states. The ester apparently moderates the alkylating power of AlEt₃ to avoid excessive formation of divalent titanium sites. There appears to be a constant fraction of 1/4–1/5 of the titanium which is isolated and the remainder is in bridged clusters independent of the oxidation states of titanium.     

Superactive and stereospecific catalysts. II. Kinetics of propylene polymerizations

The kinetics of propylene polymerization by superactive CH-catalyst prepared from toluene solution of MgCl₂ · EH/PA/TiCl₄–TEA/PES was investigated. The results are compared with CW-catalyst prepared from crystalline MgCl₂/EB/PC/TEA/TiCl₄–TEA/MPT (abbreviations given in the text). The former is four times more active than the latter and produces more isotactic polypropylene. The CH-catalyst has 25% of the Ti as isospecific sites as compared to 6.7% for the CW-catalysts. These sites have the same rate constant of propagation so that the higher polymerization activity of the CH-catalyst is attributable simply to a greater number of active sites. Differences in the kinetics of deactivation and of chain transfer for the two catalysts are described.     

Magnesium chloride supported high-mileage catalysts for olefin polymerizations. XVIII. Effect of hydrogen and lewis bases

Hydrogen has been found earlier to increase the initial rate of polymerization by MgCl₂/EB/PC/AlEt₃/TiCl₄-AlEt₃/MPT, CW-catalyst (+B_i, +B_e) (EB, ethyl benzoate; PC, p-cresol; MPT, methyl-p-toluate), but decays more rapidly as compared to polymerizations in the absence of H₂. In this study the effect of H₂ was studied when either the internal Lewis base, EB B_i, or the external Lewis base, MPT B_e, or both are deleted from the CW-catalyst. H₂ does not affect the stereospecificity of all the catalysts, but causes a slight increase of polymer yield, whereas the yield is virtually unchanged by H₂ for the catalysts activated with B_e. Unlike the catalyst (+B_i, +B_e) where H₂ increases active site concentrations [Ti^*] about threefold, it affects [Ti^*] negligibly when B_e is absent. The rate constants of propagation is about the same with or without H₂ for the CW-catalyst (+B_i, –B_e) or (–B_i, –B_e); the same statement can be said about the rate constant of chain transfer with AlEt₃ or with H₂. Hydrogen increases the rate of catalyst site deactivation for the various catalysts in the order of(+B_i, +B_e) > (–B_i, –B_e) > (+B_i, –B_e).     

Magnesium-chloride-supported high-mileage catalysts for olefin polymerization. III. Electron paramagnetic resonance studies

Electron paramagnetic resonance (EPR) was used to study a MgCl₂-supported, high-mileage olefin polymerization catalyst. Anhydrous Toho MgCl₂ was the starting material. Treatment with HCl at an elevated temperature, ethyl benzoate by ball-milling, p-cresol, AlEt₃, and TiCl₄produced a catalyst that contained a single EPR observable Ti⁺³ species A, which was strongly attached to the catalyst surface, had a D_3h symmetry, and no other Ti⁺³ ion in an immediately adjacent site. Species A constitutes only 20% of all the trivalent titaniums; the remainder is EPR-silent and may be attributed to those Ti⁺³ ions that have adjacent sites occupied by one or more Ti⁺³ ions. Activation with preformed AlEt₃/methyl-p-toluate complexes produced a single Ti⁺³ species (C) with rhombic symmetry and displaying ²⁷Al superhyperfin splitting which has attributes for a stereospecific active site. This species is unstable under polymerization conditions and is transformed to another species with axial symmetry and solubilization. Both processes could lead to catalyst deactivation and loss of stereospecificity. Catalysts activated by AlEt₃ and methyl-p-toluate separately in various sequential orders produced a multitude of EPR-observable Ti⁺³ species with varying degrees of motional freedom deemed detrimental to stereospecific polymerization of α-olefins.     

