Vapor synthesis of high-activity catalysts for olefin polymerization

Vaporization of MgCl₂ and other metal halides results in monomeric gas-phase species. Cocondensation of these species with organic diluents such as heptane yields highly activated solids which are precursors to MgCl₂ supported “high-mileage” catalysts for olefin polymerization. These catalysts, prepared by treatment with TiCl₄ followed by standard activation with aluminum alkyls display high activity for ethylene and propylene polymerization. MgCl₂ can also be evaporated into neat TiCl₄ to give a related catalyst. The concentration of MgCl₂ in the diluent affects catalyst properties as does the nature of the diluent. TiCl₃, 3TiCl₃ · AlCl₃, VCl₃ and other metal halides are subject to similar activation.     

Influence of support recrystallization techniques on catalyst performance in olefin polymerization

This paper is a comparative study of the performance of TiCl₄ catalysts supported on recrystallized MgCl₂ through different techniques for the polymerization of ethylene, propylene and ethylene-propylene copolymers. MgCl₂ was dissolved in 1-hexanol and recrystallized through solvent evaporation, quick cooling and precipitation with SiCl₄. The effect of the recrystallization conditions during the catalyst preparation on the chemical composition of catalysts was discussed with the help of IR spectroscopy. The variations of dealcoholation levels due to the different recrystallization techniques highly influenced the catalytic activity. The catalyst obtained through SiCl₄ recrystallization was not only the most active, but it also showed the highest isotacticity indexes for propylene polymerization.     

Novel Preparation of Polyethylene from Nano‐extrusion Polymerization Inside the Nanochannels of MCM‐41/MgCl2/TiCl4 Catalysts

The MCM‐41 and SiO₂ supported TiCl₄ and TiCl₄/MgCl₂ catalysts with different molar ratios of Mg/Ti were synthesized and used for ethylene polymerization under atmospheric pressure. The nanochannels of MCM‐41 serve as nanoscale polymerization reactor and the polyethylene nanofibers were extruded during the reaction. The nanofibers were observed in SEM micrographs of resulting polyethylene. The effect of MgCl₂ on catalytic activity and thermal properties of resulting polyethylene is investigated too. In the presence of MgCl₂, the catalytic activity increased and more crystalline polyethylene with higher melting points were formed. However, no fibers could be observed in the polyethylene prepared by SiO₂ supported catalysts.     

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     

Ionization of MgCl2 during the formation of α-olefin polymeryzation catalyst

The examination of the reaction between [MgCl₂(THF)₂], TiCl₄₍₃₎, AlCl₃, AlEt₃, AlEt₂Cl and the synthesis and isolation of compounds as crystals and resolution of their structure by the X-ray method were the subject of our study. It was expected that these investigations would help to understand the behaviour of MgCl₂ towards the transition metal and furnish useful relationships to the structure of catalyst active center and to the polymerization mechanism in TiCl₄₍₃₎/MgCl₂/AlEt₃ system. Our studies have revealed that the main difference between the first and higher generations of Ziegler-Natta catalysts is only the number of active centers.     

MAO‐Free Activation of Metallocenes and other Single‐Site Catalysts for Ethylene Polymerization using Spherical Supports based on MgCl2

Summary: Supports of type MgCl₂/AlR_n(OEt)_3−n, obtained by reaction of AlR₃ with adducts of MgCl₂ and ethanol, have been shown to be effective for the immobilization and activation of [Cp₂TiCl₂] and other single‐site olefin polymerization catalysts without the use of methylaluminoxane or a borate activator. Polyethylene with a spherical particle morphology and narrow molecular weight distribution was obtained.

     

Effect of inorganic salt on the dose sensitivity of polymer gel dosimeter

The effect of inorganic salts, non-transition metal chlorides, on the dose sensitivity of methacrylic-acid-based polymer gel dosimeter is investigated. Dose-R₂ responses are obtained from magnetic resonance imaging data. Temperature increase due to exothermic polymerization reaction in the gel is also measured directly during irradiation. As a result, substantial increases in R₂ response are observed in the polymer gel dosimeter containing inorganic salt, especially with MgCl₂. The sensitivity of the gel with 1.0 M MgCl₂ is approximately 2.8 times higher than that of without MgCl₂. As the salt concentration increases, an increase of polymerization rate is also observed via the temperature measurements. These results indicate that inorganic salt acts as an accelerator for radiation-induced free-radical polymerization in methacrylic-acid-based gel.     

