Metallocene systems in propylene polymerization: Effect of triisobutylaluminum and lewis bases on the behavior of catalysts and properties of polymers

For two stereospecific metallocene catalysts, namely, syndiospecific Ph₂CCpFluHfMe₂ and isospecific rac-Me₂SiInd₂ZrMe₂, the introduction of Lewis bases into a reaction medium was shown to promote a marked rise in the efficiency of catalytic systems. In the case of the syndiospecific metallocene, the maximum effect of the base (a 10-fold increase in activity) was achieved using the (Ph₂CCpFluHfMe₂ + Ph₃N)/CPh₃B(C₆F₅)₄ catalytic system in the presence of Al-i-Bu₃ at a molar ratio of Al: Hf: B: N = 15: 1: 1: 1. When the polymerization of propylene was carried out in the presence of Al-i-Bu₃ and Ph₃N, an elastomeric stereoblock syndio/atactic polypropylene was produced. For the (rac-Me₂SiInd₂ZrMe₂ + amine)/CPh₃B(C₆F₅)₄ catalytic system, a 15-to 30-fold increase in activity was observed upon introduction of amines of the aniline type: Me₂NPh, Me-n-BuNPh, and NPh₃.     

Magnesium chloride supported high-mileage catalysts for olefin polymerization. XVII. Effect of lewis base on propylene polymerization

A systematic study has been made on the functions of external Lewis base (B_e, methyl-p-toluate, MPT) and internal Lewis base (B_i, ethyl benzoate, EB) for the CW-catalyst system MgCI₂/EB/PC/AlEt₃/TiCl₄–AlEt₃/MPT (PC, p-cresol). B_i is a nonstereoselective modifier. It increases the active site concentrations and rate constants of propagation, k_p, of both the isospecific and nonspecific sites, and thus the productivities of the stereoregular and irregular polypropylenes by five- to tenfold. It seems that B_i complexes with the MgCl₂ support to lower the electronegativity of the surface Mg atoms. It also acts to lower the rate constant of chain transfer to aluminum alkyl, k, by two- to fourfold. The action of B_e is highly stereospecific. The isotacticity index of polypropylene is ? 95% in the presence of B_e but ? 68% without it. Addition of B_e decreases nonspecific [Ti^*]_a by about (11 ± 2)-fold; there is only about a twofold reduction of the isospecific [Ti^*]_i. It decreases k_p,a about three times but has no effect on k_p,i, so that the latter is (21 ± 4) times the former. B_e decreases k for transfer with aluminum alkyl much more than it does to k; but it does not affect the rates of chain transfer with monomer and by β-hydride elimination or the rate of catalyst deactivation. The number of active sites without B_e is [Ti^*]_i = 15% and [Ti^*]_a = 55% for a total of 70%. In the presence of B_e they are both about 6%. Optimum performance in propylene polymerizations requires both B_i and B_e in the case of the CW-catalyst.     

Supported titanium-magnesium catalysts for propylene polymerization

The results of studies of the synthesis and properties of supported titanium-magnesium catalysts for propylene polymerization performed at the Boreskov Institute of Catalysis, Siberian Branch, Russian Academy of Sciences, are considered. The composition of the catalysts is TiCl₄/D₁/MgCl₂-AlEt₃/D₂, where D₁ and D₂ are stereoregulating donors. With the use of the procedure proposed for the synthesis of titanium-magnesium catalysts, the morphology of catalyst particles depends on the stage of the preparation of a Mg-containing support. The titanium-magnesium catalysts developed afforded polypropylene (PP) in a high yield; this PP was characterized by high isotacticity and excellent morphology. The controllable fragmentation of the catalyst by the polymer is of crucial importance for the retention of the morphology of titanium-magnesium catalyst particles in PP. The fragmentation of catalyst particles to microparticles occurred in the formation of more than 100 g of PP per gram of the catalyst. The surface complexes were studied by DRIFT and MAS NMR spectroscopy and chemical analysis. It was shown that the role of internal donors is to regulate the distribution of TiCl₄ on different MgCl₂ faces and, thereby, to influence the properties of PP. It was found that chlorine-containing complexes of aluminum compounds were formed on the catalyst surface by the interaction of the catalyst with AlEt₃; these complexes can block the major portion of titanium chloride. Data on the number of active sites and the rate constants of polymer chain propagation (k _p) at various sites indicate that donor D₁ increases the stereospecificity of the catalyst because of an increase in the fraction of highly stereospecific active sites, at which k _p is much higher than that at low-stereospecificity active sites. Donor D₂ enhances the role of D₁. Similar values of k _p at sites with the same stereospecificity in titanium-magnesium catalysts and TiCl₃ suggest that the role of the support mainly consists in an increase in the dispersity of titanium chloride.     

