Effects of nano graphene oxide as support on the product properties and performance of Ziegler–Natta catalyst in production of UHMWPE

The synthesis of mono‐ and bi‐supported Ziegler–Natta catalysts using magnesium etoxide Mg(OEt)₂ and graphene oxide (GO) as catalyst support for production of Ultra High Molecular Weight Polyethylene (UHMWPE) is reported in this investigation. Nano‐graphene oxide was prepared by the modified Hummer's method and its structure was analyzed by XRD and FTIR indicating the presence of hydroxyl groups on graphene oxide and the formation of an exfoliated structure. The activity of TiCl₄/Mg(OEt)₂, TiCl₄/Mg(OEt)₂‐GO, and TiCl₄/GO catalysts in terms of grams of PE produced per mmol of Ti per hour was experimentally obtained for catalysts with different ratios of co‐catalyst (triisobutylaluminium) to TiCl₄. For all three series of catalysts, the activity curve showed an optimum point at a specific Al/Ti molar ratio. Catalyst activity was highest for TiCl₄/Mg(OEt)₂ and lowest for TiCl₄/GO. The characterization of UHMWPE products indicated that the viscosity average molecular weight (Mv) was highest for the polymer produced by TiCl₄/Mg(OEt)₂ and lowest for the polymer produced by TiCl₄/GO. Furthermore, thermogravimetric analysis (TGA), dynamic mechanical thermal analysis (DMTA), and mechanical tensile testing were conducted on the prepared polymers indicating that the polymer produced by TiCl₄/GO had the highest thermal and mechanical properties, while these properties were at their minimum for polymers produced by TiCl₄/Mg(OEt)₂. Copyright © 2015 John Wiley & Sons, Ltd.     

Influence of the carrier characteristics on the catalytic activity of supported TiCl4/Al(C2H5)2Cl Ziegler catalyst in the ethylene polymerization

The effect of the carrier characteristics, such as specific surface area and acidity, on the activity of supported Ziegler catalyst in the ethylene polymerization has been investigated. Silica-gel and silica-alumina, containing various quantities of alumina (5, 13 and 25 wt-%) and also modified by deposition of Zn metal, wer used as carriers. The different carriers give rise to catalysts with different activities after deposition of TiCl₄ and activated with Al(C₂H₅)₂Cl. The activity in ethylene polymerization is controlled firstly by the chemical composition of the carriers and secondly by its specific surface area. The silica-aluminas show higher acidities than silica-gel and deposition of Zn is accompanied by considerable changes in the carriers, especially increasing their acidity and decreasing the specific surface areas. The increase of the carrier acidity gives rise to an increase in the polymerization activitity and in the polymer molecular weights. Coordinately unsaturated titanium ions, on the surface of the catalysts containing Zn metal, are detected by ESR, showing a paramagnetic signal similar to those produced by TiCl₃ crystals.     

Ti complex catalysts including thiobisphenoxy group as a ligand for olefin polymerization

Titanium complexes were prepared by the reaction of 2,2′-thiobis(6-tert-butyl-4-methylphenol) (TBP) with TiCl₄ or Ti(OPrⁱ)₄. These complexes in combination with methyalumoxane as cocatalyst are highly active towards ethylene and propene, giving polymers having high molecular weights. The polymerization activities for ethylene and propene are comparable to those of Cp₂ZrCl₂-MAO catalyst. Polypropylene obtained had extremely high molecular weight (Mw>6 million) and low regioregularity (30% of head-to-head and tail-to-tail linkages). Highly syndiotactic polystyrene was obtained with these catalysts with activity up to 27 kg polymer per g Ti and hour. Copolymerization of styrene with ethylene gave highly alternating copolymer with isotactic styrene units. These catalysts are also active toward both conjugated and nonconjugated dienes such as butadiene and 1,5-hexadiene. Polybutadiene had mainly cis-1,4-structure (98%). The structure of poly(1,5-hexadiene) is rather complicated, which is quite different from that prepared with heterogeneous TiCl₃ catalysts.     