Effects of Various Amounts of New Hepta-Ether as the Internal Donor on the Polymerization of Propylene with and without the External Donor

The new hepta-ether compound as the internal donor was synthesized using the Williamson reaction of dipentaerythritol with sodium hydride as the strong base and iodomethane as the alkyl halide. The hepta-ether compound was characterized by NMR, FTIR, and GC techniques. The MgCl₂-supported catalysts incorporated with different amounts of hepta-ether compound as the internal donor and without the internal donor were synthesized and characterized. The propylene polymerization was carried out using these catalysts in the presence of triethylaluminum as a co-catalyst and hydrogen as a chain transfer agent, with and without the external donor. The effect of a new internal donor on propylene polymerization using prepared MgCl₂-supported Ziegler-Natta catalysts was investigated.     

Single-site catalyst immobilization using magnesium chloride supports

Immobilization and activation of a broad range of titanium-, chromium-and nickel-based single-site catalysts for ethylene polymerization has been carried out using supports of type MgCl₂/AlR_n(OEt)_{3 − n} , prepared by reaction of AlR₃ with adducts of magnesium chloride and ethanol. The spherical particle morphology of the support is retained and replicated during catalyst immobilization and polymerization, yielding polyethylenes with controlled particle size and morphology. The single-site nature of these catalysts is also retained, giving polymers with narrow molecular weight distribution. Furthermore, very high catalyst activities can be obtained as a result of a stabilizing effect of the support, which prevents the rapid decay in activity often observed in homogeneous polymerization with these catalysts. The text was submitted by the authors in English.     

New penta-ether as the internal donor in the MgCl2-supported Ziegler-Natta catalysts for propylene polymerization

The penta-ether compound was synthesized by the reaction of di(trimethylolpropane) with sodium hydride as the strong base and methyl iodide as the alkyl halide. This compound was characterized by NMR, FTIR, and GC techniques. The MgCl₂-supported titanium catalysts were incorporated with varying amounts of penta-ether compound as the internal donor and also the catalysts without the internal donor were synthesized. The synthesized catalysts and the conventional Ziegler- Natta catalyst were characterized. The titanium contents were determined by spectrophotometry, magnesium by complexometric titration and chloride by argentometric titration. The effects of the new internal donor on propylene polymerization with the prepared MgCl₂-supported Ziegler-Natta catalysts were investigated and then these results were compared to the results obtained using the conventional diisobutyl phthalate-besed-Ziegler-Natta catalyst. The highest crystallinity degree, melting temperature, and isotacticity of polypropylene were obtained using the catalyst with a penta-ether/Mg molar ratio equal to 0.21.     

Characterization of the changes in the initial morphology for MgCl2-supported Ziegler-Natta polymerization catalysts

Recently considerable detail has become available on the initial morphology and the morphological changes that occur for silica based Cr catalysts for ethylene polymerization. These catalysts are produced as a dry powder and may be employed either in gas phase or in slurry processes. MgCl₂-supported Ziegler-Natta polymerization catalysts are often prepared and employed as slurries. They usually are never dried and thus few studies have employed the spectra of physical techniques common to the characterization of pore structure. In the current study, we have carefully removed the solvent for both ball-milled and precipitated MgCl₂-supported catalysts. These catalysts are characterized by physical sorption, mercury porosimetry, and electron microscopy both as prepared and during the initial stages of polymerization (to ～ 100 g of polymer/g of catalyst). We find that the initial catalyst may be represented by a complex agglomerate of small crystallites as contrasted with the branched pore network found in Cr/silica catalysts. As a result, it is concluded that the initial fragmentation of the MgCl₂ based systems is more uniform as contrasted with the progressive fragmentation of the silica-based system. This fragmentation mechanism facilitates the retention of greater polymer/catalyst surface during the initial stages of the polymerization. © 1992 John Wiley & Sons, Inc.     