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.     

Three-component catalysts containing aldehydes for stereospecific polymerization of propylene

Aldehydes, when added to mixtures of ethylaluminum dichloride and titanium trichloride under pressure of propylene, have been found to promote either propylation of benzene or stereospecific polymerization of propylene. Selectivity between the two reaction paths is influenced by the molecular structure of the aldehyde. Most aldehydes promote propylation of benzene to cumene and higher isopropyl benzenes. Propylation occurs with or without titanium trichloride present. Substituted aromatic aldehydes with three or more alkyl substituents promote stereospecific polymerization of propylene. Both reactions are dependent upon the ethylaluminum dichloride/aldehyde molar ratio.     

Modification of metallocene catalysts for olefin polymerization

The metallocene catalyst developed by Kaminsky and Sinn has been demonstrated to permit the synthesis of any kind of stereoregular polymers as well as uniform copolymers with very narrow compositional and molecular weight distributions. The catalyst is, thus, expected to comprise a revolution in the polyolefin industry. More recently, a great deal of research effort has been devoted to modify it for practical applications, which has yielded a new generation of metallocene catalysts. This paper summarizes the results reported so far in the field. Some of our original data will be also reported.     

Single-center vs. multi-center post-metallocene catalysts for propylene polymerization

The structural characteristics of polypropylene samples prepared with two post-metallocene catalysts based on complexes bis-{M-(3,5-di-tert-butyl-salicylidene)-4-[bis-(5-methyl-2-furyl)methyl]aniline}titanium dichloride and [(4R,5R)-2,2-dimethyl-α,α,α′,α′-tetra(pentafluorophenyl)-1,3-dioxalan-4,4-dimethanol)titanium dichloride are investigated by GPC, ¹³C NMR, IR, DSC, and XRD methods. A combination of the first complex and MAO forms a single-center catalyst which polymerizes propylene to a nearly perfectly atactic polymer. A combination of the second complex and MAO forms a multi-center catalyst system producing polymer mixtures with broad molecular weight distributions containing five to six Flory components with different average molecular weights. Relative contents of the Flory components strongly depend on the type of solvent in the polymerization reactions. Some of the active centers produce high molecular weight, highly isotactic crystalline material with the melting point over 154 °C. The nature of steric errors in these polymer fractions (determined by ¹³C NMR) can be explained by a variant of stereocontrol similar to that exerted by metallocene catalysts of the C₁ symmetry.     

State of titanium in supported titanium-magnesium catalysts for propylene polymerization

