Catalysis of ethylene to linear low‐density polyethylene with iron‐based diimine complex immobilized on calcosilicate and silica‐supported rac‐Et(Ind)2ZrCl2

Iron‐based diimine complex was immobilized on calcosilicate (CAS‐1) to form heterogeneous precatalyst, which oligomerized ethylene to α‐olefins even without the use of aluminum alkyl compounds as activators. The α‐olefins, upon the catalysis of another catalyst, i.e., silica‐supported rac‐Et(Ind)₂ZrCl₂, copolymerized with ethylene to produce linear low‐density polyethylene (LLDPE). The copolymerization reactions could be performed with the addition of triethylaluminum alone because of the introduction of methylaluminoxane to CAS‐1 and silica during the supporting process. In addition to the formation of more α‐olefins with lower molar mass, the layered structure of CAS‐1 acted well in the controlled release of α‐olefins in the copolymerization process. The simultaneous employment of the aforementioned two catalysts hence resulted in high catalytic activities, smooth kinetic process, well‐regulated branching degree, higher molecular weights (M_n), improved thermal stability, and better morphology of the LLDPE obtained. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Synthesis and functionalization of poly(ethylene‐co‐dicyclopentadiene)

Copolymerizations of ethylene with endo‐dicyclopentadiene (DCP) were performed by using Cp₂ZrCl₂ (Cp = Cyclopentadienyl), Et(Ind)₂ZrCl₂ (Ind = Indenyl), and Ph₂C(Cp)(Flu)ZrCl₂ (Flu = Fluorenyl) combined with MAO as cocatalyst. Among these three metallocenes, Et(Ind)₂ZrCl₂ showed the highest catalyst performance for the copolymerization. From ¹H‐NMR analysis, it was found that DCP was copolymerized through enchainment of norbornene rings. The copolymer was then epoxidated by reacting with m‐chloroperbenzoic acid. ¹³C‐NMR spectrum of the resulting copolymer indicated the quantitative conversion of olefinic to epoxy groups. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 72: 103–108, 1999     

Preparation of ethylene/1‐octene copolymers from ethylene stock with tandem catalytic system

Tandem catalysis offers a novel synthetic route to the production of linear low‐density polyethylene. This article reports the use of homogeneous tandem catalytic systems for the synthesis of ethylene/1‐octene copolymers from ethylene stock as the sole monomer. The reported catalytic systems involving a highly selective, bis(diphenylphosphino)cyclohexylamine/Cr(acac)₃/methylaluminoxane (MAO) catalytic systems for the synthesis of 1‐hexene and 1‐octene, and a copolymerization metallocene catalyst, rac‐Et(Ind)₂ZrCl₂/MAO for the synthesis of ethylene/1‐octene copolymer. Analysis by means of DSC, GPC, and ¹³C‐NMR suggests that copolymers of 1‐hexene and ethylene and copolymers of 1‐octene and ethylene are produced with significant selectivity towards 1‐hexene and 1‐octene as comonomers incorporated into the polymer backbone respectively. We have demonstrated that, by the simple manipulation of the catalyst molar ratio and polymerization conditions, a series of branched polyethylenes with melting temperatures of 101.1–134.1°C and density of 0.922–0.950 g cm^?3 can be efficiently produced. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Ethylene polymerization over (nBuCp)2ZrCl2/MAO catalytic system supported on aluminosilicate SBA‐15 mesostructured materials

Heterogeneous metallocene catalysts were prepared by incipient wetness impregnation of AlSBA‐15 (Si/Al = 4.8, 15, 30, 60, and ∞) mesostructured materials with (nBuCp)₂ZrCl₂/MAO. For comparative purposes commercial silica and silica–alumina (Si/Al = 4.8) supports were also impregnated with the MAO/metallocene catalytic system. A combination of X‐ray powder diffraction, nitrogen adsorption–desorption isotherms at 77 K, transmission electron microscopy, ICP‐atomic emission spectroscopy, and UV–vis spectroscopic data, were used to characterize the supports and the heterogeneous catalysts. Ethylene polymerizations were carried out in a schlenk tube at 70 °C and 1.2 bar of ethylene pressure. The polyethylene obtained was characterized by GPC, DSC, and SEM. Catalysts prepared with mesostructured SBA‐15 supports exhibited better catalytic performance than those supported on amorphous silica and silica–alumina. In general, higher ethylene polymerization activity was achieved if (nBuCp)₂ ZrCl₂/MAO catalytic system was heterogenized using supports with lower pore size in the range of the mesopores and lower Si/Al ratio. All catalysts produced high‐density polyethylene, with high crystallinity values and fibrous morphology when SBA‐15 mesostructured materials were used as supports. POLYM. ENG SCI., 2008. © 2008 Society of Plastics Engineers     