Propylene polymerization with catalysts containing divalent titanium

The behavior in propylene polymerization of divalent titanium compounds of type [η⁶-areneTiAl₂Cl₈], both as such and supported on activated MgCl₂, has been studied and compared to that of the simple catalyst MgCl₂/TiCl₄. Triethylaluminium was used as cocatalyst. The Ti–arene complexes were active both in the presence and in the absence of hydrogen, in contrast to earlier reports that divalent titanium species are active for ethylene but not for propylene polymerization. ¹³C-NMR analysis of low molecular weight polymer fractions indicated that the hydrogen activation effect observed for the MgCl₂-supported catalysts should be ascribed to reactivation of 2,1-inserted (“dormant”) sites via chain transfer, rather than to (re)generation of active trivalent Ti via oxidative addition of hydrogen to divalent species. Decay in activity during polymerization was observed with both catalysts, indicating that for MgCl₂/TiCl₄ catalysts decay is not necessarily due to overreduction of Ti to the divalent state during polymerization. In ethylene polymerization both catalysts exhibited an acceleration rather than a decay profile. It is suggested that the observed decay in activity during propylene polymerization may be due to the formation of clustered species that are too hindered for propylene but that allow ethylene polymerization. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 2645–2652, 1997     

Gas-phase polymerization of ethylene over Ti-based Ziegler–Natta catalysts prepared from different magnesium sources

This study focuses on gas-phase polymerization of ethylene using the titanium-based Ziegler–Natta catalysts prepared from different magnesium sources including MgCl₂ (Cat A), magnesium powder (Cat B), and Mg(OEt)₂ (Cat C). During polymerization, different cocatalysts were also used. It was found that Cat C with triethylaluminum as a cocatalyst exhibited the highest activity. This was likely attributed to optimal distribution of active sites on the catalyst surface. It can be observed by increased temperature in the reactor due to highly exothermic reaction during polymerization. By the way, the morphologies of the polymer obtained from this catalyst were spherical, which is more preferable. Besides the catalytic activity, crystallinity and morphology were also affected by the different magnesium sources used to prepare the catalysts.     

Facile Synthesis of Stable MO2N Nanobelts with High Catalytic Activity for Ammonia Decomposition

In the present work, high quality γ‐Mo₂N catalysts for ammonia decomposition were successfully synthesized via temperature programmed nitridation of α‐MoO₃ nanobelts. The optimal conditions for the synthesis of MoO₃ precursors were obtained by using the orthogonal experimental method. The MoO₃ precursors and the corresponding fresh and used Mo₂N catalysts were characterized by various characterization techniques, including transmission electron microscopy, X‐ray diffraction and N₂ adsorption‐desorption. Furthermore, temperature‐ programmed desorption by N₂ or NH₃ and X‐ray photoelectron spectroscopy analysis were performed to better understand the chemical properties of Mo₂N catalysts. The results revealed that Mo₂N catalyst has good NH₃ adsorption ability and facilitates the dissociation adsorption of N₂. Moreover, the morphology and structure of Mo₂N catalysts well maintained after the reaction. Therefore, among the three transition metal nitrides (Mo₂N, W₂N and VN) and some Mo‐based catalysts previously reported, Mo₂N catalysts showed very high activity and stability. Nearly 94% conversion of NH₃ could be reached at 550°C with the gas hourly space velocity of 22000 cm³?g_cat^–1?h^–1 and no obvious deactivation was observed during a 72 h test.     

Direct observation of MgCl2‐supported Ziegler catalysts by high resolution transmission electron microscopy

The surface atomic structure of MgCl₂ crystalline particles and MgCl₂‐supported Ziegler catalysts was observed by means of high resolution transmission electron microscopy. Step‐terrace surface structures, characteristic of the structure of the MgCl₂ crystal, are found in the observed images of MgCl₂ particles. The observation of the structure of MgCl₂‐supported Ziegler catalysts shows that the MgCl₂ crystals are severely deformed by the processes of catalyst preparation. Due to the preparation procedure used the structure of the catalyst changes from crystalline to amorphous.     