The oxidation state of titanium and the coordination state of Ti³⁺ ions in TiCl₄/D₁/MgCl₂ (D₁ is a phthalate) supported titanium-magnesium catalysts (TMCs) after the interaction with an AlEt₃/D₂ cocatalyst (D₂ is propyltrimethoxysilane or dicyclopentyldimethoxysilane) were studied by chemical analysis and EPR spectroscopy. Different oxidation state distributions of titanium ions were observed in the activated catalyst and mother liquor: Ti³⁺ and Ti²⁺ ions were predominant in the activated catalyst and mother liquor, respectively. The effects of interaction conditions (reaction temperature and time and Al/Ti and D₂/Ti molar ratios) of TMCs with the cocatalyst on the state of titanium in activated samples were studied. The interaction of TMCs with the cocatalyst decreased the titanium content and caused the appearance of aluminum in the activated sample, which was most clearly pronounced at a temperature of 25°C and occurred within the first 10 min of treatment. An increase in the temperature to 70°C and an increase in the interaction time to 60 min only slightly affected the concentrations of titanium and aluminum. The presence of D₂ as a cocatalyst constituent facilitated the removal of titanium compounds and restricted the adsorption of aluminum compounds on the catalyst surface. The main fraction of titanium consisted of Ti³⁺ ions (62–89%), and the rest was Ti⁴⁺ ions (22–35%) under mild interaction conditions (25°C; Si/Ti = 25) or Ti⁴⁺ (0–21%) and Ti²⁺ (9–21%) ions under more severe conditions (50 or 70°C; Si/Ti from 0 to 5). According to EPR-spectroscopic data, at D₂/Ti from 1 to 5, Ti³⁺ ions mainly occurred as associates, whereas they occurred as isolated ions at D₂/Ti = 25. The initial and activated catalysts were similar in activity in the reaction of propylene polymerization, and titanium compounds, which were removed from the catalyst upon interaction with AlEt₃/D₂, were inactive in this process.     

Studies of Ziegler-type catalysts for the polymerization of ethylene and propylene—III the polymerization of propylene with TiCl4-MgCl2-based catalysts

It has been confirmed that a reaction product of TiCl₄ and MgCl₂ is an extremely active catalyst for the polymerization of propylene. This catalyst is markedly different from the usual Ziegler-Natta TiCl₃ catalyst in the dependence of its reactivity on additions of aluminium alkyl co-catalyst and Lewis base.     

Chain epimerization during propylene polymerization with metallocene catalysts: mechanistic studies using a doubly labeled propylene

The mechanisms of chain epimerization during propylene polymerization with methylaluminoxane-activated rac-(EBTHI)ZrCl(2) and rac-(EBI)ZrCl(2) catalysts (EBTHI = ethylenebis(eta(5)-tetrahydroindenyl); EBI = ethylenebis(eta(5)-indenyl)) have been studied using specifically isotopically labeled propylene: CH(2)=CD(13)CH(3). These isospecific catalysts provide predominantly the expected [mmmm] pentads with [minus signCH(2)CD(13)CH(3)(-)] repeating units ((13)C NMR). Under relatively low propylene concentrations at 50 and 75 degreesC, where stereoerrors attributable to chain epimerization are prevalent, (13)C NMR spectra reveal (13)C-labeled methylene groups along the polymer main chain, together with [CD(13)CH(3)] units in [mmmr], [mmrr], and [mrrm] pentads and [CH(13)CH(3)] units in [mmmmmm] and [mmmmmr] heptads, as well as [mrrm] pentads. The isotopomeric regiomisplacements and stereoerrors are consistent with a mechanism involving beta-D elimination, olefin rotation and enantiofacial interconversions, and insertion to a tertiary alkyl intermediate [Zr-C(CH(2)D)((13)CH(3))P] (P = polymer chain), followed by the reverse steps to yield two stereoisomers of [Zr-CHDCH((13)CH(3))P] and [Zr-(13)CH(2)CH(CH(2)D)P], as well as unrearranged [Zr-CH(2)CD((13)CH(3))P]. The absence of observable [-CH(2)CH(13)CH(2)D-] in the [mrrm] pentad region of the (13)C NMR spectra provides evidence that an allyl/dihydrogen complex does not mediate chain epimerization.     

Magnesium chloride supported high-mileage catalysts for olefin polymerizations. XVIII. Effect of hydrogen and lewis bases