Self‐Immobilizing Precatalysts: Norbornene‐Bridged Zirconium ansa‐Metallocenes

We report here the synthesis of new tethered biscyclopentadienyl and bisindenyl zirconocenes, bearing one unsaturation on the interannular bridge, and their use as self‐immobilizing catalysts. They proved to be active catalysts towards ethylene polymerization in solution, with activities comparable to those displayed by commercial rac‐Et(Ind)₂ZrCl₂. When tested as self‐polymerization catalysts under suitable experimental conditions, they gave colored precipitates that, once reactivated with MAO, were significantly active in ethylene polymerization, although lower than those of the corresponding catalytic systems in solution. The molecular weights of the produced polymers were similar to those obtained with the same catalysts in solution, but their distribution resulted to be broader, with values typical of heterogeneous catalytic systems. From ¹³C NMR studies we had the first spectroscopic evidence of the actual incorporation of a metallocene of this type into a polymeric chain.     

PE/OMMT nanocomposites catalyzed by the OMMT‐intercalated Et[Ind]2ZrCl2 in slurry polymerization: Effects of organic solvent on ethylene polymerization behaviors and the nanocomposite structures

In situ intercalative polymerization for ethylene monomers was carried out to produce PE‐based hybrids through a slurry polymerization method. In this approach, organic solvent for olefin polymerization was found to be one of the most significant factors for the dispersion of the OMMT‐intercalated Et[Ind]₂ZrCl₂ catalysts, which determines that whether olefin monomers polymerize is in a well‐defined confinement environment or not. Understanding the olefin polymerization occurring in between the nanoscale silicate layers of OMMT as well as the corresponding structure of OMMT in an organic polymerization solvent is a critical step toward tailoring and characterizing nanocomposites formed by OMMT in a polyolefin matrix. As we know, the Et[Ind]₂ZrCl₂ catalyst and MAO are both better dissolved in toluene than that in hexane because of the larger polarity of toluene. Thus, in hexane the active sites of the OMMT/Et[Ind]₂ZrCl₂ catalyst exist in the silicate layers of OMMT and the PE chains grow in the middle of them, while in toluene the active specimens are exposed in the gel formed by the OMMT‐intercalated catalyst with MAO, which cause that the PE chains propagated in the mixture liquids. Consequently, when hexane is selected as the polymerization solvent, the formed PE‐based nanocomposites have a good dispersion of OMMT and the nanofiller content (TGA measurement residue at 600°C) is thus higher (>7.0 wt %). However, in toluene, most of the silicate layers of OMMT are agglomerated in the PE matrix. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Preparation of linear low‐density polyethylene by in situ copolymerization of ethylene with Zr supported on montmorillonite/Fe/methylaluminoxane catalyst system

Linear low‐density polyethylene (LLDPE) was prepared by in situ copolymerization of ethylene with dual‐functional catalysts that were composed of rac‐Et(Ind)₂ZrCl₂ supported on montmorillonite (MMT) and {[(2‐ArN?C(Me))₂C₅H₃N]FeCl₂} [Ar = 2,4‐C₆H₄(Me)₂] oligomerization catalyst. A series of polyethylenes with different degrees of branching were obtained by adjusting the ratio of Fe and Zr (Fe/Zr). DSC, NMR, GPC, SEM, and density‐gradient method were used to characterize the polymers. With increasing Fe/Zr ratio, the densities and melting points of polymers decreased, whereas the branching degrees and molecular weights increased. When the Fe/Zr ratio was increased, the activities of the catalysts decreased at atmospheric pressure and increased at 0.7 MPa ethylene pressure. SEM micrographs revealed that the morphology of branched polyethylene, produced with the catalyst supported on MMT, is better than that produced by the catalyst in a homogeneous system. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 1690–1696, 2004     

