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     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. II. Mechanism of the chain‐transfer reaction

Hydrogen is a very effective chain‐transfer agent in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts. However, measurements of the hydrogen concentration effect on the molecular weight of polypropylene prepared with a supported TiCl₄/dibutyl phthalate/MgCl₂ catalyst show a peculiar effect: hydrogen efficiency in the chain transfer significantly decreases with concentration, and at very high concentrations, hydrogen no longer affects the molecular weight of polypropylene. A detailed analysis of kinetic features of chain‐transfer reactions for different types of active centers in the catalyst suggests that chain transfer with hydrogen is not merely the hydrogenolysis reaction of the Ti? C bond in an active center but proceeds with the participation of a coordinated propylene molecule. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1899–1911, 2002     

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     

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     

In‐Situ and Ex‐Situ Microscopic Study of Gas Phase Propylene Polymerization over a High Activity TiCl4‐MgCl2 Heterogeneous Ziegler‐Natta Catalyst

In‐situ gas phase poly(propylene) (PP) formation over a high activity TiCl₄‐MgCl₂‐supported Ziegler‐Natta catalyst has been studied by video microscopy combined with ex‐situ light microscopy, SEM, high‐resolution TEM, and STEM/PEELS/EDX for the first time. In‐situ observation revealed rapid formation of poly(propylene) beads 9–10 μm in size (< 1/30 s) as well as growth of significant amounts of polymer within local regions. Catalyst particles containing 2–5 nm‐sized MgCl₂ crystalline domains are subjected to transformations during catalysis that form PP/catalyst aggregated structures of 30–50 μm in size.     

Kinetic features of ethylene polymerization over supported catalysts [2,6‐bis(imino)pyridyl iron dichloride/magnesium dichloride] with AlR3 as an activator

The effects of polymerization temperature, polymerization time, ethylene and hydrogen concentration, and effect of comonomers (hexene‐1, propylene) on the activity of supported catalyst of composition LFeCl₂/MgCl₂‐Al(i‐Bu)₃ (L = 2,6‐bis[1‐(2,6‐dimethylphenylimino)ethyl] pyridyl) and polymer characteristics (molecular weight (MW), molecular‐weight distribution (MWD), molecular structure) have been studied. Effective activation energy of ethylene polymerization over LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a value typical of supported Ziegler–Natta catalysts (11.9 kcal/mol). The polymerization reaction is of the first order with respect to monomer at the ethylene concentration >0.2 mol/L. Addition of small amounts of hydrogen (9–17%) significantly increases the activity; however, further increase in hydrogen concentration decreases the activity. The IRS and DSC analysis of PE indicates that catalyst LFeCl₂/MgCl₂‐Al(i‐Bu)₃ has a very low copolymerizing ability toward propylene and hexene‐1. MW and MWD of PE produced over these catalysts depend on the polymerization time, ethylene and hexene‐1 concentration. The activation effect of hydrogen and other kinetic features of ethylene polymerization over supported catalysts based on the Fe (II) complexes are discussed. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 5057–5066, 2007     

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.     

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.     

AlR2Cl/MgR2 combinations as universal cocatalysts for Ziegler–Natta,metallocene, and post‐metallocene catalysts

Combinations of dialkylaluminum chlorides and dialkylmagnesium compounds, when used at molar [AlR₂Cl]:[MgR₂] ratios ≥ 2, act as universal cocatalysts for all three presently known types of alkene polymerization catalysts—Ziegler–Natta, metallocene, and post‐metallocene. When these cocatalysts are used with supported Ti‐based Ziegler–Natta catalysts, they produce catalyst systems which are 1.5–2 times more active than the systems utilizing AlR₃ compounds as cocatalysts. Combinations of AlR₂Cl/MgR₂ cocatalysts and various metallocene complexes produce single‐center catalyst systems similar to those formed in the presence of MAO. The same cocatalysts activate numerous post‐metallocene Ti complexes containing bidentate ligands of a different nature and produce multicenter systems of very high activity. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3271–3285, 2009     

Preparation of ultra high molecular weight amorphous poly(1‐hexene) by a Ziegler–Natta catalyst

High molecular weight polymers such as poly (α‐olefin)s play a key role as drag‐reducing agents which are commonly used in pipeline industry. Heterogeneous Ziegler–Natta catalyst system of MgCl₂.nEtOH/TiCl₄/donor was prepared using a spherical MgCl₂ support and utilized in synthesis of poly(1‐hexene)s with a viscosity average molecular weight (M_v) up to 3.5 × 10³ kDa. The influence of effective parameters including Al/Ti ratio, polymerization temperature, monomer concentration, effect of alkylaluminus type on the productivity, and molecular weight of the products was evaluated. It was suggested that the reactivity of the Al‐R group and the bulkiness of the cocatalyst were correlated to the performance of the Ziegler–Natta catalyst at different polymerization time and temperatures, affecting the catalyst activity and M_v of polymers. Moreover, bulk polymerization method leads to higher viscosity average molecular weights, revealing the remarkable effect of polymerization method on the chain microstructure. Fourier transform infrared, ¹³C Nuclear magnetic resonance spectra, and DSC thermogram of the prepared polymers confirmed the formation of poly(1‐hexene). The properties of the polymers measured by vortex test showed that these polymers could be used as a drag‐reducing agent. Drag‐reducing behaviors of the polymers exhibited a dependence on the M_v of the obtained polymers that was changed by variation in polymerization parameters. Copyright © 2016 John Wiley & Sons, Ltd.     

