Comparative characterization of MgCl2/ethyl benzoate/TiCl4 and MgCl2/2,2,6,6 tetramethylpiperidine/TiCl4 Ziegler-Natta precatalysts

In this article we present the results of the preparation and characterization of two Ziegler–Natta precatalysts: MgCl₂/Ethyl benzoate (EB)/TiCl₄ and MgCl₂/2,2,6,6 tetramethylpiperidine (TMPiP)/TiCl₄ by means of FTIR, X-ray diffraction, SEM, BET surface area measurements, and other techniques applied at different steps of their preparation procedures. The precatalysts were prepared by impregnating with TiCl₄ a given amount of MgCl₂, which was previously ball-milled with the electron donor chosen. Prior to impregnation, the ball-milled material presented different surface compounds depending on the electron donor used: [(MgCl₂)₂] · 2EB, MgCl₂ · EB, or a salt of the amine. The solid milled with EB is more homogeneous than the one milled with the TMPiP. Titanium is better retained in the solid milled with EB. This precatalyst has better morphological properties and larger BET surface area. By means of FTIR, we found evidences that an adequate surface structure for the formation of stereospecific sites in MgCl₂/TMPiP/TiCl₄ was formed. © 1994 John Wiley & Sons, Inc.     

Catalyseurs Zieger-Natta supportés sur MgCl2 pour la polymérisation stéréorégulée du propène. II. Système catalytique simple: Solide binaire MgCl2-TiCl4 et solution cocatalytique triéthylaluminium,benzoate d'ethyle

The kinetics of propene polymerization in heptane slurry at 1–4 bars was studied with a catalytic system that consisted of a solid catalyst prepared by adsorption of TiCI₄ on pure porous MgCl₂ (by dehydrating MgCl₂, 6 H₂O with thionyl chloride) and a cocatalytic, heptanic solution of ethylbenzoate (BE) and triethylaluminium (TEA). At a temperature approaching 60°C/polymerization began immediately after the introduction of the monomer. The polymerization rate decreased continuously during the reaction. The loss in activity, however, was not due to a diffusional effect (e.g., blocking of the catalyst by the growing polymer). Studies of the ageing of the catalytic system showed a deactivation of the catalytic system itself as a function of the time of contact between the catalyst and the cocatalyst. The product of the thermal decomposition of the complex 1:2 formed by the reaction of BE with TEA was not associated with the deactivation process or stereospecific control, which depend on the BE/AI ratio and the presence of the complex.     

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     

Adsorption of TiCl4 and electron donor on defective MgCl2 surfaces and propylene polymerization over Ziegler-Natta catalyst: A DFT study

The formations of defective MgCl₂ surfaces, and subsequent adsorption of Ti species and electron donor, as well as propylene polymerization over the Ziegler-Natta catalyst have been investigated using density functional theory (DFT) method. Twelve possible support models of regular and defective MgCl₂ (110) and (100) surfaces were built. The individual adsorptions of titanium chlorides as mononuclear or dinuclear, and ethyl benzoate (EB) as electron donor, on these models were evaluated. The analysis of energies presented the cases of EB adsorption were generally more stable than titanium chlorides on both surfaces. Thus, EB as internal electron donor mainly prevented TiCl₄ from coordinating on the MgCl₂ surfaces where mostly non-stereospecific active sites could be formed. Exceptionally, A5 the site model with terminal Cl-vacancy on the MgCl₂ support, presented stronger adsorption of TiCl₄ than that of EB on (110) surface. Since the TiCl₄ and ethyl benzoate (EB) would compete to adsorb on the support surface, it seems reasonable to assume that TiCl₄ might predominately occupy this site, which can act as the most plausible active site for propylene polymerization. The first insertion of propylene monomer into the A5 active site model showed that it exhibited good regioselectivity but poor stereospecificity in the absence of electron donor.     

