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.     

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.     

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.     

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.     

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.     

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     

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.     

Synthesis of carboxylic esters from aldehydes using metal carbonyl anions,part 2. Dimerization of aldehydes to carboxylic esters catalyzed by disodium pentacarbonylchromate,na2[cr(co)5]

Na₂[Cr(CO)₅] (1) was found to be an efficient catalyst for the dimerization of aldehydes to carboxylic esters. Several aromatic aldehydes including furfural gave the corresponding esters in good yields. This reaction also proceeded intramolecularly to give phthalide from phthalaldehyde. Compared with M₂[Fe(CO)₄] (M = Na, K), 1 was found to be a more efficient catalyst for this reaction. However, aliphatic aldehydes gave aldolcondensation products instead of the corresponding esters. In the reactions of p-substituted benzaldehydes with 1, the reactivity decreased with the increase of the electron-releasing ability of the substituents. However, even p-anisaldehyde, which hardly reacted with M₂[Fe(CO)₄], reacted with 1 to give the ester in moderate yield. The reaction mechanism, including the nucleophilic attack of the pentacarbonylchromate dianion on the carbonyl carbon, is discussed.     

Ethylaluminum oxide catalysts from Et2AlOLi–Et2AlCl binary system in relation to species of AlEt3–water catalyst

Equimolar reaction of Et₂AlOLi and Et₂AlCl gave Et₂AlOAlEt₂. The catalyst behavior for polymerization of acetaldehyde, propylene oxide, and epichlorohydrin was compared with that of the AlEt₃–H₂O (1:0.5) catalyst system. The thermal disproportionation product of Et₂AlOAlEt₂ derived from Et₂AlOLi–Et₂AlCl had the structure, ? (EtAlO)_n? , and it showed catalyst behavior quite similar to that of the product obtained by the same treatment of AlEt₃–H₂O (1:0.5). These ethylaluminum oxides can be regarded as species predominating in AlEt₃–H₂O (1:0.5) and AlEt₃–H₂O (1:1), respectively. Stereospecific or high molecular weight polymerizations of these species were investigated.     

Polymerization of tetrahydrofuran by AlEt3–H2O promoter system: Rate of propagation reaction

Kinetic studies were carried out on the polymerization of tetrahydrofuran with catalyst systems of aluminum alkyl–epichlorohydrin. As aluminium alkyl species AlEt₃, AlEt₃–H₂O (1:0.1 to 1:1.0), and “oxyaluminum ethyl” were employed. The polymerizations with these catalysts are characterized by a mechanism of stepwise addition without chain transfer or termination, which is expressed by the kinetic relation R_p = K_p[P*] ([M]–[M]_e), where [M] and [M]_e are the instantaneous and equilibrium concentrations of monomer and [P*] is the concentration of propagating species calculated from the amount and molecular weight of the product polymer. The determination of the rate constant k_p for these catalysts has shown that the polymerization rate varied considerably with the change of aluminum alkyl species, i.e., with the water-to-aluminum ratio, but the propagation rate constant itself varied very little. The variation of polymerization rate was, therefore, attributed primarily to the differences in concentration of the propagating species, i.e. the efficiency of the catalyst in forming propagating species. The catalyst efficiency was closely related to the acid strength of the aluminum alkyl species, which was estimated from the magnitude of shift of the xanthone carbonyl band in the infrared spectrum of its coordination complex with aluminum alkyl. The maximal catalyst efficiency was attained at about [H₂O]/[AlEt₃] = 0.75.     

Microwave‐assisted ring‐opening polymerization of p‐dioxanone

The ring‐opening polymerization (ROP) of p‐dioxanone (PDO) under microwave irradiation with triethylaluminum (AlEt₃) or tin powder as catalyst was investigated. When the ROP of PDO was catalyzed by AlEt₃, the viscosity‐average molecular weight (M_v) of poly(p‐dioxanone) (PPDO) reached 317,000 g mol^?1 only in 30 min, and the yield of PPDO achieved 96.0% at 80 °C. Tin powder was successfully used as catalyst for synthesizing PPDO by microwave heating, and PPDO with M_v of 106,000 g mol^?1 was obtained at 100 °C in 210 min. Microwave heating accelerated the ROP of PDO catalyzed by AlEt₃ or tin powder, compared with the conventional heating method. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 3207–3213, 2008     