(nBuCp)2ZrCl2‐catalyzed ethylene‐4M1P copolymerization: Copolymer backbone structure,melt behavior,and crystallization

The judicious design of methylaluminoxane (MAO) anions expands the scope for developing industrial metallocene catalysts. Therefore, the effects of MAO anion design on the backbone structure, melt behavior, and crystallization of ethylene?4‐methyl‐1‐pentene (E?4M1P) copolymer were investigated. Ethylene was homopolymerized, as well as copolymerized with 4M1P, using (1) MAO anion A (unsupported [MAOCl₂]^?) premixed with dehydroxylated silica, (ⁿBuCp)₂ZrCl₂, and Me₂SiCl₂; and (2) MAO anion B (Si?O?Me₂Si?[MAOCl₂]^?) supported with (ⁿBuCp)₂ZrCl₂ on Me₂SiCl₂‐functionalized silica. Unsupported Me₂SiCl₂, opposite to the supported analogue, acted as a co‐chain transfer agent with 4M1P. The modeling of polyethylene melting and crystallization kinetics, including critical crystallite stability, produced insightful results. This study especially illustrates how branched polyethylene can be prepared from ethylene alone using particularly one metallocene‐MAO ion pair, and how a compound, that functionalizes silica as well as terminates the chain, can synthesize ethylene?α‐olefin copolymers with novel structures. Hence, it unfolds prospective future research niches in polyethyne systhesis. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1688–1706, 2016     

Functionalization of polyethylene using borane reagents and metallocene catalysts

A new method to prepare functionalized polyethylene involving borane intermediates and transition metal catalysts is described. Two processes, direct and post polymerizations, were employed to prepare borane-containing polyethylene (PE-B), which can be transformed to functionalized polyethylene (LLDPE-f) with various functional groups, such as ? BR₂, ? OH, ? NH₂, ? OSi(CH₃)₃. In the direct process, the PE-B copolymers were prepared in one step by copolymerization of ethylene with a borane monomer (ω-borane-α-olefin). The post polymerization process requires two steps: copolymerization of ethylene and 1,4-hexadiene, and subsequential hydroboration reaction of unsaturated PE. Three transition metal catalysts, including two homogeneous metallocene (Cp₂ZrCl₂ [bis(cyclopentadienyl) zirconium dichloride] and Et(Ind)₂ZrCl₂ [1,1′-ethylenedi-η⁵-indenyl-zirconium dichloride] with MAO (methylaluminoxane)) and one heterogeneous (TiCl₃·AA/Et₂AlCl) ones, were studied in the copolymerization reactions. The single site Et(Ind)₂ZrCl₂/MAO homogeneous catalyst, with a strained ligand geometry and opened active site, is by far the most effective system in the incorporation of high olefins into polyethylene structures.     

Ethylene/propylene copolymerization over three conventional C2‐symmetric metallocene catalysts: Correlation between catalyst configuration and copolymer microstructure

This work reports on a correlation between catalyst configuration and copolymer microstructure for ethylene/propylene (E/P) copolymerization using three conventional C₂‐symmetric metallocene catalysts, namely, rac‐Et(Ind)₂ZrCl₂ (EBI), rac‐Me₂Si(2‐Me‐4‐Ph‐Ind)₂ZrCl₂ (SiPh), and rac‐CH₂(3‐tBu‐Ind)₂ZrCl₂ (MBu), with MAO as a common cocatalyst. Copolymerization reactions were conducted in toluene at three different temperatures with varied E/P ratios. Some typically obtained copolymers were characterized in detail using ¹³C‐NMR spectroscopy, by which triad distribution data were elaborated in a statistical method to determine the reactivity ratios (r_E and r_P) of the comonomers, which were also obtained by Fineman‐Rose estimation. The production of alternating‐like copolymers from EBI is attributed to the rapid interconversion between two conformation states of the active site, one of which favors the incorporation of propylene but the other one does not. Both SiPh and MBu are structurally more rigid and of larger dihedral angles than EBI; however, SiPh which owns open active site conformation tend to produce random copolymers at all studied temperatures, and for MBu, sterically hindered catalyst, block‐like copolymers were obtained. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Preparation and properties of polyethylene/montmorillonite nanocomposites formed via ethylene copolymerization

