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     

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     

Organic nanoparticles as fragmentable support for Ziegler–Natta catalysts

A fragmentable support material for Ziegler–Natta catalysts is presented based on micrometer‐sized aggregates of polystyrene nanoparticles. Hydroxyl anchoring groups are introduced by copolymerization of hydroxymethylstyrene in emulsion process to immobilize the catalysts. The catalytic activity in ethylene slurry polymerizations is found to be directly correlated to the hydroxyl group content of the supports. Furthermore, the fragmentation behavior of dye‐labeled support aggregates into the initial nanoparticles is demonstrated using laser scanning confocal fluorescence microscopy as a nondestructive method. These supported catalysts fulfill two important design criteria, high fragmentability and high catalyst loading, and produce high‐density polyethylene with medium molecular weight distributions (MWDs = 3–4). These values lie between those obtained using single‐site metallocene‐based (narrow MWD < 3) or inorganic supported multi‐site Ziegler–Natta‐based (broad MWD = 4–12) polymerizations without the need of blending. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 15–22     

Ethylene polymerization reactions with multicenter Ziegler‐Natta catalysts—Manipulation of active center distribution

This article describes ethylene/1‐hexene copolymerization reactions with a supported titanium‐based, multicenter Ziegler‐Natta catalyst. The catalyst was modified by pretreating its solid precursor with AlEt₂Cl and with similar organoaluminum chlorides, Al₂Et₃Cl₃, AlEtCl₂, and AlMe₂Cl. Testing of the untreated and the pretreated catalysts in copolymerization reactions under standard reaction conditions demonstrated that the modifying agents produce two changes in the catalyst. First, the pretreatment significantly reduces the reactivity of active centers that produce high molecular weight, highly crystalline copolymer components with a low 1‐hexene content. Second, the pretreatment noticeably increases the reactivity of active centers that produce low molecular weight copolymer components with a high 1‐hexene content. The first effect is caused by Lewis acid‐base interactions of the modifiers with the active centers, whereas the second (activating) effect is due to the removal of catalyst poisons (organosilicon compounds generated in the process of the catalyst synthesis) by AlEt₂Cl. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 4219–4229, 2010     

Reaction of phenylacetylene with Ti(OR)4?AlEt3 and V(acac)3?AlEt3: Cyclotrimerization versus chain oligomerization

The polymerization of phenylacetylene with the microheterogeneous Ti(OR)₄? AlEt₃ and homogeneous vanadium acetylacetonate/aluminum triethyl Ziegler–Natta catalyst systems was analyzed. The effects of some cocatalysts (e.g., pyridine and phenylacetylide) and the solvent, temperature, and time were analyzed. Both catalyst systems produced poly(phenylacetylene) (PPA) and a 1,2,4‐triphenylbenzene (1,2,4‐TPB)/1,3,5‐triphenylbenzene (1,3,5‐TPB) cyclotrimer mixture in various molar ratios. The titanium catalyst showed the lowest PPA/triphenylbenzene ratio. The 1,2,4‐TPB/1,3,5‐TPB molar ratio decreased with increasing PPA. On the basis of the spectroscopic data, PPA had a cis–transoidal stereoregular structure. The molecular mass of PPA was determined with vapor pressure osmometry and gel permeation chromatography. A mechanism for the polymerization reaction versus cyclotrimerization was proposed. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 1228–1237, 2005     

Polymerization of alkenes with a post‐metallocene catalyst containing a titanium complex with an oxyquinolinyl ligand

Polymerization reactions of ethylene, propylene, higher 1‐alkenes (1‐hexene, 1‐octene, 1‐decene, vinyl cyclohexane, 3‐methyl‐1‐butene), and copolymerization reactions of ethylene with 1‐octene with a post‐metallocene catalyst containing an oxyquinolinyl complex of Ti and a combination of Al(C₂H₅)₂Cl and Mg(C₄H₉)₂ as a cocatalyst were studied. The catalyst is highly active and, judging by the broad molecular weight distribution of the polymers, contains several active center populations. The active centers differ not only in their kinetic parameters but also in stereospecificity. Most of the active centers produce essentially atactic polypropylene but a small fraction of the centers produces polypropylene of moderate isotacticity degree. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 1844–1854     

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     

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     

Unusual ethylene polymerization results with metallocene catalysts supported on silica

With the development of methods to support metallocenes and methylaluminoxane cocatalysts on suitable carriers, it became possible to combine the specific advantages of homogeneous metallocene catalysis with those of heterogeneous Ziegler catalysts in olefin polymerization. By means of ethylene polymerization it could be shown that the method of supporting methylaluminoxane and metallocene on porous silica has a substantial influence on the progress of polymerization. In particular, fragmentation of catalyst particles during polymerization can be circumvented, maintaining the catalyst activity, if active catalyst sites are being generated on the particle surface only. A method of preparation for such newly designed supported metallocene catalysts is presented, where the active catalyst sites are located exclusively on the particle surface. Furthermore, the kinetics of ethylene polymerization and morphology properties prior to and after polymerization are discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 677–682, 1999     