Tetraalkyl titanium and zirconium metal chloride catalyst systems for ethylene polymerization

Coordination polymerization of olefins has become an industrially important, yet still poorly understood enterprise. The ethylene polymerization activity of (neophyl)_nZrCl_4-n shows a twentyfold increase from n = 4 to n = 3 and a further tenfold increase to n = 2. The heterogeneous MR₄/TiCl₄ catalysts (M = Ti, R = benzyl; M = Zr, R = benzyl, neophyl) have been developed. To explore the breadth of extendability, other metal chlorides (main group and transition metal) were substituted for TiCl₄. Indeed, excess AlCl₃ or MgCl₂ and the MR₄ compounds also produced ethylene polymerization catalysts. The inactivity of corresponding (neophyl)₄Ti systems is attributed to sterics. The abovementioned catalysts highlight the necessity of alkyl and chloride ligands at the transition metal catalyst centers.     

Monomer-Isomerization polymerization. XXVIII. Catalytic activity of transition metals and alkylaluminums in monomer-isomerization polymerization of 2-butene

Monomer-isomerization polymerization of cis-2-butene (c2B) with Ziegler–Natta catalysts was studied to find a highly active catalyst. Among the transition metals [TiCl₃, TiCl₄, VCl₃, VOCl₃, and V (acac)₃] and alkylauminums used, TiCl₃? R₃Al (R = C₂H₅ and i-C₄H₉) was found to show a high-activity for monomer-isomerization polymerization of c2B. The polymer yield was low with TiCl₄? (C₂H₅)₃Al catalyst. However, when NiCl₂ was added to this catalyst, the polymer yield increased. With TiCl₃? (C₂H₅)₃Al catalyst, the effect of the Al/Ti molar ratio was observed and a maximum for the polymer yields was obtained at molar ratios of 2.0–3.0, but the isomerization increased as a function of Al/Ti molar ratio. The valence state of titanium on active sites for isomerization and polymerization is discussed.     

Copolymerization of 2‐butene and ethylene with catalysts based on titanium and zirconium complexes

The polymerization of 2‐butene and its copolymerization with ethylene have been investigated using four kinds of dichlorobis(β‐diketonato)titanium complexes, [ArN(CH₂)₃NAr]TiCl₂ (Ar = 2,6‐ⁱPr₂C₆H₃) and typical metallocene catalysts. The obtained copolymers display lower melting points than those produced of homopolyethylene under the same polymerization conditions. ¹³C NMR analysis indicates that 9.3 mol‐% of 2‐butene units were incorporated into the polymer chains with Ti(BFA)₂Cl₂‐MAO as the catalyst system. With the trans‐2‐butene a higher copolymerization rate was observed than with cis‐2‐butene. A highly regioselective catalyst system for propene polymerization, [ArN(CH₂)₃NAr]TiCl₂ complex using a mixture of triisobutylaluminium and Ph₃CB(C₆F₅)₄ as cocatalyst, was found to copolymerize a mixture of 1‐butene and trans‐2‐butene with ethylene up to 3.1 mol‐%. Monomer isomerization‐polymerization proceeds with typical metallocene catalysts to produce copolymers consisting of ethylene and 1‐butene.     

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     

Living copolymerization of ethylene with norbornene mediated by heteroligated (Salicylaldiminato)(β‐enaminoketonato)titanium catalysts