Preparation of hindered piperidine and its copolymerization with propylene over a supported high activity ziegler–natta catalyst

A new polymerizable stabilizer 4-(hex-5-enyl)-2,2,6,6-tetramethylpiperidine is prepared. This sterically hindered piperidine was copolymerized with propylene over a fourth generation TiCl₄/MgCl₂ Ziegler–Natta catalyst, using Al(C₂H₅)₃ as cocatalyst and diphenyldimethoxysilane, DMS, as external electron donor. The copolymer exhibited high thermo-oxidative stability even after exhaustive extraction with n-heptane.     

Superactive and stereospecific catalysts. III. Definitive identification of active sites by electron paramagnetic resonance

Superactive Ziegler–Natta catalysts have been prepared from a soluble MgCl₂·2-ethyl hexanol adduct in the presence of organic esters through reactions with TiCl₄ and activated with AlEt₃/phenyltriethoxy-silane. Electron paramagnetic spectra (EPR) were used to elucidate the nature and amount of those Ti⁺³ ions not bridged to another Ti⁺³ ion; the chlorine bridged Ti⁺³ ions are EPR silent. The EPR spectra were attributed to two rhombic Ti⁺³ sites with principal values for the g-tensors (1.967, 1.949, 1.915; and 1.979, 1.935, 1.887). The total amount of the EPR species, obtained by double integration of the EPR spectra, is in close agreement with the concentration of isospecific catalytic sites determined by radiotagging. This suggests that the nonspecific sites are EPR silent. When o-phthalic ester was present during the catalyst synthesis, there appears an EPR signal at the free electron g-value. This signal was attributed to a Ti⁺³ phthalate species with resonance stabilization and spin delocalization; it is absent in the catalysts made in the presence of monoesters such as ethyl benzoate. The effects of monomer, O₂, H₂O, and I₂ on the EPR spectra were investigated. The changes in the EPR spectral intensity and the total Ti⁺³ ions, the latter determined by redox titrations during a polymerization or catalyst aging, are described. The results were extensively compared with those observed for supported Ziegler–Natta catalyst prepared with crystalline MgCl₂.     

Ethylene polymerization with porous polystyrene spheres supported Cp2ZrCl2 catalyst

A catalyst with porous polystyrene beads supported Cp₂ZrCl₂ was prepared and tested for ethylene polymerization with methylaluminoxane as a cocatalyst. By comparison, the porous supported catalyst maintained higher activity and produced polyethylene with better morphology than its corresponding solid supported catalyst. The differences between activities of the catalysts and morphologies of the products were reasonably explained by the fragmentation processes of support as frequently observed with the inorganic supported Ziegler–Natta catalysts. Investigation into the distribution of polystyrene in the polyethylene revealed the fact that the porous polystyrene supported catalyst had undergone fragmentation during polymerization. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 3313–3319, 2003     

Probing the Coordinative Unsaturation and Local Environment of Ti3+ Sites in an Activated High‐Yield Ziegler–Natta Catalyst

The typical activation of a fourth generation Ziegler–Natta catalyst TiCl₄/MgCl₂/phthalate with triethyl aluminum generates Ti³⁺ centers that are investigated by multi‐frequency continuous wave and pulse EPR methods. Two families of isolated, molecule‐like Ti³⁺ species have been identified. A comparison of the experimentally derived g tensors and ^35,37Cl hyperfine and nuclear‐quadrupole tensors with DFT‐computed values suggests that the dominant EPR‐active Ti³⁺ species is located on MgCl₂(110) surfaces (or equivalent MgCl₂ terminations with tetra‐coordinated Mg). O₂ reactivity tests show that a fraction of these Ti sites is chemically accessible, an important result in view of the search for the true catalyst active site in olefin polymerization.     

Dramatic decrease of the cis content and molecular weight of cis‐transoidal polyphenylacetylene at 23 °C in solutions prepared in air

The thermal cis–trans isomerization of cis‐transoidal polyphenylacetylene (PPA) synthesized with Noyori's catalyst [Rh(C?CPh)(norbornadiene)(PPh₃)₂] has been investigated under both ambient and inert atmospheres in solution and in bulk. In all cases, an intramolecular cyclization results in cis–trans isomerization, and subsequent chain cleavage produces 1,3,5‐triphenylbenzene. This reaction is accelerated by the presence of air, particularly when the reaction takes place in solution. Decreases in the cis content and molecular weight show that the intramolecular cyclization process takes place at 23 °C in solution. The mechanism of this reaction is identical to that reported previously for cis‐cisoidal and cis‐transoidal PPA synthesized with Ziegler–Natta catalysts. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3212–3220, 2002     