Copolymerization of ethylene and α‐olefins with combined metallocene catalysts. I. A formal criterion for molecular weight bimodality

Metallocene and other single‐site catalysts can be combined to produce polyolefins with broadened distributions of molecular weight, chemical composition, and long‐chain branching. These resins are finding increasing applications because of their enhanced properties compared to ones made with conventional Ziegler–Natta catalysts. Resins with bimodal molecular weight distributions (MWDs) have especially attractive mechanical and rheological properties. Although the use of these resins is expected to increase, there are very few studies available to quantify MWD bimodality or to decide a priori which combinations of metallocene catalysts will lead to the formation of polyolefins with bimodal MWDs. In this article, a necessary condition for the production of polymer with bimodal MWD using two single‐site‐type catalysts is derived. Additionally, a bimodality index is defined to quantify MWD bimodality. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1408–1416, 2000     

A novel efficient Ti(O-<Emphasis Type="Italic">iso</Emphasis>-C<Subscript>3</Subscript>H<Subscript>7</Subscript>)<Subscript>4</Subscript>-based olefin polymerization catalyst system

The polymerization of ethylene and propylene and the copolymerization of ethylene and hexene-1 with a Ti(O-iso-Pr)₄–AlR₂Cl/MgBu₂ catalyst system have been studied. The advantages of this system over metallocene and postmetallocene catalysts are high activity, low cost, and ease of synthesis. The resulting polymers and copolymers are characterized by a broad molecular-mass distribution, which reflects the heterogeneity of the active sites with respect to kinetic parameters. As a consequence, the ethylene/hexene-1 copolymers exhibit compositional heterogeneity. The active sites of the system produce copolymers with a pronounced tendency toward alternation of monomer units. The propylene polymerization product is mostly amorphous atactic polypropylene.     

Kinetics of ethylene polymerization reactions with chromium oxide catalysts

Principal kinetic data are presented for ethylene homopolymerization and ethylene/1‐hexene copolymerization reactions with two types of chromium oxide catalyst. The reaction rate of the homopolymerization reaction is first order with respect to ethylene concentration (both for gas‐phase and slurry reactions); its effective activation energy is 10.2 kcal/mol (42.8 kJ/mol). The r₁ value for ethylene/1‐hexene copolymerization reactions with the catalysts is ～30, which places these catalysts in terms of efficiency of α‐olefin copolymerization with ethylene between metallocene catalysts (r₁ ～ 20) and Ti‐based Ziegler‐Natta catalysts (r₁ in the 80–120 range). GPC, DSC, and Crystaf data for ethylene/1‐hexene copolymers of different compositions produced with the catalysts show that the reaction products have broad molecular weight and compositional distributions. A combination of kinetic data and structural data for the copolymers provided detailed information about the frequency of chain transfer reactions for several types of active centers present in the catalysts, their copolymerization efficiency, and stability. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5315–5329, 2008     

Polymerization of propylene by metallocene and Ziegler–Natta mixed catalytic systems. Study of polypropylene properties

Propylene was polymerized with metallocene and Ziegler–Natta mixed-catalytic systems to obtain reactor blends of metallocene and Ziegler–Natta-derived propylene homopolymers. The two catalytic systems are able to act jointly, providing individual polymers with different melting and crystallization temperatures. Compatibility between the components of the mixed-catalytic systems and the influence of the components on the polymerization process and on the properties of the reactor blends were studied. Thermal, mechanical, viscoelastic, rheological, and optical properties of the blends were tested and compared with those of conventional polypropylene grades. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 3063–3072, 1998     

Characterization of Ziegler–Natta catalyst by ESCA

The surface composition of TiCl₃-based Ziegler—Natta catalysts prepared by various methods was analyzed by ESCA to correlate the total amount of surface titanium with the catalyst activity in propylene polymerization. The ESCA peak ratio (Ti 2P_3/2/Cl 2P) of the catalysts was measured to estimate the surface composition. The titanium index defined as the product of the (Ti/Cl peak ratio and surface area) was closely correlated with the catalyst activity in polymerization. This indicates that surface titanium concentration and surface area determine the catalyst activity. It was also found that removal of surface aluminum and chlorine at the catalyst preparation stage results in concentration of titanium at the surface and an increase in surface area.     