BACKGROUND: In situ formation of polyethylene/clay nanocomposites is one of the prevalent preparation methods that include also solution blending and melt blending with regard to process simplification, economy in cost, environment protection and marked improvement in the mechanical properties of the polymeric matrix. In the work reported here, the preparation of linear low‐density polyethylene (LLDPE) and fabrication of polymer/clay nanocomposites were combined into a facile route by immobilizing pre‐catalysts for ethylene oligomerization on montmorillonite (MMT). RESULTS: [(2‐ArN?C(Me))₂C₅H₃N]FeCl₂ (Ar = 2,4‐Me₂(C₆H₃)) was supported on MMT treated using three different methods. The MMT‐supported iron complex together with metallocene compound rac‐Et(Ind)₂ZrCl₂ catalyzed ethylene to LLDPE/MMT nanocomposites upon activation with methylaluminoxane. The oligomer that was formed between layers of MMT promoted further exfoliation of MMT layers. The LLDPE/MMT nanocomposites were highly stable upon heating. Detailed scanning electron microscopy analysis revealed that the marked improvement in impact strength of the LLDPE/MMT nanocomposites originated from the dispersed MMT layers which underwent cavitation upon impact and caused plastic deformation to absorb most of the impact energy. In general, the mechanical properties of the LLDPE/MMT nanocomposites were improved as a result of the uniform dispersion of MMT layers in the LLDPE matrix. CONCLUSION: The use of the MMT‐supported iron‐based diimine complex together with metallocene led to ethylene copolymerization between layers of MMT to form LLDPE/MMT nanocomposites. The introduction of exfoliated MMT layers greatly improved the thermal stability and mechanical properties of LLDPE. Copyright © 2009 Society of Chemical Industry     

Copolymerization of ethylene/α‐olefins over (2‐MeInd)2ZrCl2/MAO and (2‐BzInd)2ZrCl2/MAO systems

Ethylene homopolymerization and ethylene/α‐olefin copolymerization were carried out using unbridged and 2‐alkyl substituted bis(indenyl)zirconium dichloride complexes such as (2‐MeInd)₂ZrCl₂ and (2‐BzInd)₂ZrCl₂. Various concentrations of 1‐hexene, 1‐dodecene, and 1‐octadecene were used in order to find the effect of chain length of α‐olefins on the copolymerization behavior. In ethylene homopolymerization, catalytic activity increased at higher polymerization temperature, and (2‐MeInd)₂ZrCl₂ showed higher activity than (2‐BzInd)₂ZrCl₂. The increase of catalytic activity with addition of comonomer (the synergistic effect) was not observed except in the case of ethylene/1‐hexene copolymerization at 40°C. The monomer reactivity ratios of ethylene increased with the decrease of polymerization temperature, while those of α‐olefin showed the reverse trend. The two catalysts showed similar copolymerization reactivity ratios. (2‐MeInd)₂ZrCl₂ produced the copolymer with higher M_w than (2‐BzInd)₂ZrCl₂. The melting temperature and the crystallinity decreased drastically with the increase of the α‐olefin content but T_m as a function of weight fraction of the α‐olefins showed similar decreasing behavior. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 75: 928–937, 2000     

Synthesis and characterization of ethylene-1-hexene copolymers using homogeneous Ziegler-Natta catalysts

Summary This study investigated the copolymerization of ethylene with 1-hexene using the homogeneous Et[Ind]₂ZrCl₂ and [Ind]₂ZrCl₂ catalysts. The Et[Ind]₂ZrCl₂ catalyst gave a higher catalytic activity than the [Ind]₂ZrCl₂ and also showed a better incorporation of 1-hexene for the same comonomer concentration in the feed. Thermal analysis (DSC) and viscosity measurements showed that an increase of the 1-hexene incorporated in the copolymer results in a decrease of the melting point, crystallinity and molecular weight of the polymer formed. The reactivity ratios for ethylene and 1-hexene confirmed the more successful incorporation of the comonomer for the polymerization catalyzed by Et[Ind]₂ZrCl₂.     

