Metallocene–methylaluminoxane catalysts for olefin polymerization. I. Trimethylaluminum as coactivator

Ethylene was polymerized by Cp₂ZrCl₂–methylaluminoxane (MAO) catalysts where a portion of the MAO was replaced with trimethyl aluminum (TMA). At a total Al to Zr ratio of 1070, there is neither appreciable loss of productivity nor change in polymerization profile for TMA/MAO ≤ 10. The productivity is reduced only by two- to three-fold for TMA/MAO ≤ 100 accompanied by a 10 min induction period. Aging of this catalyst did not affect the induction period, but improves its productivity. The kinetic isotope effect for radiolabeling with tritiated methanol is 2.0. About 40% of the Zr is active for the catalyst with {99 [TMA] + 1[MAO]} to Zr ratio of 100. The rate constants for propagation and chain transfer were obtained. The mechanisms for the mixed TMA and MAO cocatalyst system are discussed. The results of this work have important practical significance. MAO is a hazardous material to synthesize and only in low yields. The replacement of > 90% of MAO with TMA represents a substantial saving since as much as 0.1M of the former is commonly used for a polymerization.     

Metallocene–methylaluminoxane catalysts for olefin polymerizations. III. Reduction of η5-cyclopentadienyl trichlorides of titanium and zirconium

The reactions occurring between the components of metallocene and methylaluminoxane (MAO) catalyst leading to the reduction of the former were studied by electron paramagnetic resonance (EPR). At low Al/Zr ratios, C_pZrCl₃ (C_p = η⁵-cyclopentadienyl) was reduced to simple trivalent Zr species (g = 1.998, a(⁹¹Zr) = 12.3 G) without other superhyperfine splittings. At higher Al/Zr ratios the reactions proceed further to form two CpZr(III) hydrides (g = 1.991, a(H) = 5.5 G; and g = 2.00, a(H) = 3 G). Two CpTi(III) hydrides were also produced by the reaction of MAO with CpTiCl₃ (g = 1.989, a(H) = 7.4 G, a(Ti) = 8 G; and, g = 1.995, a(H) = 4.5 G, a(Ti) = 8 G). In the case of Cp^*TiCl₃ (Cp^* = η⁵-pentamethyl cyclopentadienyl) initially a multitude of paramagnetic species were formed. After long reaction time the final products show EPR features consistent with two η³: η⁴-(1,2,3-trimethyl-4,5-dimethylene cyclopentadienyl)hydrido Ti(III) species: the abundant one with g = 1.999, (H, sextet) = 9.5 G, a(Ti) = 9.5 G, and a weaker one of g = 1.975, a(H) = 4.8 G. All the five protons of these species and as well as those in the Cp hydrido complexes of Ti and Zr undergo facile H? D exchanges with D₂. MAO is important in the formation of these hydrides because they are not formed by trimethyl aluminum reduction. The presence of tetrahydrofuran suppresses the hydride formation. The possible structures for the hydrido species and reactions producing them are discussed.     

Metallocene–methyl aluminoxane catalysts for olefin polymerization. VIII. Infrared spectra of anisotactic polypropylene

Polypropylenes obtained with the homogeneous racemic ethylene bis(indenyl) zirconium dichloride/methyl-aluminoxane catalyst were fractionated by solvent extraction. The IR absorbance ratios, A₉₉₈/A₉₇₃ and A₈₄₁/A₉₇₃, were found to vary linearly with the homosteric sequence population, [m m m m] and [m m]. These results are compared with the results of a similar study by Burfield and Loi on commercial and laboratory polypropylenes of the conventional types.     