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     

Electron transfer mechanism in olefin polymerization

Polymerization of olefins mediated by transition metal derivatives (Ziegler–Natta polymerization) is one of the most scientifically and industrially important processes of molecular conversion. Electron transfer mechanism could play a significant role in both heterogeneous and homogeneous catalysts. The catalytic activity strongly depends on the presence of two metallocene ligands attached to the transition metal (more commonly zirconium) which grants the valence form of zirconium in complexes of the type Cp₂ZrX₂(X=Cl or CH₃) followed by the formation of the (Cp₂ZrX)⁺ cation under the effect of a Lewis acid. On the other hand, Ti complexes with only one metallocene ligand give the syndiospecific polymerization of styrene, where the phenyl group appears to act as electron donor for the transition metal. The remarkable electronic effect of the metallocene groups in determining catalytic activity is demonstrated by the study of substituted metallocene ligands as well as other ligands around the metal. These effects cannot be, however, completely separated from steric effects which seem to be responsible for the impressive and versatile stereochemical control determined by symmetry properties of the transition metal complex.     

Melting behavior of polyethylene/α‐olefin copolymers: Narrow composition distribution copolymers and fractions from Ziegler–Natta and single‐site catalyst products

The melting temperature and heat of fusion were measured for an extensive series of compositionally uniform copolymers of ethylene with butene‐1, hexene‐1, and octene‐1. Fractions and whole polymers that exhibited minimal interchain compositional heterogeneity were from commercial copolymers made with either Ziegler–Natta (ZN) or single‐site metallocene catalysts. The present results do not support recent claims that ZN and corresponding metallocene catalyst copolymers melt at significantly different temperatures, nor the implication that comonomer incorporation is “blocky” in ZN copolymers. In five of the six comonomer/catalyst systems the dependencies of the melting temperature on comonomer type and amount were scarcely distinguishable. This common behavior is the same as that for a model random copolymer, so we conclude that most ethylene/α‐olefin copolymers have random distributions of ethylene sequences. The exception in the present study is a metallocene ethylene/butene‐1 copolymer that melts at lower temperatures and apparently has perceptibly alternating sequence distributions. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3416–3427, 2004     

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

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

A WAXD/SAXS/DSC study on the melting behavior of Ziegler–Natta and metallocene catalyzed isotactic polypropylene

A small- and wide-angle X-ray scattering study was performed on two metallocene catalyzed isotactic polypropylene (miPP) resins. The results were compared with two similar molecular weight Ziegler–Natta catalyzed isotactic polypropylene (zniPP) materials. Wide-angle X-ray diffraction (WAXD) results showed the existence of two crystalline structures in the metallocene samples, the α-monoclinic and γ-orthorhombic crystal structure, with increasing relative amounts of γ-orthorhombic phase as the lamellae thickness increased. Differential scanning calorimetry (DSC) scans exhibited a melting peak for each crystal structure. The metallocene resins had the same equilibrium melting temperature (186 ± 2 °C) as the high tacticity Ziegler–Natta (ZNHT) resin, whereas a second Ziegler–Natta resin had a lower equilibrium melting temperature (178 ± 2 °C). The equilibrium melting temperature for the γ-orthorhombic crystal structure in the metallocene resins was found to be 178 ± 4 °C. The results were explained by the distribution of defects within the miPP chains, generating higher fold surface free energies for the miPP resins. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 3050–3064, 1999     

Ethylene polymerization reactions with Ziegler–Natta catalysts. II. Ethylene polymerization reactions in the presence of deuterium

Ethylene polymerization reactions with many Ziegler–Natta catalysts exhibit several features which differentiate them from polymerization reactions of α-olefins: a relatively low ethylene reactivity, higher polymerization rates in the presence of α-olefins, a high reaction order with respect to ethylene concentration, and strong reversible rate depression in the presence of hydrogen. A detailed kinetic analysis of ethylene polymerization reactions (see ref. 1 ) provided the basis for a new reaction scheme which explains all these features by postulating the equilibrium formation of a Ti C₂H₅ species with the H atom in the methyl group β-agostically coordinated to the Ti atom in an active center. This mechanism predicts that the β-agostically stabilized Ti C₂H₅ groups can decompose in the β-hydride elimination reaction with expulsion of ethylene and the formation of a Ti H bond even in the absence of hydrogen in the reaction medium. If D₂ is used as a chain transfer agent instead of H₂, the mechanism predicts the formation of deuterated ethylene molecules, which copolymerize with protioethylene. To prove this prediction, several ethylene homopolymerization reactions were carried out with a supported Ziegler–Natta titanium-based catalyst in the presence of large amounts of D₂. Analysis of gaseous reaction products and polymers confirmed the formation of several types of deuterated ethylene molecules and protio/deuterioethylene copolymers, respectively. In contrast, a metallocene catalyst, Cp₂ZrCl₂ MAO, does not exhibit these kinetic features. In the presence of deuterium, it produces only DCH₂ CH₂ (CH₂ CH₂)_x CH₂ CH₂D molecules. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4273–4280, 1999