Propene polymerization with the MgCl2-supported dichlorobis(β-diketonato)titanium catalysts activated by ordinary alkylaluminums

Several kinds of dichlorobis(β-diketonato)titanium complexes, i.e., Ti(ace-tylacetonato)₂Cl₂, Ti(1-benzoylacetonato)₂Cl₂, Ti(2,2,6,6-tetramethyl-3,5-heptanedionato)₂Cl₂ and Ti(4,4,4-trifluoro-1-phenyl-1,3-butanedionato)₂Cl₂, were synthesized and the corresponding MgCl₂-supported catalysts were prepared by impregnation method. The test of them for propene polymerization revealed that those MgCl₂-supported catalysts could be activated not only by methylaluminoxane (MAO) but also by ordinary alkylaluminums as well. The effect of typical Lewis bases on the catalyst performance was investigated in some detail, which indicated that organic silanes are most effective for the improvement of isospecificity of those catalysts. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 129–135, 1998     

Amalgamation of ziegler-natta and metallocene catalysts

The MgCl₂ supported half titanocenes and Ti(4, 4, 4-trifluoro-1-phenyl-1, 3-butanedionato)₂Cl₂ catalysts were synthesized and applied to propene polymerization. Without supporting on MgCl₂, those complexes displayed almost no activity even using methylaluminoxane (MAO) as cocatalyst. When supported on MgCl₂, on the other hand, the resulting catalysts could be activated by ordinary alkylaluminums to yield polypropene in fairly high yields. The catalyst isospecificity was markedly improved by the addition of a suitable Lewis base.     

Highly active MgCl2‐supported catalysts containing novel diether donors for propene polymerization

A new generation of MgCl₂‐supported catalysts for the polymerization of propene without any external donors was prepared. Two diethers, 9,9‐bis(methoxymethyl)fluorene (for Cat‐A) and 2,2‐dipropyl‐1,3‐dimethoxypropane (for Cat‐B) differing in the bulkiness of alkyl substituents in position 2, have been used as internal donors in MgCl₂/TiCl₄/diether‐AlR₃ catalysts. The weight‐average molecular weights produced with both catalysts were over 3.5×10⁵ at low temperature in slurry polymerization (< 40°C). Cat‐A showed higher activity and produced higher isotactic polypropene than Cat‐B. The activity of both catalysts proved to be dependent on the temperature.     

Effect of temperature on the number of active sites and propagation rate constant at ethylene polymerization over supported bis(imino)pyridine iron catalysts

The inhibition of ethylene polymerization with radioactive carbon monoxide (¹⁴CO) was used to obtain data on the number of active sites (C_P) and propagation rate constant (k_P) at ethylene polymerization in the temperature range of 35–70 °C over supported catalysts LFeCl₂/Al₂O₃, LFeCl₂/SiO₂, and LFeCl₂/MgCl₂ (L: 2,6‐(2,6‐(Me)₂C₆H₃N = CMe)₂C₅H₃N) with activator Al(i‐Bu)₃. The values of effective activation energy (E_eff), activation energy of propagation reaction (E_P), and temperature coefficients of variation of the number of active sites (E_Cp = E_eff ? E_P) were determined. The activation energies of propagation reaction for catalysts LFeCl₂/Al₂O₃, LFeCl₂/SiO₂, and LFeCl₂/MgCl₂ were found to be quite similar (5.2–5.7 kcal/mol). The number of active sites diminished considerably as the polymerization temperature decreased, the E_Cp value being 5.2–6.2 kcal/mol for these catalysts at polymerization in the presence of hydrogen. The reactions of reversible transformations of active centers to the surface hydride species at polymerization in the presence and absence of hydrogen are proposed as the derivation of E_Cp. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 6621–6629, 2008     

MgCl2·6H2O-BASED ZIRCONOCENE CATALYST FOR ETHYLENE POLYERIZATION

Several supported zirconocene catalysts were prepared by using MgCl_2·6H_2O as a precursor forproducing an active support. Such catalysts combined with methylaluminoxane (MAO) obtained by reactingMgCl_2·6H_2O with AlMe_3 show good activity for ethylene polymerization similar to that of anhydrousMgCl_2 supported zirconocene catalyst.