Copolymerization of ethylene with higher linear α-olefins—reactivity ratios

Copolymerization of ethylene with mixtures of linear α-olefins C₆–C₃₆ in the presence of two heterogeneous Ziegler–Natta catalysts, δ-TiCl₃–AlEt₃ and TiCl₄/MgCl₂–AlEt₃, at 90°C was studied by the GC method, and reactivity ratios for all paris ethylene–α-olefin were estimated from the data on olefin consumption in the reactions. In the case of the δ-TiCl₃–AlEt₃ system, the r₂ value decreases from ca. 0.05 for 1-decene to ca. 0.02 for α-C₂₂H₄₄ and then remains approximately constant. This change is similar to the dependence of the modified steric parameter E_S^C of the olefin alkyl group on the size of the alkyl group. In the case of the supported TiCl₄/MgCl₂–AlEt₃ system a similar variation of r₂ with the length of the alkyl group were observed but the absolute values of r₂ were six to ten times lower than those for the first catalytic system.     

Kinetics and mechanism of stereospecific polymerization of methyl methacrylate with VOCl3–AlEt2Cl catalyst system

Methyl methacrylate was polymerized at 40°C with VOCl₃–AlEt₂Cl catalyst system in n-hexane. The rate of polymerization was proportional to catalyst and monomer concentration at Al/V ratio of 2 and overall activation energy of 9.25 kcal/mole support a coordinate anionic mechanism of polymerization. The catalytic activity and stereospecificity of this catalyst system is discussed in comparison with that of VOCl₃–AlEt₃ catalyst system.     

Polymerization of styrene with VOCl3–aluminum alkyls

The polymerization of styrene with VOCl₃ in combination with AlEt₃ and with Al(i-Bu)₃ in n-hexane at 40°C. has been investigated. The rate of polymerization was found to be second order with respect to monomer in both systems. With respect to catalyst the rate of polymerization was first order for VOCl₃–AlEt₃ and second order for VOCl₃-Al(i-Bu)₃ systems. The activation energies for VOCl₃–AlEt₃ and VOCl₃–Al(i-Bu)₃ systems were 7.37 and 11.25 kcal./mole, respectively. The molecular weight of polystyrene in the AlEt₃ system was considerably higher than that in the Al(i-Bu)₃ system. The valence of vanadium obtained by a potentiometric method showed that the catalyst sites in the AlEt₃ system are different in nature from those in the Al(i-Bu)₃ system. The effect of diethylzinc as a chain-transfer agent in the AlEt₃ system was also studied.     

Supported catalysts for stereospecific polymerization of propylene

Tetrabenzyltitanium (B₄Ti), tribenzyltitanium chloride (B₃TiCl), tetra(p-methylbenzyl)titanium (R₄Ti) and tri(p-methylbenzyl)titanium chloride (R₃TiCl) have been used as catalysts for ethylene and propylene polymerization activated by AlEt₂Cl. B₄Ti-AIEt₂Cl in solution polymerizes ethylene readily but its activity decays rapidly. B₄Ti was also supported on Cab-O-Sil, Alon C, and Mg(OH)Cl. The last support was found to give catalyst with longest lifetime with a rate of polymerization, R_p = 7.0 g/hr-mmole Ti-atm ethylene. ¹⁴CO counting techniques gave 1.13 × 10^?3 mole of propagating center per mole of B₄Ti; the rate constant of propagation, k_p = 540 l./mole-sec. None of the tetravalent titanium compounds polymerize propylene in solution. However, when supported on Mg(OH)Cl, Cab-O-Sil, Alon C, Cab-O-Ti, and charcoal, they all polymerize propylene. In this work the supports were characterized by various techniques, including the paramagnetic probe method, to determine the concentration and nature of surface hydroxyls. Those factors controlling the rate and stereospecificity of propylene polymerization were investigated. The system B₃TiCl–Mg(OH)Cl–AlEt₂Cl is the most active with R_p = 2.89 g/hr-mmole Ti-atm propylene. The concentration of propagation center is 0.9 × 10^?3 mole per mole of B₃TiCl; k_p = 32 l./mole-sec. This catalyst gave only about 70% stereoregular polymer. Diethyl ether is found to raise stereospecificity to 100%, but there is a concommittent tenfold decrease of activity. Other interesting catalyst systems are: (π-C₅H₅)TiMe₃–Mg(OH)Cl–AlEt₂Cl (1.56, 89.5); (π-C₅H₅)TiMe₂–Mg(OH)Cl–AlEt₂Cl (0.075, 94.5); and (π-C₅H₅)TiMe₃–Alon C–Al-Et₂Cl (0.08,97.2), where the first number in the parenthesis is R_p in g/mmole Ti-hr-atm and the second entry corresponds to percentage yield of stereoregular polypropylene. Hafnocene and titanocene supported on Mg(OH)Cl produce only oligomers of propylene.     