Metallocene–methylaluminoxane catalyst for olefin polymerization. II. Bis-η5-(neomenthyl cyclopentadienyl)zirconium dichloride

Bis(neomenthyl cyclopentadienyl)zirconium dichloride/methyl aluminoxane (η⁵-(NMCp)₂ZrCl₂/MAO) catalyst has been investigated for ethylene polymerization. About 51% of the Zr forms active sites more or less instantaneously according to quenching with tritiated methanol. There is an initial drop of rate of polymerization, R_p, of about 30% which remains constant thereafter. The catalytic activity increases monotonically with temperature; it is proportional to [MAO]^1.75 at a constant [Zr] = 1.5 μM and proportional to [Zr]^?1.2 at a constant [MAO] = 64.5 mM. At very large [MAO]/[Zr], the catalyst has extremely high activity; κ_p = 5 × 10³ (Ms)^?1 at 50°C. There is also facile chain transfer to aluminum, κ = 0.14 s^?1 at 50°C. Both κ_p and κ are about 30 times greater than the corresponding rate constants for MgCl₂ supported TiCl₃ catalysts. The TiCl₃/MgCl₂ and (NMCp)₂/MAO catalysts have nearly the same activation energy for propagation (ca. 7 kcal/mol^?1). The higher activity of the latter is due to its larger preexponential factor in κ_p. The dependence of catalytic activity on the [MAO]/[Zr] ratio may be explained by rapid association-dissociation equilibria of MAO involving acid-base and/or electron deficient bridge complexation.     

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. IV. FTIR and quantitative analysis of modifiers in the catalysts

Fourier transform infrared (FTIR) spectra were obtained for a typical MgCl₂-supported, high-mileage catalyst for propylene polymerization. When ball-milling MgCl₂ with ethyl benzoate (EB), the latter is incorporated into the support (I) by Lewis acid-base complexation involving both oxygen atoms of the ester. Reaction of (I) with p-cresol (PC) resulted in a material (II) that contains all the characteristic IR bands of PC. The reaction of (II) that contains all the characteristic IR bands of PC. The reaction of (II) with AlEt₃ (TEA) resulted in (III) whose spectrum supports the reaction observed by product analysis and NMR spectroscopy. There was no evidence of any reaction between TEA and EB. Further reaction of (III) with an excess of TiCl₄ caused substantial removal of the p-cresol moiety as shown by the diminution of its characteristic bands. Finally, activation with 3TEA-1MT (methyl-p-toluate) complexes gave spectra that revealed the presence of MT in the activated catalyst without any visage of p-cresol moiety. The nondestructive FTIR method, however, is not quantitative. Quantitative analysis of the organic components in the support materials (I), (II), and (III) and the catalysts was accomplished by hydrolysis of the inorganic components, extraction with ether, and analysis by gas chromatography. The results are in good agreement with composition deducted from elemental analysis and substantiate the FTIR conclusions.     

Design of organometallic group IV heteroallylic complexes and their catalytic properties for polymerizations and olefin centered transformations

The use of metallocenes in many stoichiometric and catalytic processes has been the impetus for the development of new organometallic complexes, especially those containing early transition metals. The formation of coordinative unsaturated complexes using allylic, benzamidinate and aminopyridine families is presented. The synthesis and structural parameters of the new complexes, their activation and use in the polymerization of alpha-olefins and dienes, in the dehydrogenative coupling of silanes and in the hydroamination reactions comprise the objectives of this review.     

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.     

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     

Magnesium chloride supported high-mileage catalysts for olefin polymerization. X. Effect of hydrogen and catalytic site deactivation

The effect of H₂ on propylene polymerization initiated by a MgCl₂/EB/PC/AlEt₃/TiCl₄–3 AlEt₃/MPT catalyst was studied. Hydrogen increases significantly the initial rate during the early stage of the polymerization to give a higher yield of polymer than reactions without H₂. But H₂ reduces the yield toward the latter stages so that the net effect on the total yield can be quite small. There is no appreciable effect of H₂ on either the isotacticity index or polydispersity of the products. It decreases molecular weight proportional to (p_H2)^1/2. The chain transfer by H₂ resulted in a decrease of total metal polymer bond concentration with time of polymerization. The rate constants of hydrogen chain transfer for the two kinds of isospecific and nonspecific sites are = 5.1 × 10^?3, = 2.7 × 10^?3, = 7.5 × 10^?3, = 4.4 × 10^?3, in units of torr^1/2 sec^?1 at 50°. Hydrogen assists in the deactivation of the catalytic sites as does propylene; rates of the former and the latter vary with (p_H2)^1/2 and [C₃H₆]^1/2, respectively, with k = (12.1 ± 0.9) M^?1 torr^?1/2 sec^?1 and k = (65.3 ± 3.3) M^?3/2 sec^?1 at 50° and A/T = 167. The mechanism for deactivation of catalytic sites are 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.     