Three heteroligated (salicylaldiminato)(β‐enaminoketonato)titanium complexes [3‐Bu^t‐2‐OC₆H₃CH?N(C₆F₅)][(p‐XC₆H₄)N?C(Bu^t)CHC(CF₃)O]TiCl₂ ( 3a : X = F, 3b : X = Cl, 3c : X = Br) were synthesized and investigated as the catalysts for ethylene polymerization and ethylene/norbornene copolymerization. In the presence of modified methylaluminoxane as a cocatalyst, these unsymmetric catalysts exhibited high activities toward ethylene polymerization, similar to their parallel parent catalysts. Furthermore, they also displayed favorable ability to efficiently incorporate norbornene into the polymer chains and produce high molecular weight copolymers under the mild conditions, though the copolymerization of ethylene with norbornene leads to relatively lower activities. The sterically open structure of the β‐enaminoketonato ligand is responsible for the high norbornene incorporation. The norbornene concentration in the polymerization medium had a profound influence on the molecular weight distribution of the resulting copolymer. When the norbornene concentration in the feed is higher than 0.4 mol/L, the heteroligated catalysts mediated the living copolymerization of ethylene with norbornene to form narrow molecular weight distribution copolymers (M_w/M_n < 1.20), which suggested that chain termination or transfer reaction could be efficiently suppressed via the addition of norbornene into the reaction medium. Polymer yields, catalytic activity, molecular weight, and norbornene incorporation can be controlled within a wide range by the variation of the reaction parameters such as comonomer content in the feed, reaction time, and temperature. ©2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6072–6082, 2009     

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.     

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     

Monomer-isomerization polymerization. XXVI. Formation of polyallylcyclohexane from propenylcyclohexane through monomer-isomerization polymerization with Ziegler–Natta catalysts

Monomer-isomerization polymerization of propenycyclohexane (PCH) with TiCl₃ and R_3-xAICI_x (R = C₂H₅ or i-C₄H₉, x = 1–3) catalysts was studied. It was found that PCH underwent monomer-isomerization polymerization to give a high molecular weight polymer consisting of an allylcyclohexane (ACH) repeat unit. Among the alkyaluminum cocatalysts examined, (C₂H₅)₃Al was the most effective cocatalyst for the monomer-isomerization polymerization of PCH, and a maximum for the polymerization was observed at a molar ratio of Al/Ti of about 2.0. The addition of isomerization catalysts such as nickel acetylacetonate [Ni(acac)₂] to the TiCl₃–(C₂H₅)₃Al catalyst accelerated the monomer-isomerization polymerization of PCH and gave a maximum for the polymerization at a Ni/Ti molar ratio of 0.5. PCH also undergoes monomer-isomerization copolymerization with 2-butene (2B).     

Ziegler polymerization of olefins. IX. Donor effects in metal alkyl-free and Ziegler-type stereospecific catalysts

Electron donors, especially trialkylamines and azulene, have been examined in aluminum alkyl-, CH₃TiCl₃- and hydrogen-activated TiCl₃ catalysts for the polymerization of propylene to isotactic polymer. A comparison and an evaluation were made with findings which were established earlier with zinc alkyl-based TiCl₃ catalysts. We find that the donor, when it is present in low concentrations in all of the above catalysts, can inactivate preferentially the less stereoregulating sites. In this way the isotactic content and the molecular weight of the polymer are increased, but only at the expense of a lower catalyst activity. The addition of hydrogen to the TiCl₃–donor catalyst at ?78°C produced a threefold effect: (1) the activity of the catalyst was increased about 5 to 15 times and higher, (2) the polypropylene formed with this more active catalyst was more isotactic (ca. 10–15%), and (3) the polymer had a lower molecular weight. It is proposed that the increase in catalyst activity was due to the generation of Ti-H bonds to which propylene molecules then added, the Ti-H bonds thus being transformed into active Ti-C centers.     

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.     