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.     

Synthesis of poly(p‐methoxyphenylacetylene) with the vanadium acetylacetonate‐aluminum triethyl Ziegler–Natta catalyst system: Cyclotrimers/polymer ratio analysis

Poly(p‐methoxyphenylacetylene) was obtained by the reaction of p‐methoxyphenylacetylene (MOPA) with the vanadium acetylacetonate‐aluminum triethyl V(acac)₃‐AlEt₃ homogeneous catalyst system. The crude product was always a mixture of 1,2,4‐ and 1,3,5‐tris(p‐methoxyphenyl)benzene and poly(MOPA) of low averaged molecular weight. The 1,2,4‐ and 1,3,5‐cyclotrimers versus poly(MOPA) ratio was analyzed. The poly(MOPA) obtained under different conditions, on the basis of the spectroscopic data, always shows a cis–transoidal stereo‐regular structure. Molecular mass of poly(MOPA) was determined by vapor pressure osmometry, high pressure liquid chromatography (HPLC), and gel permeation chromatography (GPC) techniques. The kinetics of the reaction has been also analyzed. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 5987–5997, 2005     

Dimerization of aldehydes to carboxylic esters catalyzed by K2[Fe(CO)4]–crown ether system

K₂[Fe(CO)₄] (1) with a crown ether was found to be an efficient catalyst for the dimerization of aldehydes to carboxylic esters. Several aromatic aldehydes including furfural gave the corresponding esters in good yields. This reaction also proceeded intramolecularly to give phthalide from phthalaldehyde. However, aliphatic aldehydes gave aldol-condensation products instead of the corresponding esters. In the reactions of p-substituted benzaldehydes with 1, the reactivity decreased with increase of the electron-releasing ability of the substituents. On the basis of these results, the reaction mechanism including the nucleophilic attack of tetracarbonylferrate dianion to the carbonyl carbon is discussed.     

Kinetics of propylene polymerization in the initial acceleration stage

The kinetics of propylene polymerization catalyzed over a superactive and stereospecific catalyst for the initial build-up period was investigated in slurry-phase. The catalyst was prepared from Mg(OEt)₂/benzoyl chloride/TiCl₄ co-activated with AlEt₃ in the absence or presence of external donor. Despite a very fast activation of the prepared catalyst the acceleration stage of polymerization could be identified by the precise estimation of polymerization kinetics for a very short period of time after the commencement of polymerization (ca. 2 min). The initial polymerization rate, (dR_p/dt)₀ extrapolated to the beginning of the polymerization was second order with respect to monomer concentration. The dependence of initial polymerization rate on the concentration of AlEt₃ could be represented by Langmuir adsorption mechanism. The initial rate was maximum at about Al/Ti ratio of 20. The activation energy for the initiation reaction was estimated to be 14.3 kcal/mol for a short-time polymerization. The addition of a small amount of p-ethoxy ethyl benzoate (PEEB) as an external donor increased the percentage of isotactic polymer, which was obtained after 120 s of polymerization, to 98% and the initial polymerization rate decreased sharply as [PEEB]/[AlEt₃] increased. © 1994 John Wiley & Sons, Inc.     

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.