Hydrogen has been found earlier to increase the initial rate of polymerization by MgCl₂/EB/PC/AlEt₃/TiCl₄-AlEt₃/MPT, CW-catalyst (+B_i, +B_e) (EB, ethyl benzoate; PC, p-cresol; MPT, methyl-p-toluate), but decays more rapidly as compared to polymerizations in the absence of H₂. In this study the effect of H₂ was studied when either the internal Lewis base, EB B_i, or the external Lewis base, MPT B_e, or both are deleted from the CW-catalyst. H₂ does not affect the stereospecificity of all the catalysts, but causes a slight increase of polymer yield, whereas the yield is virtually unchanged by H₂ for the catalysts activated with B_e. Unlike the catalyst (+B_i, +B_e) where H₂ increases active site concentrations [Ti^*] about threefold, it affects [Ti^*] negligibly when B_e is absent. The rate constants of propagation is about the same with or without H₂ for the CW-catalyst (+B_i, –B_e) or (–B_i, –B_e); the same statement can be said about the rate constant of chain transfer with AlEt₃ or with H₂. Hydrogen increases the rate of catalyst site deactivation for the various catalysts in the order of(+B_i, +B_e) > (–B_i, –B_e) > (+B_i, –B_e).     

Exploring Si/Mg composite supported Ziegler-Natta Ti-based catalysts for propylene polymerization

A series of(Si_O2/MgO/ID/MgCl_2)·TiClx Ziegler-Natta catalysts for propylene polymerization has been prepared with a new method. These catalysts were synthesized using soluble Mg-compounds as the Mg-source and the preparation progress was relatively simple. The catalyst could copy the spherical shape of the carrier very well. The propylene polymerization results showed that the catalyst revealed the best activity with 9,9-di(methoxymethyl)fluorene(BMMF) as internal donor at 50 °C with the optimal molar ratio Al/Ti = 5, which was much lower than what the industrial polypropylene catalyst used(at least molar ratio Al/Ti = 100), resulting in great cost saving. Additionally, the polymerization kinetics of the catalyst exhibited very stable property after achieving a relatively high value. These catalysts possessed rather high activity and good hydrogen response. The isotactic index(Ⅱ.) value of the PP products could be higher than 98% in the presence of both internal and external electron donors. Moreover, temperature rising elution fractionation method was used to understand the influence of donors and H2 on the properties of the PP products.     

Phosphaacetylenehexacarbonyldicobalt complexes: new cluster lewis bases

The reaction of RCCl₂ PCl₂ (R = CH₃, C₆ H₅, (CH₃)₃ Si) with dicobalt octacarbonyl in THF at ?78°C gave the new (RCP)Co₂(CO)₅ complexes, which contain the CPCo₂ cluster unit, as air-sensitive red oils. The complex with R = CH₃ reacted with (OC)₅M-THF to give the corresponding M(CO)₅ (M = Cr, W) adducts and the complex with R = C₆H₅ could be acetylated in the para position with CH₃ C(O)Cl/AlCl₃.     

Ansa bis(fluorenyl) complexes as homogeneous catalysts for propylene polymerization

Preparation and characterization of new ansa-metallocene complexes containing two substituted fluorenyl ligands connected by an R₂E bridge (R = Me, Ph; E = Si, Sn) are reported. The complexes, activated with methylaluminoxane (MAO), polymerize propylene. The degree of stereospecifity of the propylene polymerization depends on the size of the hetero atom in the bridge and the position of the substituents.Translated fromIzvestiya Akademii Nauk. Seriya Khimicheskaya, No. 9, pp. 2334–2339, September, 1996.     

Polydentate phosphine oxides as external electron donors for titanium-magnesium catalysts for propylene polymerization

The possibility of using R _n P(O)(CH₂OR′)_3—n (R = alkyl, R′ = methyl or acyl, n = 0–2) polydentate phosphine oxides as external electron donors for the titanium-magnesium catalysts for isotactic polypropylene synthesis is demonstrated for the first time. The kinetics of propylene polymerization in liquid monomer at 70°C and the isotacticity and molecular-weight characteristics of the resulting polypropylene are studied as functions of the nature of the substituents at the phosphorus atoms in the external donor and the molar ratio of the cocatalyst AlEt₃ to the external electron donor. Among the compounds examined, isoamyldi(methoxymethyl)phosphine oxide (R = iso-Am, R′ = Me, n = 1) is the most efficient. The isotacticity index of the polypropylene (PP) synthesized on the titanium-magnesium catalyst with this external donor is as high as 94–95%, and the activity of the catalyst (Cat) in the absence of hydrogen is 5.0–6.5 (kg PP) (g Cat)^?1 h^?1. With the optimum combination, the activity of this catalyst is ≈5 (kg PP) (g Cat)^?1 h^?1 and the isotacticity index is 94%. These parameters are close to those obtained for propylene polymerization in the absence of hydrogen on the same titanium-magnesium catalyst with phenyltriethoxysilane (external donor used in the industrial synthesis of PP): the activity is 5.6 (kg PP) (g Cat)^?1 h^?1, and the isotacticity index is 95%. The introduction of hydrogen into the reaction zone makes it possible to efficiently control the molecular weight of PP, increases the catalyst activity by a factor of 1.5–2.5, and somewhat decreases the isotacticity index (from 94 to 91–92%).     