Influence of the particle size of the MgCl2 support on the performance of Ziegler catalysts in the polymerization of ethylene to ultra‐high molecular weight polyethylene and the resulting polymer properties

A highly systematic size series of Ziegler catalysts with similar porosities and surface textures are synthesized by varying the stirring speed during the MgCl₂ support synthesis. Besides the mean particle size, the only substantial difference observed between the various catalysts is the size and number of nodules per particle. Varying the mean diameter of the catalyst particles between 1.5 and 11.9 µm, leads to a pronounced impact on the activity in ultra‐high molecular weight polyethylene (UHMWPE) polymerization, while the M_w capabilities are only affected to a limited extend. In addition, it is observed that both the M_ws as the polymer bulk density (BD) increases during the course of the polymerization. This particularity allows to optimize the M_w and/or BD at a set polymer size, by tuning the catalyst particle size. This is particularly interesting in UHMWPE production, as control of the morphological and structural properties of the UHMWPE reactor powders are critical for efficient processing as well as the performance of the final product. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2679–2690     

The discovery and progress of MgCl2‐supported TiCl4 catalysts

Polyolefins represented by polyethylene (PE) and polypropylene (PP) are indispensable materials in our daily lives. TiCl₃ catalysts, established by Ziegler and Natta in the 1950s, led to the births of the polyolefin industries. However, the activities and stereospecificities of the TiCl₃ catalysts were so low that steps for removing catalyst residues and low stereoregular PP were needed in the production of PE and PP. Our discovery of MgCl₂‐supported TiCl₄ catalysts led to more than 100 times higher activities and extremely high stereospecificities, which enabled us to dispense with the steps for the removals, meaning the process innovation. Furthermore, they narrowed the molecular weight and composition distributions of PE and PP, enabling us to control the polymer structures precisely and create such new products as very low density PE or heat‐sealable film at low temperature. The typical example of the product innovations by the combination of the high stereospecificity and the narrowed composition distribution is high‐performance impact copolymer used for an automobile bumper that used to be made of metal. These process and product innovations established these polyolefin industries. The latest MgCl₂‐supported TiCl₄ catalyst is very close to perfect control of isotactic PP structure and is expected to bring about further innovations. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1–8, 2004     

Theoretical investigation of the Ziegler–Natta catalysis in heterogeneous conditions

We present ab initio calculations on the Ziegler–Natta catalysis in heterogeneous conditions. Both cluster and periodic models with different basis sets have been used to explain the chemical reactivity of the various species that are involved. In heterogeneous conditions, several parameters contribute to the catalysis: the oxidation state of the titanium atom, the structure of the titanium site, the interaction with the support, MgCl₂, and the cocatalyst, AlR₃. This article yields to a synthetic view of the catalytic activity. © 2002 Wiley Periodicals, Inc. Int J Quantum Chem, 2002     

Hydrogen effects in propylene polymerization reactions with titanium‐based Ziegler–Natta catalysts. I. Chemical mechanism of catalyst activation

The hydrogen activation effect in propylene polymerization reactions with Ti‐based Ziegler–Natta catalysts is usually explained by hydrogenolysis of dormant active centers formed after secondary insertion of a propylene molecule into the growing polymer chain. This article proposes a different mechanism for the hydrogen activation effect due to hydrogenolysis of the Ti? iso‐C₃H₇ group. This group can be formed in two reactions: (1) after secondary propylene insertion into the Ti? H bond (which is generated after β‐hydrogen elimination in the growing polymer chain or after chain transfer with hydrogen), and (2) in the chain transfer with propylene if a propylene molecule is coordinated to the Ti atom in the secondary orientation. The Ti? CH(CH₃)₂ species is relatively stable, possibly because of the β‐agostic interaction between the H atom of one of its CH₃ groups and the Ti atom. The validity of this mechanism was demonstrated in a gas chromatography study of oligomers formed in ethylene/α‐olefin copolymerization reactions with δ‐TiCl₃/AlEt₃ and TiCl₄/dibutyl phthalate/MgCl₂–AlEt₃ catalysts. A quantitative analysis of gas chromatography data for ethylene/propylene co‐oligomers showed that the probability of secondary propylene insertion into the Ti? H bond was only 3–4 times lower than the probability of primary insertion. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1353–1365, 2002     

A new route to atactic polypropylene: The second life of premetallocene homogeneous polymerization catalyst

Amorphous atactic polypropylene (PP) with an average molecular weight of 50,000–100,000 is produced by polymerizing propylene with a ternary Ti(Oiso‐Pr)₄ ‐ AlEt₂Cl/MgBu₂ catalyst at 30–50 °С. Main advantages of this catalyst compared with other catalysts capable of nearly exclusively producing atactic PP (such as some heterogeneous Ziegler‐Natta, metallocene and postmetallocene catalysts) are high activity, low cost and the ease of use: the catalyst is prepared in situ from three commercially available compounds readily soluble in aliphatic and aromatic hydrocarbons. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2124–2131