Studies on Ziegler-Natta catalysts. Part IV. Chemical nature of the active site

The determination of the number of sites active in the polymerization of ethylene on the surface of α-TiCl₃–Al(CH₃)₃ dry catalysts leads to the conclusion that this number is small in comparison to the total surface of the catalyst. Qualitatively this conclusion is also reached by two other independent methods. Infrared spectra of the catalyst before and after polymerization do not show a change in the type of bonds present in the surface. Electron microscopy proves that no active sites are formed on the basal plane of the α-TiCl₃ which constitutes 95% of the total surface. The results strongly favor the lateral faces of α-TiCl₃ as the preferred location of active centers. The lateral faces contain chlorine vacancies and incompletely coordinated titanium atoms. This must then be the essential conditions for the formation of active centers. The propagation of the polymer chain has been repeatedly shown to follow an insertion mechanism. The active site, therefore, necessarily contains a metal–carbon bond. The study of catalysts derived from TiCl₃CH₃ leads to the conclusion that a Ti? C bond on titanium of incomplete coordination is the active species in these cases. The alkylation of surface titanium atoms was proven to be an intermediate step in the catalyst formation from TiCl₃ and AlR₃. Survival of titanium–alkyl bonds on the lateral faces, where titanium atoms are incompletely coordinated explains best, in the light of our data, the activity of Ziegler-Natta catalysts. Coordination of aluminum alkyl compounds in or around the active center probably complicates the structure of the active centers.     

Experimental and theoretical investigations of the structure of methylaluminoxane (MAO) cocatalysts for olefin polymerization

The structure of methylaluminoxane (MAO), used as a cocatalyst for olefin polymerization, has been investigated by Raman and in situ IR spectroscopy, polymerization experiments, and density functional calculations. From experimental results, a number of quantum chemical calculations, and bonding properties of related compounds, we have suggested a few Me₁₈Al₁₂O₉ cage structures, including a highly regular one with C_3h symmetry, which may serve as models for methylaluminoxane solutions. The cages themselves are rigid but may contain up to three bridging methyl groups on the cage surfaces that are labile and reactive. Bridging methyls were substituted with Cl atoms to form a compound otherwise similar to MAO. Chlorinated MAO is unable to activate a metallocene catalyst, even in the presence of trimethylaluminum (TMA), but allows subsequent activation by regular MAO. With bis(pentamethylcyclopentadienyl)zirconium dichloride, MAO and TMA seem to influence chain termination independently. Several findings previously poorly explained are rationalized with the new model, including the observed lack of reaction products with excess TMA. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3106–3127, 2000     

Magnesium chloride supported catalysts for olefin polymerization. XIX. Titanium oxidation states,catalyst deactivation,and active site structure