Detitanation of MgCl2‐supported Ziegler‐Natta catalysts for the study of active sites organization

Thermal treatments under vacuum of conventional supported Ziegler‐Natta precatalysts (MgCl₂/TiCl₄/Dibutylphthalate) were conducted to gradually remove titanium to modify the active sites distribution. Only limited detitanations of precatalysts were achieved paying attention not to chemically alter the internal donor (T < 150 °C). Used in combination with the required cocatalyst and external donor in the propylene slurry polymerization, the modified precatalysts exhibited a drop of activity versus decreasing titanium content but the distributed polymer properties are almost not affected (a slight narrowing of molecular weight distribution was observed). After a titanium chloride secondary impregnation (possibly done in presence of an additional Lewis base), activity resumed but polymer properties are once again unchanged. These findings highlight the difficulty to separate the different families of active sites and lead us to propose a cluster organization of titanium active sites. Active sites are composed of titanium clusters having a size distribution at the precatalyst surface, possessing a critical operating size and operating collectively in polymerization. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5461–5470, 2008     

Development of novel MgCl2 supported catalyst with trivalent titanocene complex of CP2TiCl2AlCl2 for propylene polymerization

Three kinds of MgCl₂‐supported trivalent titanocene catalyst (Cat. 1: Cp₂TiCl₂AlCl₂/MgCl₂, Cat. 2: CpCp*TiCl/MgCl₂, Cat. 3: Cp₂TiCl/MgCl₂) were prepared and tested for propylene polymerization. It was found that Cat. 1, combined with ordinary alkylaluminum as cocatalyst, produced PP containing 31.8 wt % of isotactic PP in fairly good yield. On the other hand, Cats. 2 and 3 hardly showed any activity. The effects of diisopropyldimethoxysilane (DIPDMS) on isospecificity of the Cat. 1 also were investigated. The isotactic index (I.I.) of PP was improved drastically by the addition of DIPDMS as external donor and reached the value as high as 98.4%, even in the absence of any internal donors. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3355–3359, 2000     

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.     

Superactive and stereospecific catalysts. II. Kinetics of propylene polymerizations

The kinetics of propylene polymerization by superactive CH-catalyst prepared from toluene solution of MgCl₂ · EH/PA/TiCl₄–TEA/PES was investigated. The results are compared with CW-catalyst prepared from crystalline MgCl₂/EB/PC/TEA/TiCl₄–TEA/MPT (abbreviations given in the text). The former is four times more active than the latter and produces more isotactic polypropylene. The CH-catalyst has 25% of the Ti as isospecific sites as compared to 6.7% for the CW-catalysts. These sites have the same rate constant of propagation so that the higher polymerization activity of the CH-catalyst is attributable simply to a greater number of active sites. Differences in the kinetics of deactivation and of chain transfer for the two catalysts are described.     

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.     

Catalyseurs Ziegler-Natta supportés sur MgCl2 pour la polymérisation du propène. I. Etude de la réaction entre le triéthylaluminium et le benzoate d'ethyle

In this article we describe a study of the reaction between triethylaluminium (TEA) and ethylbenzoate (BE) in a heptane solution by Fourier transform, infrared (IR), and ultraviolet (UV) spectroscopy. These compounds were chosen as a model of the cocatalytic solution used with a Ziegler-Natta catalyst supported on MgCl₂ for the stereospecific polymerization of propene. In the polymerization concentration range a 2 TEA:1 BE yellow complex was added to the solution and no free BE could be detected at a AI/BE molar ratio above 2: the solution contained only free and complexed TEA. The complex decomposed spontaneously to a colorless aluminium alcoholate. The rate of decomposition remained slow at room temperature and the reaction was enhanced by heating or by a high AI/BE ratio or high AI concentration. The decomposition was inhibited in the presence of an olefin.     

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.     

Polymerization of 1‐olefins by zirconium/titanium precatalysts with O,N,O‐ligating atoms—can aggregation of catalyst be inferred from the reaction profile?