Magnesium-chloride-supported high-mileage catalysts for olefin polymerization. II. Reactions between aluminum alkyl and promoters

The reactions between AlEt₃ and the modifiers, promoters, and coactivators of a typical magnesium-chloride-supported, high-activity propylene polymerization catalyst were studied. Infrared, MS analysis of the gas evolved, and GC–MS of the hydrolysis products for the reaction between AlEt₃ and p-cresol showed rapid and quantitative reactions with p-cresol either in the support or solution. The reaction products from AlEt₃ and esters were hydrolyzed, acidified, and dehydrated. The resulting carbonyl and olefinic compounds were identified by GC–MS. Proton and carbon nuclear magnetic resonance (NMR) techniques were also used to study these reactions. The expected intermediates were found in the PMR and CMR spectra. The mechanisms of reactions were proposed. The results of this study showed that when AlEt₃ and esters are used as coactivators reaction products that can significantly influence the performance of the catalyst are formed.     

Magnesium chloride supported high-mileage catalysts for olefin polymerization. XVII. Effect of lewis base on propylene polymerization

A systematic study has been made on the functions of external Lewis base (B_e, methyl-p-toluate, MPT) and internal Lewis base (B_i, ethyl benzoate, EB) for the CW-catalyst system MgCI₂/EB/PC/AlEt₃/TiCl₄–AlEt₃/MPT (PC, p-cresol). B_i is a nonstereoselective modifier. It increases the active site concentrations and rate constants of propagation, k_p, of both the isospecific and nonspecific sites, and thus the productivities of the stereoregular and irregular polypropylenes by five- to tenfold. It seems that B_i complexes with the MgCl₂ support to lower the electronegativity of the surface Mg atoms. It also acts to lower the rate constant of chain transfer to aluminum alkyl, k, by two- to fourfold. The action of B_e is highly stereospecific. The isotacticity index of polypropylene is ? 95% in the presence of B_e but ? 68% without it. Addition of B_e decreases nonspecific [Ti^*]_a by about (11 ± 2)-fold; there is only about a twofold reduction of the isospecific [Ti^*]_i. It decreases k_p,a about three times but has no effect on k_p,i, so that the latter is (21 ± 4) times the former. B_e decreases k for transfer with aluminum alkyl much more than it does to k; but it does not affect the rates of chain transfer with monomer and by β-hydride elimination or the rate of catalyst deactivation. The number of active sites without B_e is [Ti^*]_i = 15% and [Ti^*]_a = 55% for a total of 70%. In the presence of B_e they are both about 6%. Optimum performance in propylene polymerizations requires both B_i and B_e in the case of the CW-catalyst.     

Superactive and stereospecific catalysts. I. Structures and productivity

Two series of catalysts were made, one from MgCl₂–A solution containing MgCl₂, EH (2-ethylhexanol), and EB (ethyl benzoate) dissolved in decane and another from MgCl₂–B solution containing MgCl₂, EH, and phthalic anhydride which reacted to form the corresponding phthalic ester. Reactions of these solutions with TiCl₄ with or without another ester produced a family of eight catalysts. They form two groups, one having monoesters as modifiers, and the other containing diesters as modifiers. The surface area, pore volume, x-diffractions, polymerization activity, and catalytic stereospecificity of these catalysts have been compared. The diester catalysts differ from the monoester catalysts in every respect. By comparison the corresponding member of the diester catalysts have half as much Ti per Mg, more than 10 times the pore volume, more than a 100-fold the surface area, about 50% more productivity, and greatly increased steroespecificity.     

Rhodium and platinum complexes as catalysts for the polymerization of phenylacetylene

In polymerization reactions of phenylacetylene three different types of polyphenylacetylene (PPA) were prepared by using Rh and Pt complexes as catalysts in different reaction conditions. Type I PPA is obtained with [Rh (COD) Chel] PF₆ complexes (COD = cis,cis-cycloocta 1,5-diene; chel = 2,2′-bipyridine, 1,10-phenanthroline, 2,9-dimethyl-1,10-phenanthroline, 5,6-dimethyl-1,10-phenanthroline, 3,4,7,8-tetramethyl-1,10-phenanthroline) in bulk, benzene methanol, while type II PPA is obtained with the same catalysts in p-dioxane and type III PPA in the presence of [Pt (? C?CPh)₂(PPh₃)₂] in bulk. Type I, II, and III PPA exhibit different IR and ¹H-NMR spectra, which have been compared with literature data. Correlations proposed by different Authors between spectral properties of PPA and chain structures are also discussed.     

