Olefin terpolymerizations. III. Symmetry,sterics, and monomer structure in ansa-zirconocenium catalysis of EPDM synthesis

Ethylenebis (η⁵-fluorenyl) zirconium dichloride ( 1 ) and rac-dimethylsilylene bis (1-η⁵-in-denyl) zirconium dichloride ( 2 ) were activated with methylaluminoxane (MAO) to catalyze ethylene (E) propylene (P) copolymerizations. The former produces high MW copolymer at 20°C rich in ethylene with reactivity ratio values of r_E = 1.7 and r_P <0.01, whereas the latter produces lower MW random copolymers with r_E = 1.32 and r_p = 0.36. Ethylidene norbornene (ENB) complexes with 1/MAO but does not undergo insertion in the presence of E and P. In contrast, 2/MAO catalyzes terpolymerization incorporating 9-15 mol % of ENB with slightly lower MW and activity than the corresponding copolymerizations. In comparison, 1,4–hexadiene was incorporated by 2/MAO with much lower A and MW . Terpolymerizations were also conducted with vinylcyclohexene using both catalyst systems. The steric and electronic effects in these processes were discussed. © 1995 John Wiley & Sons, Inc.     

Olefin terpolymerizations. I. 1,4-hexadiene

Ethylene (E), propylene (P), and 1,4-hexadiene (HD) were terpolymerized with rac-1,2-ethylenebis (1-η⁵-indenyl) zirconium(IV) dichloride and methylaluminoxane (Et[Ind]₂ZrCl₂/MAO), and compared with the copolymerizations of E/P, E/HD, P/HD, and terpolymerization using ethylidene norbornene (ENB) as the termonomer. HD lowers the polymerization activity, the effect is more pronounced for P/HD and E/P/HD using large amount of P, than for E/HD and E/P/HD using feed low in P. The polymer molecular weight is most strongly affected by the temperature of polymerization (T_p), whereas the E/P ratio in the feed has virtually no effect. The reactivity ratios r_E and r_P are 3.0 and 0.3, respectively, at 20°C but r_P becomes larger than r_E at T_P = 70°C. ¹H-NMR spectra showed occurrence of cycloaddition in the homopolymerization of HD; on the other hand, HD is incorporated in the terpolymer only by linear 1,2-addition. © 1995 John Wiley & Sons, Inc.     

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     

Polymer-supported Ziegler–Natta catalysts. II. Ethylene homo- and copolymerization with TiCl4/MgR2/poly(ethylene-co-acrylic acid) catalyst

A novel polymer-supported titanium-based catalyst shows high activity and nondecaying kinetic profiles for ethylene polymerization. The presence of 1-hexene comonomer drastically increases the catalyst activity, exhibiting a similarity to the MgCl₂-supported catalysts. However, the nondecaying kinetic profiles of copolymerization distinguish this catalyst from the latter. Infrared analysis indicates that the transition metals were immobilized on the polymer support via functional groups. The effects of polymerization conditions on catalyst activity have been assessed. Characterization of the resulting polymer product by means of ¹³C-NMR, DSC, and SEM demonstrates a branch-free structure with high melting point, high crystallinity, and high molecular weight for the ethylene homopolymer. The reactivity ratios of ethylene-1-hexene copolymerization are evaluated from ¹³C-NMR analysis data. © 1994 John Wiley & Sons, Inc.     

Ethylene–hexene copolymerization by heterogeneous and homogeneous Ziegler–Natta catalysts and the “comonomer” effect

Homopolymerization of ethylene and 1-hexene and their copolymerizations were compared to investigate the influence of α-olefin on the enhancement of ethylene polymerization rate (R_p), which is often referred to as the “comonomer” effect. With the two homogeneous Ziegler–Natta catalysts, Et[Ind]₂ZrCl₂/MAO and (π-C₅H₅)₂ZrCl₂/MAO (MAO = methylaluminoxane), hexene causes reduction of R_p—in other words a negative “comonomer” effect. In the case of the high activity MgCl₂ supported TiCl₃ catalysts there is a slight positive “comonomer” effect; the R_p increases by 25 to 70% with the addition of 15 mol % of hexene. The “comonomer” effects in there catalyst systems are much smaller than that observed for the classical TiCl₃ catalyst. © 1993 John Wiley & Sons, Inc.     