The production of ethene/propene/5-ethylidene-2-norbornene terpolymers using metallocene catalysts: Polymerization,characterization and properties of the metallocene EPDM

Metallocene catalysts Et(Ind)₂ZrCl₂/MAO and Et(Ind)₂HfCl₂/MAO were used in ethene/propene copolymerization and in ethene/propene/5-ethylidene-2-norbornene (E/P/ENB) terpolymerization. The copolymerization activity of the Et(Ind)₂ZrCl₂/MAO system was 20 × 10³ kg_polym/mol_Mt *h, the Et(Ind)₂HfCl₂/MAO yielding 5 × 10³ kg_polym/mol_Mt *h. The polymerization activity decreased with diene addition, but this effect was significant only at very large diene feeds. The catalysts incorporated diene readily. Materials with an ethene content of 55 to 70 mol % and an ENB content of 2 to 16 mol % were produced. Et(Ind)₂HfCl₂ produced a considerably higher molar mass material than the Et(Ind)₂ZrCl₂ catalyst. The molar mass distributions were narrow. Copolymers and terpolymers with up to 3 mol % ENB content had some crystallinity. Copolymer T_gs were between −59°C and −55°C. The terpolymer glass transition temperature rose 1.5°C per wt % of ENB in the polymer. Polymer characteristics reported include composition, molar mass distribution, melt flow rate, density, and thermal behavior. The dynamic mechanical and rheological properties of the materials in comparison with commercial E/P/ENB terpolymers are discussed. © 1997 John Wiley & Sons, Inc. J Appl Polym Sci 66: 35–44, 1997     

Alkoxysilane modification of a Ti‐based catalyst system for ethylene dimerization: A step forward in enhancing productivity and selectivity

Alkoxysilanes were used as novel enhancing agents in the Ti‐based catalyst for the highly selective ethylene dimerization to butene‐1. The dimerization of ethylene was carried out using the homogeneous Ti(OBu)₄/THF/TEA/alkoxysilane catalyst system, where Ti(OBu)₄, THF (tetrahydrofuran), TEA (triethylaluminum), and alkoxysilane were used as catalyst, additive, activator, and modifier, respectively. The nature and concentration of alkoxysilanes on the dimerization rate, catalyst yield, by‐products production, and selectivity to butene‐1 were investigated in detail. It was found that the performance of alkoxysilanes assisted with the class of the Ti‐based catalyst system, developed in this work, has been furthered by high productivity and selectivity with respect to the bare catalyst system. It proved that alkoxysilanes could play an excellent improving role in the selective ethylene dimerization process. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44615.     

Dynamic simulation and experimental evaluation of EPDM synthesis with ET(IND)2ZRCL2/MAO catalyst system

A mathematical model for the homogeneous terpolymerization of ethylene–propylene–diene (EPDM) in a semibatch reactor using Et(Ind)₂ZrCl₂/MAO as a catalyst system was developed and reported herein. In this study, we developed a kinetic model in order to explain the catalyst and EPDM properties such as catalyst activity, weight‐average molecular weight, and terpolymer composition, which were experimentally and theoretically obtained. For this system, a lower E/P feed ratio leads to a lower molecular weight and a broader initial molecular weight distribution, while the increase in diene concentration leads to a decrease in the catalyst activity without broadening the MWD of the resulting polymers. The proposed model accounts for these experimental trends and for some data in the literature.     