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.     

Magnesium chloride-supported,high-mileage catalysts for olefin polymerization. V. BET,porosimetry, and x-ray diffraction studies

The physical state of the material obtained during the various stages of preparation of a typical MgCl₂-supported, high-mileage propylene polymerization catalyst was studied by BET, mercury porosimetry, and x-ray diffraction techniques. The starting MgCl₂ and the substance after HCl treatment have negligible BET surface areas. Mercury porosimetry showed that they have large pores with radii > 200 nm which are probably crevices between MgCl₂ crystallites. The most pronounced physical changes occur during dry porcelain ball milling in the presence of ethyl benzoate. After 60 h or more of ball milling the material had a 5.1–7.3 m² g^?1 BET surface area, twice the pore surface area, and a smaller pore radius than before ball milling and a large reduction in crystallite sizes to almost ultimate dimensions. The crystallites were probably held together by complexation with ethyl benzoate in the form of large agglomerates. Subsequent reactions with p-cresol and triethyl aluminum had minor effects in further reduction of the MgCl² crystallite size but efficiently brokeup the agglomerates. The final refluxing with TiCl₄ increased the BET surface area to 110–150 m² g^?1 but may have increased the crystallite size somewhat due to cocrystallization of TiCl₃ and AlCl₃ with MgCl₂. There may have been only 8–10 crystallites in each catalyst particle. The surface structure of the catalyst resembled those of the classical Ziegler-Natta γ-TiCl₃·0.33 AlCl₃ catalyst.     

Comparative characterization of MgCl2/ethyl benzoate/TiCl4 and MgCl2/2,2,6,6 tetramethylpiperidine/TiCl4 Ziegler-Natta precatalysts

In this article we present the results of the preparation and characterization of two Ziegler–Natta precatalysts: MgCl₂/Ethyl benzoate (EB)/TiCl₄ and MgCl₂/2,2,6,6 tetramethylpiperidine (TMPiP)/TiCl₄ by means of FTIR, X-ray diffraction, SEM, BET surface area measurements, and other techniques applied at different steps of their preparation procedures. The precatalysts were prepared by impregnating with TiCl₄ a given amount of MgCl₂, which was previously ball-milled with the electron donor chosen. Prior to impregnation, the ball-milled material presented different surface compounds depending on the electron donor used: [(MgCl₂)₂] · 2EB, MgCl₂ · EB, or a salt of the amine. The solid milled with EB is more homogeneous than the one milled with the TMPiP. Titanium is better retained in the solid milled with EB. This precatalyst has better morphological properties and larger BET surface area. By means of FTIR, we found evidences that an adequate surface structure for the formation of stereospecific sites in MgCl₂/TMPiP/TiCl₄ was formed. © 1994 John Wiley & Sons, Inc.     

Effect of catalyst aging on catalyst activity and stereospecificity for MgCl2/ethyl benzoate or dioctyl phthalate/TiCl4-triethylaluminium for propene polymerization

The aging of the MgCl₂/dioctyl phthalate (DOP) or ethyl benzoate (EB)/TiCl₄ catalyst was studied. Because of the strong complexation of DOP with the catalyst, only a small fraction of DOP was extracted by cocatalyst triethylaluminium (TEA) during aging, resulting in converting some highly isospecific sites into aspecific ones. No change of the overall number of sites was detected. EB, on the other hand, could be readily removed by TEA, resulting in a large increase in aspecific sites. Clustering of those sites facilitated catalyst deactivation.     