Investigation of Catalyst Fragmentation in Gas‐Phase Olefin Polymerisation: A Novel Short Stop Reactor

Summary: A short stop reactor (SSR) was developed to study nascent particle morphology and reaction kinetics in the gas‐phase polymerisation of olefins on supported catalysts. It is shown that the SSR provides a useful means to look into important phenomena such as catalyst fragmentation and catalyst site activation and deactivation that take place during the very early stages of the heterogeneous polymerisation of olefins. New experimental results obtained from gas‐phase polymerisation of ethylene show that, depending on the type of catalyst system and on the reaction conditions, different kinds of morphologies can be obtained for the nascent polymer (e.g., cracks and folded chain). Experimental data also indicate that the growth of the polymer chains occur at a non‐steady state during the very early stages of the polymerisation.

SEM image showing the morphology of a polymer/catalyst particle after 2 seconds of polymerisation at 8 bars of ethylene on an MgCl₂‐supported Ziegler‐Natta catalyst.     

An experimental and computational evaluation of ethylene/styrene copolymerization with a homogeneous single‐site titanium(IV)‐constrained geometry catalyst

Styrene was copolymerized with ethylene using the geometry constrained Me₂Si(Me₄Cp)(N‐tert‐butyl)TiCl₂ Dow catalyst activated with methylaluminoxane. Increasing the styrene/ethylene ratio in the reactor feed had the effects of reducing both the activity of the catalyst and the molecular weight of the copolymers produced. However, the higher the styrene/ethylene ratio used, the greater the amount of styrene that became incorporated in the copolymer. We discuss these experimental findings within the framework of a computational analysis of ethylene/styrene copolymerization performed through hybrid density functional theory (B3LYP). In general, there was good agreement between the experimental and theoretical results. Our findings point to the suitability of combining experimental and theoretical data for clarifying the copolymerization mechanisms that take place in α‐olefin‐organometallic systems. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 711–725, 2005     

Polymerizations of olefins and diolefins catalyzed by monocyclopentadienyltitanium complexes containing a (dimethylamino)ethyl substituent and comparison with ansa-zirconocene systems

{[2-(dimethylamino)ethyl]cyclopentadienyl}titanium trichloride (Cp^NTiCl₃, 1 ) was activated with methylaluminoxane (MAO) to catalyze polymerizations of ethylene (E), propylene (P), ethylidene norbornene (ENB), vinylcyclohexene (VCH), and 1,4-hexadiene (HD). The dependence of homopolymerization activity ( A ) of 1 /MAO on olefin concentration ([M]ⁿ) is n = 2.0 ± 0.5 for E and n = 1.8 ± 0.2 for P. The value of n is 2.4 ± 0.2 for CpTiCl₃/MAO catalysis of ethylene polymerization; this system does not polymerize propylene. 1 /MAO catalyzes HD polymerization at one-tenth of A _H for 1-hexene, probably because of chelation effects in the HD case. The copolymerization of E and P has reactivity ratios of r_E = 6.4 and r_P = 0.29 at 20°C, and r_Er_P = 1.9, which suggests 1 /MAO may be a multisite catalyst. The copolymerization activity of CpTiCl₃/MAO is 50 times smaller than that of Cp^NTiCl₃/MAO. Terpolymerization of E/P/ENB has A of 10⁵ g of polymer/(mol of Ti h), incorporates up to 14 mol % (∼ 40 wt %) of ENB, and high MW's of 1 to 3 × 10⁵. All of these parameters are surprisingly insensitive to the ENB concentration. The E/P/VCH terpolymerization has comparable A value of (1.3 ± 0.3) × 10⁵ g/(mol of Ti h). The incorporation of VCH in terpolymer increases with increasing [VCH]. Terpolymerization with HD occurs at about one-third of the A of either ENB or VCH; the product HD–EPDM is low in molecular weight and contains less than 4% of HD. These terpolymerization results are compared with those obtained previously for three zirconocene precursors: rac-ethylenebis(1-η⁵-indenyl)dichlorozirconium ( 6 ), rac-(dimethylsilylene)bis(1-η⁵-indenyl)dichlorozirconium ( 7 ), and ethylenebis(9-η⁵-fluorenyl)dichlorozirconium ( 8 ). The last compound is a particularly poor terpolymerization catalyst; it incorporates very little VCH or HD and no ENB at all. 7 /MAO is a better catalyst for E/P/VCH terpolymerization, while 6 /MAO is superior in E/P/HD terpolymerization. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 319–328, 1998     