The 2‐[benzyl‐(2‐hydroxy‐2‐phenylethyl)‐amino]‐1‐phenylethanol ligand (1‐H₂) prepared as a diastereomeric mixture or in racemic and meso forms, from known procedure, has been disodiated and complexed with ZrCl₄. The precatalysts (mix‐1‐ZrCl₂, rac‐1‐ZrCl₂, and meso‐1‐ZrCl₂) were used in combination with methylaluminoxane and found to be active for the polymerization of 1‐hexene and 1‐octene. The high molecular weight polyhexenes (PHs) and polyoctenes (POs) thus obtained were isotactic in nature and showed a negligible amount of end groups arising from the chain termination reactions. In PHs and POs, there was linear correlation in the modified Arrhenius plot (the natural logarithm of the number‐average molecular weight vs. the reciprocal of the temperature), indicating the presence of a single active species. The enantiomerically pure titanium precatalyst ((R,R)‐1‐TiCl₂), when employed for the polymerization of 1‐hexene, was found to be active and the modified Arrhenius plot showed linear dependence demonstrating presence of a single active species. The analogous titanium precatalysts (mix‐1‐TiCl₂, rac‐1‐TiCl₂, and meso‐1‐TiCl₂) obtained from known procedures were also found to be active for the polymerization of 1‐octene. The rac‐1‐TiCl₂ precatalyst demonstrated a sigmoidal behavior in the modified Arrhenius plot for the POs and the mix‐1‐TiCl₂ precatalyst showed an exponential type of behavior. The obtained POs seemed to have small amounts of chain termination via β‐hydride elimination alone. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 3599–3610, 2007     

Copolymerization of ethylene and 1-hexene with TiCl4/MgCl2 catalysts modified by 2,6-diisopropylphenol

A supported TiCl4/MgCl2 catalyst without internal electron donor (O-cat) was prepared firstly. Then it was modified by 2,6-diisopropylphenol to make a novel modified catalyst (M-cat). These two catalysts were used to catalyze ethylene/1-hexene copolymerization and 1-hexene homopolymerization. The influence of cocatalyst and hydrogen on the catalytic behavior of these two catalysts was investigated. In ethylene/1-hexene copolymerization, the introduction of 2,6-iPr2C6H3O-groups did not deactivate the supported TiCl4/MgCl2 catalyst. Although the 1-hexene incorporation in ethylene/1-hexene copolymer prepared by M-cat was lower than that prepared by O-cat, the composition distribution of the former was narrower than that of the latter. Methylaluminoxane (MAO) was a more effective activator for M-cat than triisobutyl-aluminium (TIBA). MAO led to higher yield and more uniform chain structure. In 1-hexene homopolymerization, the presence of 2,6-iPr2C6H3O-groups lowered the propagation rate constants. Two types of active centers with a chemically bonded 2,6-iPr2C6H3O-group were proposed to explain the observed phenomena in M-cat.     

Experimental and Computational Approaches on the Isospecific Role of Monoester-Type Internal Electron Donor for TiCl4/MgCl2 Ziegler-Natta Catalysts

In this work, a combination of experimental and computational approaches on the isospecific role of monoester-type internal electron donors (ED) such as phenylpropionate (PhP), ethylheptanoate (EH), methylbenzoate (MB), ethylbenzoate (EB) for TiCl₄/ED/MgCl₂ Ziegler-Natta catalysts had been performed. The propylene polymerization results revealed that the isospecificity of catalysts increases in the following order: PhP < EH < MB < EB. The subsequent molecular modeling on the electronic properties of the donors and two kinds of cluster model catalysts: TiCl₄/ED/MgCl₂ and TiCl₄/ED/(MgCl₂)₄ based on density functional theory (DFT) method was carried out. Two kinds of ED coordination on MgCl₂ clusters through either O or  O within the monoester-type ED had been disclosed. A perfect correlation between the dipole moment of ED, the coordination bond length of O … Mg, the competitive coordination from  O with Mg ion and the isospecificity of the catalysts had been established.     

The activation of MgCl2-supported ziegler-natta catalysts—II: Correlation between activity and structural disorder

The properties have been examined for Ziegler-Natta catalysts comprising TiCl₄ (Ti contents 2.0, 3.4 and 4.2%) supported on MgCl₂ activated by dry ball-milling up to 250 hr. The samples have been investigated by measurements of catalytic activity in polymerization, of surface area and of some structural parameters related to the crystal disorder introduced by ball-milling. It is shown that the TiCl₄ content affects the activation; a relationship has been found between the crystal disorder of the MgCl₂ support and the catalytic activity.     