Magnesium chloride supported high mileage catalysts for olefin (decene-1) polymerization XV. Termination and energetics

Polymerizations of decene-1 were carried out from 0° to 70° at A/T = 167 and [M] = 0.75 M initiated by 0.17, 0.34, and 0.69 mM of Ti contained in the MgCl₂/ethylbenzoate/p-cresol/AlEt₃/TiCl₄-AlEt₃/methyl-p-toluate catalyst. The rate of polymerization is directly proportional to the catalyst concentration. About 12% of the Ti in the catalyst is initially active at 50°; they are 1.4%, 8.8%, and 9.4% at 0°, 25°, and 70°, respectively. The changes of R_p with temperature parallels the variations in the active site concentration. The decline of R_p with time has second-order plots with slopes which are inversely proportional to the catalyst concentration, but the rate constants for these deactivations are nearly the same for decene and propylene polymerizations. These results strongly support a mechanism of deactivation involving two adjacent sites in the catalyst particle surfaces. The rate constants of propagation and of chain transfer to AlEt₃, the energetics for these processes, and MW and MW distribution data have been obtained.     

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     

Superactive and stereospecific catalysts. IV. Influence of structure of esters on MgCl2 supported olefin polymerization catalysts

CH-type catalysts were prepared by reacting MgCl₂ · ROH, where ROH is 2-ethyl hexanol (EH), (R)-2-octanol (R-20), and (S)-2-octanol (S-20), with TiCl₄ in the presence of di-i-butyl phthalate (BP), di-i-butyl terephthalate (BT), (-)-dimenthyl phthalate (MP), or (-)-dimenthyl terephthalate (MT). The MT catalysts were found to incorporate 8.9 to 13% Ti whereas the BP catalysts contain only 1.9 to 2.6% Ti. Comparison of the CH(EH, BP) and CH(EH, MT) catalysts showed that they have about equal number of isospecific active sites per gram of catalyst and the same rate constants of propagation for their nonspecific sites, however, the isospecific sites in the latter are less active by comparison. Consequently, the CH(EH, BP) catalysts is five times more active than the CH(EH, MT) catalysts and produces polypropylene which is 97% isotactic (reflux n-heptane insoluble) as compared to 84.7% for the latter. The catalysts derived from 2-octanols are much less active than the corresponding catalysts prepared with 2-ethyl hexanol due to lack of reactivity with phthalic anhydride which permits excessive incorporation of TiCl₄ to form nonstereospecific catalytic sites as well as inactive Ti species.     

Organometallic vanadium-based heterogeneous catalysts for ethylene polymerization. Study of the deactivation process

Slurry polymerizations of ethylene over vanadium catalysts (based on VCl₄ and VOCl₃) and their MgCl₂(THF)₂-supported equivalents were studied. Unsupported vanadium catalysts were found to be unstable while the vanadium active sites deposited on the MgCl₂(THF)₂ complex are stable. A sharply outlined correlation was found between the concentration of vanadium(III) and catalyst productivity. The high activity and stability of the vanadium catalyst when supported on the magnesium complex is attributed to the increase of resistance to reduction of active vanadium(III) to inactive vanadium(II) by an organoaluminium co-catalyst.     

Zinc Transfer Kinetics of Metallothioneins and Their Fragments with Apo‐carbonic Anhydrase

The zinc transfer reactions from Zn₇‐MT‐I, Zn₇‐MT‐II, Zn₄‐α fragment (MT‐I) and Zn₄,‐α fragment (MT‐II) to apo‐carbonic anhydrase have been studied. In each reaction, no more than one zinc ion per molecule is involved in metal transfer. Zn₇‐MT‐I and Zn₇‐MT‐II donate zinc to apo‐carbonic anhydrase and de novo constitute it at a comparable efficiency, while Zn₇‐MT‐II exhibits a little faster rate. Surprisingly, Zinc is released from Zn₄‐α fragment (MT‐II) with a much faster rate than from Zn₄‐α fragment (MT‐I), whose rate is close to that of Zn₇‐MT‐I. The reason for the difference is still unknown. Introducing complex compounds into this system may give rise to an effect on the reaction. The transfer from Zn₇‐MT‐II in the presence of reduced glutathione shows little difference compare to the control, suggesting that the reduced glutathione is not involved in zinc transfer process. However, glutathione disulfide does accelerate this zinc transfer reaction remarkably, indicating that the oxidative factors contribute to zinc release from metallothioneins.     