Kinetic study of gas phase olefin polymerization with a TiCl4/MgCl2 catalyst. II. Kinetic parameter estimation and model building

Monomer transport and polymerization kinetics are two key phenomena in olefin polymerization with heterogeneous transition metal catalysts. To have a better understanding of these interrelated kinetics and diffusion phenomena, a quantitative calculation of the monomer diffusion directly from experimental study is essential. In this work, a novel temperature-perturbation technique is developed to systematically study the kinetic and diffusion limitations in catalyzed gas phase olefin polymerization. A physical model of the particle growth mechanism as well as its mathematical representation is presented and the diffusion limitations occurring in the system at high temperature are characterized and quantitatively analyzed. Finally, the practical implications of the results of this study on the operation of industrial scale polyolefin reactors are examined. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 2075-2096, 1997     

Polymer-supported Ziegler–Natta catalysts. I. A preliminary study of catalyst synthesis

Polymer-supported Ziegler–Natta catalysts based on various polymer carriers were synthesized by different methods, including (1) loading TiCl₄ directly onto the polymer supports; (2) loading TiCl₄ onto the polymer supports modified by magnesium chloride (MgCl₂); (3) loading TiCl₄ onto the polymer supports modified by Grignard reagent (RMgCl); and (4) loading TiCl₄ onto the polymer supports modified by magnesium alkyls (MgR₂). The activity and kinetic features of the catalysts for ethylene polymerization were examined. Among the combinations tested, the best was found to be TiCl₄/n-Bu₂Mg.Et₃Al/poly(ethylene-co-acrylic acid) (92:8), which produced a catalyst of very high activity for ethylene polymerization. © 1994 John Wiley & Sons, Inc.     

Asymmetric zirconocene precursors for catalysis of propylene polymerization

Racemic isopropylidene (1-η⁵-cyclopentadienyl)(1-η⁵-indenyl) dichlorozirconium and the 3-methylindenyl derivative have been synthesized and characterized. These precursors activated with methylaluminoxane produce poly(propylene) with hemiisotactic microstructures. © 1994 John Wiley & Sons, Inc.     

Polymerization of ethylene using a high-activity Ziegler–Natta catalyst. II. Molecular weight regulation

This article describes studies on the variables that regulate the molecular weight in ethylene polymerization using a highly active Ziegler–Natta catalyst with hydrogen for molecular weight control. The dependence of the degree of polymerization on the concentration of catalyst, cocatalyst, monomer, partial pressure of hydrogen, and temperature has been established. The rate constant for chain transfer with cocatalyst has been evaluated. © 1993 John Wiley & Sons, Inc.     

Substituent effects on titanocenium catalysts

Titanocene dichloride (1) and its bis(trifluoromethyl) (2) and bis(N,N-dimethylamino) (3) derivatives have been compared as catalysts for ethylene and propylene polymerizations using both methylaluminoxane (MAO) and triphenylcarbenium tetrakis(pentafluorophenyl)borate (4)/triisobutylaluminum (TIBA) as cocatalysts. The differences between the activities of the three ‘free’ titanocenium ions and the M _w of the polyolefins produced by them may be attributable to the relative stabilities of the intermediate olefin–titanocenium π-complexes. Interaction of either the neutral MAO or its anion with the titanocenium species may be responsible for the significantly lower catalytic efficiencies when the precursors were activated by MAO than by the 4/TIBA system.     