Propylene Polymerization Performance of Isolated and Aggregated Ti Species Studied Using a Well‐Designed TiCl3/MgCl2 Ziegler‐Natta Model Catalyst

In propylene polymerization with MgCl₂‐supported Ziegler‐Natta catalysts, it is known that the reduction of TiCl₄ with alkylaluminum generates Ti³⁺ active species, and at the same time, leads to the growth of TiCl_x aggregates. In this study, the aggregation states of the Ti species were controlled by altering the Ti content in a TiCl₃/MgCl₂ model catalyst prepared from a TiCl₃ · 3C₅H₅N complex. It is discovered that all the Ti species become isolated mononuclear with a highly aspecific feature below 0.1 wt.‐% of the Ti content, and that the isolated aspecific Ti species are more efficiently converted into highly isospecific ones by the addition of donors than active sites in aggregated Ti species.

     

Kinetics of polymerization of 1-octene with Mgcl2-supported Ticl4 catalysts

A number of TiCl₄ catalysts supported on MgCl₂ which was activated by the recrystallization method using different alcohols were prepared with ethyl benzoate or dibutyl phthalate as the internal electron donor. All the catalysts were characterized by BET, x-ray diffraction, and hydrolysis–GC analysis. Kinetics of polymerization of 1-octene was studied with three of the above catalysts (having different internal electron donors) activated by AlEt₃. The rate of polymerization increased linearly with increasing temperature, and catalyst and monomer concentrations. From the Arrhenius plot, the overall activation energies of polymerization were determined and the dependence of rate on the AlEt₃ concentration could be explained by the Langmuir-Hinshelwood mechanism. ¹³C-NMR was used to study the effect of internal electron donors on the % isotacticity of poly(1-octene). The catalytic activities of all the catalysts were compared in 1-octene polymerization. © 1994 John Wiley & Sons, Inc.     

State of various stereoregulating electron-donating compounds in titanium-magnesium catalysts for propylene polymerization: A diffuse reflectance IR spectroscopic study

Propylene polymerization on TiCl₄/donor/MgCl₂ (donor = ethyl benzoate, dibutyl phthalate, diisobutyl phthalate, diethyl 2,3-diisopropylsuccinate) supported catalysts is considered. The states of the donors in the catalysts have been investigated by diffuse reflectance IR spectroscopy. Data characterizing the distribution of the donors and the active component (TiCl₄) on the support surface have been obtained. Molecular weight distribution data for polypropylene are presented. The molecular weight distribution of polypropylene depends on the location of the donor and TiCl₄ molecules.     

Modeling of isospecific Ti sites in MgCl2 supported heterogeneous Ziegler-Natta catalysts

New models for the steric environment of Ti isospecific polymerization sites for poly(propylene) on MgCl₂ microcrystals are proposed. They directly involve a donor molecule in order to obtain isospecific activable Ti atoms otherwise belonging to isolated adsorbed TiCl₄ molecules or Ti₂Cl₈ dimers which are lacking of the required chirality for stereocontrol. The donor molecules able to attain at best this effect keep to some peculiar conformational rules settled by the authors in a previous theoretical-correlative study on highly active Lewis bases. The new 1,3-dimethoxypropane series suggested by the authors and recently patented by Montell has been examined in detail. Essentially three different types of closeness between Ti atoms and donor molecules can take place, in which different moieties of the diether compound help to build the ‘right’ steric environment in the site's neighbouring. In the three proposed models S1, S2, S3 the stereocontrol is attained through, respectively, one of the methoxy moieties, one of the methyls, and one of the central carbon atom substituents. New hypotheses on the role of Lewis bases in the preparation of isospecific heterogeneous Ziegler-Natta catalysts are discussed.     

Effect of external donor in polymerization of propylene by a MgCl2 supported titanium catalyst

Polypropylene (PP) prepared with a MgCl₂/TiCl₄-Et₃Al/Ph₂Si(OMe)₂ catalyst system was fractionated by temperature rising elution fractionation method in order to investigate the effect of Ph₂Si(OMe)₂ as an external donor (ED). This PP had a broad and continuous distribution of tacticity. In comparison to the system without donor, however, ED brought a decrease of lower isotactic portions and an increase of higher isotactic ones simultaneously to the resulting polymer. The latter portions were eluted at higher temperature than the corresponding component obtained without donor, showing that the higher isotactic PP was newly produced by ED.