Acute Toxicity of Cresols to Pseudomonas — An Initial Oxygen Uptake Method

Acute toxicity of cresols to both Pseudomonas I and II was estimated by an initial oxygen uptake method. Inhibition studies of toluene and cresols on the oxidation of either benzoate by Pseudomnas I or phenol by Pseudomonas II were analyzed and expressed as oxygen uptake rates. Double reciprocal plots for the inhibiton by cresols of oxygen uptake in Pseudomonas, two physical constants, Vmaxi and Ki, were obtained. The Vmaxi of o?, m? and p-cresol were 80%, 81% and 57% of Vmax in Pseudomnas I, and 10%, 25% and 36% in Pseudomonas II, respectively. Thus, the toxicity to Pseudomonas I decreases in the order p- > o- ≥ m-cresol, whereas to Pseudomonas II, the order is changed to o- > m- > p-cresol. This difference in the toxicity order is probably due to the allosteric effect of p-cresol towards Pseudomonas II. Inasmuch as most compounds inhibit noncompetively, the relative toxicity of different compounds can be estimated by a new toxicity parameter RI (relative inhibition) which is defined as 100/Ki. By comparing the RI value of each compound, the toxicity to Pseudomonas I decreases in the order m-chlorophenol > p-cresol > p-chlorophenol > o-cresol ≥ m-cresol > o-chlorophenol > toluene > phenol.     

Magnesium chloride supported high mileage catalysts for olefin polymerization. XXI. Isospecific and regiospecific vanadium catalyst for propylene polymerization

Several CW–V catalysts were prepared by supporting VCl₄ on Mg Cl₂ with ethyl benzoate and CH–V catalysts prepared by reacting MgCl₂.ROH, phthalic anhydride, and VCl₄. These vanadium catalysts, activated with TEA (triethyl aluminum)/MPT (methyl-p-toluate) produce mainly (88–96%) refluxing n-heptane insoluble isotactic PP. The active site has $ k_{p,i} = 1580 \left( M {\rm s} \right)^{ - 1}, k_{tr,i}^{\rm A} = 2 \times 10^{ - 3} {\rm s}^{ - 1} , k_{tr}^{\rm H} = 3.8 \times 10^{ - 2} \left( {\rm torr} \right)^{ - {1 \mathord{\left/ {\vphantom {1 2}} \right. \kern-\nulldelimiterspace} 2}} {\rm s}^{ - 1}$ for the isospecific ones and $ k_{p,a} = 58 \left( M {\rm s} \right)^{ - 1} ,k_{tr,a}^{\rm A} = 3 \times 10^{ - 3} {\rm s}^{ -1}$ for the nonspecific sites. Catalyst of VCl₃ supported on MgCl₂ has comparable productivity as the VCl₄/MgCl₂ catalyst but catalyst of VCl₂ supported on MgCl₂ exhibit only one-ninth of the productivity. Extensive comparison has been made between the CW–V and the CW–Ti systems which revealed striking similarities between their polymerization behaviors. MgCl₂ exerts profound influence on the stereochemical control of the vanadium ion on its activity for monomer coordination and insertion.     

Nitrosation kinetics of phenolic components of foods and beverages

The kinetics of the reactions between sodium nitrite and phenol or m-, o-, or p-cresol in potassium hydrogen phthalate buffers of pH 2.5–5.7 were determined by integration of the monitored absorbance of the C-nitroso reaction products. At pH > 3, the dominant reaction was C-nitrosation through a mechanism that appears to consist of a diffusion-controlled attack on the nitrosatable substrate by NO⁺/NO₂H₂⁺ ions followed by a slow proton transfer step; the latter step is supported by the observation of basic catalysis by the buffer which does not form alternative nitrosating agents as nitrosyl compounds. The catalytic coefficients of both anionic forms of the buffer have been determined. The observed order of substrate reactivities (o-cresol ≈ m-cresol > phenol ≫ p-cresol) is explained by the hyperconjugative effect of the methyl group in o- and m-cresol, and by its blocking the para position in p-cresol. Analysis of a plot of ΔH^# against ΔS^# shows that the reaction with p-cresol differs from those with o- and m-cresol as regards the formation and decomposition of the transition state. The genotoxicity of nitrosatable phenols is compared with their reactivity with NO⁺/NO₂H₂⁺. © 1997 John Wiley & Sons, Inc.