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     

Effects of Alterations to Ziegler–Natta Catalysts on Kinetics and Comonomer (1‐Butene) Incorporation

Various MgCl₂‐supported Ziegler–Natta (ZN) catalysts are synthesized with the intention to influence polymerization performance and 1‐butene incorporation in an ethylene copolymer. Modifications are introduced during different steps in the synthesis process, namely support preparation, titanation, and catalyst workup. While multiple different effects are observed upon modification, heat treatment during titanation shows the greatest impact. Increasing the heat‐treatment temperature increases polymerization activity. More importantly, the 1‐butene distribution can be shifted toward a more homogeneous profile. The amount of 1‐butene incorporated is similar to both for short‐ and for very long‐chain molecules. This behavior has so far been known only from metallocene‐based polyethylene and suggests that active sites are distributed more homogeneously in the ZN catalyst.

     

Zirconium‐chelate and mono‐η‐ cyclopentadienyl zirconium‐chelate/ methylalumoxane systems as soluble Ziegler–Natta olefin polymerization catalysts

Zirconium‐chelate and mono‐η‐cyclopentadienyl zirconium‐chelate complexes were tested as ethene and propene polymerization catalysts in combination with methylalumoxane (MAO) as a co‐catalyst: in particular (acac) _nZrCl_4−n (1a–c) (acac = acetylacetonato), (dbm) _nZrCl_4−n (2a–2c) (dbm = dibenzoylmethanato = 1,3‐diphenylpropanedionato) (n = 2–4) and (dbm)₂ZrCl₂(thf) (3) (thf = tetrahydrofuran), (η‐C₅H₅)[H₂B (C₃H₃N₂)₂]ZrCl₂ (4), (η‐C₅H₅)[HB (C₃H₃N₂)₃] ZrCl₂ (5) and (η‐C₅H₅)[(Me₃SiN)₂ CPh]ZrCl₂ (6). Polymerization productivities comparable with the (η‐C₅H₅)₂ZrCl₂ reference system were observed towards ethene for all of the above complexes. In addition, compound 6 showed some minor polymerization activity towards propene. Ethylalumoxane or isobutylalumoxane did not exhibit a co‐catalytic activity for these chelate complexes; in combination with MAO these higher alumoxanes were even found to be deactivating ⁹¹Zr NMR data are reported for 1b, 1c, 4 and 5. Copyright © 2000 John Wiley & Sons, Ltd.     

Preparation of Polyethylene/Graphene Nanocomposites with Octadecylamine‐Modified Graphene Oxide‐MgCl‐Supported Ziegler–Natta Catalyst

In this work, an octadecylamine‐modified graphene oxide (ODA‐GO)‐MgCl‐supported Ziegler–Natta catalyst was synthesized by reacting ODA‐GO with a Grignard reagent, followed by anchoring TiCl₄ to the structure. The effect of the ODA‐GO on the catalyst morphology and ethylene polymerization behavior was examined. The resultant polyethylene (PE)/ODA‐GO nanocomposites directly mirrored the catalyst morphology by forming a layered morphology, and the ODA‐GO fillers were well dispersed in the PE matrix and showed strong interfacial adhesion with it. The resultant PE/ODA‐GO nanocomposites exhibited better thermal stability and mechanical properties than neat PE, even with a small amount of ODA‐GO added. Thus, this work provides a facile approach to the production of high‐performance PE. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 855–860     

New Quenching Procedure for Preservation of Initial Polymer/Catalyst Particle Morphology in Ziegler–Natta Olefin Polymerization

Preservation of initial polymer/catalyst particle morphology under air, was examined using stopped‐flow Ziegler–Natta polymerization with various quenching conditions and post‐chemical treatments. The exposure of the initial particles to air caused the fast formation of cracks on the surface, finally leading to significant reformation of the particle shape, when polymerizing particles were washed with heptane at ?65 °C under N₂ or under CO₂. On the other hand, when the particles were washed with heptane containing an appropriate amount of tetrahydrofuran under CO₂, the particle morphology under air was almost completely maintained even after 1 h exposure. The present results are useful for various ex situ characterizations of unstable initial polymer/catalyst particles.