Effect of nano-SiO2 particle size on the formation of LLDPE/SiO2 nanocomposite synthesized via the in situ polymerization with metallocene catalyst

Here, we revealed the effect of particle size of the nanoscale SiO₂ on catalytic and characteristic properties of LLDPE/nano-SiO₂ composites synthesized via the in situ polymerization with a zirconocene/MAO catalyst. In the experiment, SiO₂ (10 and 15 nm) was first impregnated with MAO. Then, copolymerization of ethylene/1-hexene was performed in the presence of nano-SiO₂/MAO to produce LLDPE/nano-SiO₂ composites. It was found that the larger particle exhibited higher polymerization activity due to fewer interactions between SiO₂ and MAO. The larger particle also rendered higher insertion of 1-hexene leading to decreased melting temperature (T_m). There was no significant change in the LLDPE molecular structure by means of ¹³C NMR.     

Homopolymerization of Higher 1‐Olefins with Metallocene/MAO Catalysts

Linear 1‐olefins from 1‐pentene to 1‐octadecene are polymerized by non‐stereospecific Cp₂HfCl₂ ( 1 ), syndiospecific Me₂C(Cp)(9‐fluorenyl)ZrCl₂ ( 2 ) and isospecific Et(Ind)₂ZrCl₂ ( 3 ) catalysts in the presence of MAO. The molecular weight of the resulting polymers (GPC) is highly dependent on the nature of the catalyst, but more or less independent of the monomer chain length. The stereoregularity of the poly(1‐olefins) obtained with 2 and 3 as determined by NMR spectroscopy decreases linearly with increasing monomer chain length. A decrease in isotacticity occurs for the poly(1‐olefins) synthesized with 3 when increasing the catalyst concentration. Vinylidene, 1,2‐disubstituted and 1,1,2‐trisubstituted double bonds attributed to different chain termination mechanisms are generated during the polymerization processes.     

A comparative study of tetraisobutyldialuminoxane and methylaluminoxane as cocatalysts for Cp2ZrCl2 catalyzed ethylene polymerization

Summary The effect of [A1]/[Zr] mol ratio and temperature on the cocatalytic effects of tetraisobutyldialuminoxane (TIBDAO) and methylaluminoxane (MAO) for ethylene polymerization using Cp₂ZrCl₂ catalyst were studied. The decay type kinetic profile was observed for both TIBDAO and MAO cocatalyzed ethylene polymerizations. Catalytic activity and rate of polymerization were found to be low for TIBDAO cocatalyzed ethylene polymerization when compared to MAO cocatalyzed ethylene polymerization. The differences in catalytic activity and rate of polymerization for ethylene polymerization catalyzed by Cp₂ZrCl₂-TIBDAO and Cp₂ZrCl₂-MAO were discussed with respect to the structures of MAO and TIBDAO. An active species for Cp₂ZrCl₂-MAO and Cp₂ZrCl₂-TIBDAO catalyzed ethylene polymerizations was also discussed. The polyethylene was characterized by intrinsic viscosity measurements.     

Ethylene polymerization by phenylenedimethylene‐bridged homobinuclear zirconocene/methylaluminoxane systems

In the presence of methylaluminoxane (MAO), ethylene polymerization was successfully performed with homobinuclear zirconocene complexes {[(C₅H₅)ZrCl₂](C₅H₄CH₂ C₆H₄CH₂C₅H₄)[(C₅H₅)ZrCl₂]; 3o , 4m , and 5p }, which were prepared conveniently by the reaction of disodium(phenylenedimethylene)dicyclopentadienide [C₆H₄(CH₂C₅H₄Na)₂] with 2 equiv of (N⁵‐Cyclopentadienyl)trichlorozirconium dimethoxyethane (CpZrCl₃(DME)) in tetrahydrofuran and characterized by ¹H‐NMR and elemental analysis. The effects of the polymerization parameters, such as the temperature, time, concentration of the catalyst, MAO/catalyst molar ratio, and isomeric difference of the homobinuclear metallocene complexes 3o , 4m , and 5p were studied in detail. The results showed that all three catalytic systems had moderate activities in ethylene polymerization and afforded polyethylene with relatively broad polydispersities. The catalytic activity of 4m was somewhat higher than that of 3o and 5p but lower than that of 4,4′‐bis(methylene)biphenylene‐bridged zirconocene catalysts; this indicated that the distance between the two metal centers was too short in comparison with a 4,4′‐bis(methylene)biphenylene bridge to increase the catalytic activity. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci, 2006