Polymerization of ethylene with self-immobilizing bis(phenoxyimine) catalytic systems

The kinetic features of polymerization of ethylene with five methylaluminoxane-activated selfim-mobilizing bis(phenoxyimine) complexes of titanium chloride, namely, bis{2-[(4-allyloxyphenylimino)methyl]-6-tert-butylphenoxy}TiCl₂, bis{2-[(4-allyloxyphenylimino)methyl]-4,6-di-tert-butylphenoxy}TiCl₂, bis{2-[(4-allyloxyphenylimino)methyl]-6-cumylphenoxy}TiCl₂, bis{2-[(4-allyloxyphenylimino)methyl]-4,6-dicumylphenoxy}TiCl₂, and bis{2-[(4-allyloxyphenylimino)methyl]-6-1-(4-tert-butylphenyl)ethylphenoxy}TiCl₂ have been studied. The activity of these complexes in the polymerization of ethylene in the temperature range 20–80°C and an ethylene pressure of 0.3 MPa has been investigated both in the homogeneous and polymer matrix-bound states. The self-immobilizing catalytic systems possess high activity (up to 40000 kg_PE/mol_cat MPa h) and give rise to ultrahigh-molecular-weight PE (M = (2–7) × 10⁶) with an improved morphology of polymer particles.     

Monomer-isomerization polymerization. XXIII.. Monomer-isomerization polymerization of 5-phenyl-2-pentene with ziegler–natta catalysts

5-Phenyl-2-pentene (5Ph2P) was found to undergo monomer-isomerization polymerization with TiCl₃–R₃Al (R = C₂H₅ or i-C₄H₉, Al/Ti > 2) catalysts to give a polymer consisting of exclusively 5-phenyl-1-pentene (5Ph1P) unit. The geometric and positional isomerizations of 5Ph2P to its terminal and other internal isomers were observed to occur during polymerization. The catalyst activity of alkylaluminum examined to TiCl₃ was in the following order: (C₂H₅)₃Al > (i-C₄H₉)₃Al > (C₂H₅)₂AlCl. The rate of monomer-isomerization polymerization of 5Ph2P with TiCl₃–(C₂H₅)₃Al catalyst was influenced by both the Al/Ti molar ratio and the addition of nickel acetylacetonate [Ni(acac)₂], and the maximum rate was observed at Al/Ti = 2.0 and Ni/Ti = 0.4 in molar ratios.     

Selective vinyl polymerization of 4-vinyl-1-cyclohexene with ziegler–natta catalyst

The polymerization of 4-vinyl-1-cyclohexene (4VCHE) with Ziegler–Natta catalysts was studied. The polymerization of 4VCHE by the vinyl group took place with TiCl₃–aluminum alkyls catalysts, while vinylene group of 4VCHE did not participate in the reaction, but it affected the polymerization rate of 4VCHE. The effects of aluminum alkyl and type of TiCl₃ on the polymerization were examined. The overall activation energy for the polymerization was estimated to be 41.9kJ/mol. Monomer-isomerization copolymerization of 4VCHE and trans-2-butene occurred with the TiCl₃-(i-C₄H₉)₃Al catalyst to give copolymers consisting of 4VCHE and 1-butene units.     

Polymerization of vinylcyclohexane with ziegler–natta catalyst

Polymerization of vinylcyclohexane (VCHA) with TiCl₃–aluminum alkyl catalysts was investigated. The polymerization rate of VCHA was low due to the branch at the position adjacent to the reacting double bond. The effects of aluminum alkyl on the polymerization and monomer-isomerization were observed; the polymer yield decreased in the following order: (CH₃)₃Al > (i–C₄H₉)₃Al > (C₂H₅)₃Al. Isomerization of VCHA was observed with the TiCl₃–(i–C₄H₉)₃Al and the TiCl₃–(C₂H₅)₃Al catalysts during the polymerization, while with the TiCl₃–(CH₃)₃Al catalyst such isomerization was not observed. Monomer-isomerization copolymerization of VCHA and trans-2-butene took place to give copolymers consisting of VCHA and 1-butene units.     