A precise method for the determinations of Ti⁺², Ti⁺³ and Ti⁺⁴ was developed. The CW-procatalyst before activation contains mostly Ti⁺⁴ ions with 6% Ti⁺³ and 4% Ti⁺² ions. Activation with AlEt₃ alone at room temperature reduced all the titaniums to lower valence states consisting of 71% Ti⁺³ and 29% Ti⁺². Reduction is incomplete when methyl-p-toluate was present as external Lewis base during activation: at 25°C the distribution of Ti⁺⁴ : Ti⁺³ : Ti⁺² is 36% : 25% : 38%; the distribution at 50°C is 37% : 22% : 40%. Aging of the activated catalyst caused little or no changes in the distribution of [Ti⁺ⁿ]; whereas the catalytic activity decays rapidly with aging. The aged catalysts have polymerization activity comparable to the decreased activity of the catalyst during a polymerization. The [Ti⁺ⁿ] was determined for the CW-catalyst during the course of a decene polymerization; they were found to be Ti⁺⁴ : Ti⁺³ : Ti⁺² = 30% : 27% : 43%, which did not change with polymerization time. These results suggest that the reducibility of Ti⁺⁴ species by AlEt₃ or 3AlEt₃/MPT to different valence states is predicated by their structures. These species do not undergo further changes in their oxidation states during either aging or polymerization. Their decays probably involve nonreductive metathesis reactions like those known for zirconium alkyls. Possible structures for the stereospecific and nonspecific sites are proposed.     

Statistical Approach for the Determination of the Stereoregularity of Optically Active Propylene–CO Copolymers

A two‐parameter statistic model was applied to analyze the NMR spectra of a series of stereoregular propylene–CO copolymers synthesized by catalytic polymerization in the presence of various transition‐metal complexes containing chiral ligands. The concentration of the different pentads, estimated to be recognizable in the spectra, was determined. A tentative assignment of the nature of the different peaks composing the signal of the C?O group in the ¹³C‐NMR spectra is proposed.     

The atomic-level regulation of single-atom site catalysts for the electrochemical CO2 reduction reaction

The electrochemical CO₂ reduction reaction (CO₂RR) is viewed as a promising way to remove the greenhouse gas CO₂ from the atmosphere and convert it into useful industrial products such as methane, methanol, formate, ethanol, and so forth. Single-atom site catalysts (SACs) featuring maximum theoretical atom utilization and a unique electronic structure and coordination environment have emerged as promising candidates for use in the CO₂RR. The electronic properties and atomic structures of the central metal sites in SACs will be changed significantly once the types or coordination environments of the central metal sites are altered, which appears to provide new routes for engineering SACs for CO₂ electrocatalysis. Therefore, it is of great importance to discuss the structural regulation of SACs at the atomic level and their influence on CO₂RR activity and selectivity. Despite substantial efforts being made to fabricate various SACs, the principles of regulating the intrinsic electrocatalytic performances of the single-atom sites still needs to be sufficiently emphasized. In this perspective article, we present the latest progress relating to the synthesis and catalytic performance of SACs for the electrochemical CO₂RR. We summarize the atomic-level regulation of SACs for the electrochemical CO₂RR from five aspects: the regulation of the central metal atoms, the coordination environments, the interface of single metal complex sites, multi-atom active sites, and other ingenious strategies to improve the performance of SACs. We highlight synthesis strategies and structural design approaches for SACs with unique geometric structures and discuss how the structure affects the catalytic properties.

Electrochemical CO₂ reduction reaction (CO₂RR) is a promising way to remove CO₂ and convert it into useful industrial products. Single-atom site catalysts provide opportunities to regulate the active sites of CO₂RR catalysts at the atomic level.     

High-throughput approaches for the discovery and optimization of new olefin polymerization catalysts

The discovery of new olefin polymerization catalysts is currently a time-intensive trial-and-error process with no guarantee of success. A fully integrated high-throughput screening workflow for the discovery of new catalysts for polyolefin production has been implemented at Symyx Technologies. The workflow includes the design of the metal-ligand libraries using custom-made computer software, automated delivery of metal precursors and ligands into the reactors using a liquid-handling robot, and a rapid primary screen that serves to assess the potential of each metalligand-activator combination as an olefin polymerization catalyst. "Hits" from the primary screen are subjected to secondary screens using a 48-cell parallel polymerization reactor. Individual polymerization reactions are monitored in real time under conditions that provide meaningful information about the performance capabilities of each catalyst. Rapid polymer characterization techniques support the primary and secondary screens. We have discovered many new and interesting catalyst classes using this technology.