Kinetics of propylene and ethylene polymerization reactions with heterogeneous ziegler-natta catalysts: Recent results

The article discusses recent results of kinetic analysis of propylene and ethylene polymerization reactions with several types of Ti-based catalysts. All these catalysts, after activation with organoaluminum cocatalysts, contain from two to four types of highly isospecific centers (which produce the bulk of the crystalline fraction of polypropylene) as well as several centers of reduced isospecificity. The following subjects are discussed: the distribution of active centers with respect to isospecificity, the effect of hydrogen on polymerization rates of propylene and ethylene, and similarities and differences between active centers in propylene and ethylene polymerization reactions over the same catalysts. Ti-based catalysts contain two families of active centers. The centers of the first family are capable of polymerizing and copolymerizing all α-olefins and ethylene. The centers of the second family efficiently polymerize only ethylene. Differences in the kinetic effects of hydrogen and α-olefins on polymerization reactions of ethylene and propylene can be rationalized using a single assumption that active centers with alkyl groups containing methyl groups in the β-position with respect to the Ti atom, Ti-CH(CH₃)R, are unusually unreactive in olefin insertion reactions. In the case of ethylene polymerization reactions, such an alkyl group is the ethyl group (in the Ti-C₂H₅ moiety) and, in the case of propylene polymerization reactions, it is predominantly the isopropyl group in the Ti-CH(CH₃)₂ moiety. Published in Russian in Vysokomolekulyarnye Soedineniya, Ser. A, 2008, Vol. 50, No. 11, pp. 1911–1934. The text was submitted by the authors in English.     

Temperature dependence of stereospecificity of active sites in heterogeneous catalysts for propylene polymerization

Temperature dependences of the stereoregularity parameters of the most stereospecific active centres of α-TiCl₃-AlEt₃ catalytic system from ?25 to 120 and of VCl₃-AlEt₃ catalytic system from ?15° to 90° have been measured. It was found that this temperature dependence could be represented by a curve with a minimum at 20–50. The results could be explained by a two-step mechanism of isotactic chain growth (propagation) with preliminary co-ordination of monomer on the active centres.     

Recent advances in propylene polymerization with MgCl2 supported catalysts

The role of Lewis bases in MgCl₂ supported catalysts for olefin polymerization is a subject of continuous interest and discussion in order to obtain more and more active and stereospecific catalysts and to explain their stereoregulating mechanism. Through molecular calculation and conformational analysis it was possible to identify chelating diethers that have the correct oxygen-oxygen distance necessary to tightly coordinate with the Mg ions of the support, even in the presence of other strong Lewis acids, and unable to give secondary reactions with TiCl₄, AlR₃, Ti-C and Ti-H bonds. The use of these donors has allowed the synthesis of catalytic systems that are both highly active and stereospecific even in the absence of external donors. Kinetic data of propylene polymerization with these catalyst systems are reported. The importance of the distance between the donor atoms in bifunctional Lewis bases has been proved also in the case of new classes of internal donors. Molecular modelling studies have enabled us to formulate models of active sites, located on some corners of MgCl₂ crystallites, whose chirality is induced by the presence of a donor molecule in their environment. These models could explain, at least in part, the exceptional increase of isotactic polymer productivity observed for stereospecific catalyst systems, containing only the internal donor, with respect to catalysts lacking the Lewis base and could account for the influence of the donor on the molecular properties of the obtained polymers.