Modification of the (SiO<Subscript>2</Subscript>/MgO/MgCl<Subscript>2</Subscript>)·TiCl<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript> Ziegler-Natta polyethylene catalysts using the third metal elements

Various (SiO₂/MgO/MgCl₂)·TiCl _x Ziegler-Natta catalysts modified by the third metal elements were synthesized by the co-impregnation of water-soluble magnesium and the third metal salts. Several key factors including the electronegativity of the third metal elements, catalyst performances in ethylene homo-polymerization, ethylene/1-hexene copolymerization and hydrogen response were systematically investigated. Both the catalyst performance and the polymer properties are influenced by the introduction of the third metal elements. Compared with the unmodified (SiO₂/MgO/MgCl₂)·TiCl _x Ziegler-Natta catalyst, activity and 1-hexene incorporation are enhanced by the introduction of zirconium, vanadium, aluminum and chromium, while deteriorated by the addition of ferrum, nickel, molybdenum and tungsten. Correlations of the catalyst activities and 1-hexene incorporation ability with the electronegativity of the third metal elements are discovered. It is found that the lower electronegativity of the third metal elements leads to the catalyst with higher activity and higher α-olefin co-polymerization ability. The polyethylene produced by a nickel modified catalyst showed broad molecular weight distribution (MWD) and the lowest average molecular weight (MW), while by using a ferrum modified catalyst, the resulting polyethylene had the highest MW, reaching the ultra-high MW area. Vanadium and chromium modified catalysts demonstrated the best hydrogen response.     

Multicenter nature of titanium‐based Ziegler–Natta catalysts: Comparison of ethylene and propylene polymerization reactions

This article discusses the similarities and differences between active centers in propylene and ethylene polymerization reactions over the same Ti‐based catalysts. These correlations were examined by comparing the polymerization kinetics of both monomers over two different Ti‐based catalyst systems, δ‐TiCl₃‐AlEt₃ and TiCl₄/DBP/MgCl₂‐AlEt₃/PhSi(OEt)₃, by comparing the molecular weight distributions of respective polymers, in consecutive ethylene/propylene and propylene/ethylene homopolymerization reactions, and by examining the IR spectra of “impact‐resistant” polypropylene (a mixture of isotactic polypropylene and an ethylene/propylene copolymer). The results of these experiments indicated that Ti‐based catalysts contain two families of active centers. The centers of the first family, which are relatively unstable kinetically, are capable of polymerizing and copolymerizing all olefins. This family includes from four to six populations of centers that differ in their stereospecificity, average molecular weights of polymer molecules they produce, and in the values of reactivity ratios in olefin copolymerization reactions. The centers of the second family (two populations of centers) efficiently polymerize only ethylene. They do not homopolymerize α‐olefins and, if used in ethylene/α‐olefin copolymerization reactions, incorporate α‐olefin molecules very poorly. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 1745–1758, 2003     

Stereospecific polymerization of isobutyl vinyl ether. III. Polymerization with VCl3 • LiCl

The polymerization of isobutyl vinyl ether by vanadium trichloride in n-heptane was studied. VCl₃ ? LiCl was prepared by the reduction of VCl₄ with stoichiometric amounts of BuLi. This type of catalyst induces stereospecific polymerization of isobutyl vinyl ether without the action of trialkyl aluminum to an isotactic polymer when a rise in temperature during the polymerization was depressed by cooling. It is suggested that the cause of the stereospecific polymerization might be due to the catalyst structure in which LiCl coexists with VCl₃, namely, VCl₃ ? LiCl or VCl₂ ? 2LiCl as a solid solution in the crystalline lattice, since VCl₃ prepared by thermal decomposition of VCl₄ and a commercial VCl₃ did not produce the crystalline polymer and soluble catalysts such as VCl₄ in heptane and VCl₃ ? LiCl in ether solution did not yield the stereospecific polymer. It was found that some additives, such as tetrahydrofuran or ethylene glycol diphenyl ether, to the catalyst increased the stereospecific polymerization activity of the catalysts. Influence of the polymerization conditions such as temperature, time, monomer and catalyst concentrations, and the kind of solvent on the formed polymer was also examined.