13C-NMR study of ethylene/1-hexene and ethylene/1-octene copolymers obtained using homogeneous catalysts

Summary This study employed the ¹³C-NMR spectroscopy to investigate the influence of the increase of the comonomer concentration on the microstruture of ethylene/1-hexene and ethylene/1-octene copolymers obtained by the use of MeSiCp₂ZrCl₂, Cp₂ZrCl₂, Et[Ind]₂ZrCl₂ and [Ind]₂ZrCl₂ catalysts. For both comonomers butyl or hexyl branches were isolated between ethylene blocks. As the -olefin concentration in the copolymer increased, butyl or hexyl branches became closer, some of them, separated by only one or two ethylene units. Incorporation of -olefin in the copolymer was higher for the bridged catalysts, MeSiCp₂ZrCl₂, and Et[Ind]₂ZrCl₂ than for the unbridged ones. The -olefin size did not seem to effect its reactivity towards ethylene.     

The effect of the ethylene pressure on its reaction with 1-hexene, 1-octene and 4-methyl-1-pentene

Summary Copolymers of ethylene and 1-hexexe, 1-octene and 4-methyl-1-pentene were obtained using Et[In]₂ZrCl₂/MAO catalyst at various pressures. The increase of 1-hexene and 1-octene concentration in the feed increases catalyst activity(g/nZr.h.bar) and productivity(g/nZr.h). For 4-methyl-1-pentene the activity is independent on comonomer concentration. Increasing the ethylene pressure the productivity of the copolymerization increases and the activity shows a weak decay. Characterization of the copolymer shows that at higher pressure the cristallinity of the copolymers is higher due to lower comonomer incorporation. There is a good linear correlation of cristallinity with comonomer concentration in the feed for 1-hexene and 1-octene at a fixed pressure, but not for 4-methyl-1-pentene.     

Optimization of olefin copolymerization: effects of reaction parameters on catalytic activity and properties

The copolymerization of ethylene with 1-hexene using Et[Ind]₂ZrCl₂/MAO as catalyst was studied by multivariate methods. Three complete factorial designs were performed to study the influence of 1-hexene concentration, reaction temperature and [Al]/[Zr] ratio on catalytic activity, copolymer viscosity, crystallinity and melting point. Since the [Al]/[Zr] ratio has a small effect on the catalytic activity, a fourth design with 1-hexene and temperature was developed, giving higher catalytic activities. Temperature and 1-hexene concentration were the main effects found in the system. A second order effect arising from 1-hexene versus [Al]/[Zr] ratio was also detected. Polymer viscosity, crystallinity and melting points decreased with 1-hexene concentration. Viscosity decreased with temperature whereas crystallinity increased when the temperature was raised from 30 to 60 °C. Received: 13 June 1997/Revised version: 2 November 1997/Accepted: 21 November 1997     

Highly active ethylene/hydroxyl comonomers copolymerization using metallocene catalysts

Ethylene was copolymerized with 10‐undecen‐1‐ol and 5‐hexen‐1‐ol using stereorigid [rac‐ethylene(Ind)₂ZrCl₂], [rac‐ethylene(H₄Ind)₂ZrCl₂], and the new catalyst systems [rac‐norbornane(Ind)₂TiCl₂] and [mesonorbornane(Ind)₂TiCl₂], activated with methylaluminoxane. The characterization of the copolymers by ¹³C NMR spectroscopy revealed that the polymerization products were copolymers and that the conversion of the polar comonomer was strongly favored in the case of the zirconocene precursors. Very high catalytic activity values, nearly independent on the amount of comonomer in the feed, and comonomer incorporations up to 25.4%‐weight have been found for 10‐undencen‐1‐ol comonomer. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Ethylene polymerization with catalysts on the base of Zr-cenes and methylaluminoxanes synthesized on zeolite support

Summary The fixed aluminoxanes have been prepared on zeolite support Na-form of ZSM-5 (Si/Al=42) in reaction of partial hydrolysis of trimethylaluminium (TMA) with inside zeolite water. It was shown that aluminoxanes synthesized on zeolite surface form the heterogenized complexes with Cp₂ ZrCl₂ and Et[Ind]₂ ZrCl₂ which are active in ethylene polymerization without addition of other aluminiumorganic cocatalyst for a long time. The activation energy of ethylene polymerization in the presence of ZSM-5(H₂O)/TMA - Et[Ind]₂ ZrCl₂ is equal to 32 kJ/mol. Molecular weight and melting point of polyethylene obtained with such zeolite supported Zr-cene catalysts are higher than those of polyethylene formed with appropriate homogeneous metallocene systems. Received: 15 February 2000/Revised version: 10 May 2000/Accepted: 10 May 2000     

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.     

Study of the influence of the reaction parameters on the composition of the metallocene‐catalyzed ethylene copolymers using temperature rising elution fractionation and 13C nuclear magnetic resonance

Polyethylene copolymers prepared using the metallocene catalyst rac‐Et[Ind]₂ZrCl₂ were fractionated by preparative Temperature Rising Elution Fractionation (p‐TREF) and characterized by ¹³C nuclear magnetic resonance (NMR), differential scanning calorimetry (DSC), and gel permeation chromatography (GPC) to study the heterogeneity caused by experimental conditions. Two ethylene–1‐hexene copolymers with different 1‐hexene content and an ethylene–1‐octene copolymer all obtained using low (1.6 bar) ethylene pressure were compared with two ethylene–1‐hexene copolymers with different 1‐hexene content obtained at high ethylene pressure (7.0 bar). Samples obtained at low ethylene pressure and with low 1‐hexene concentration in the reactor presented narrow distributions in composition. Samples prepared with high comonomer concentration in the reactor or with high ethylene pressure showed an heterogeneous composition. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 155–163, 2002; DOI 10.1002/app.10284     

Synthesis and properties coming from the copolymerization of propene with α-olefins using different metallocene catalysts

Copolymerization of propene with two α-olefins (1-hexene and 1-octadecene) using iso- and syndioselective metallocene catalysts (EtInd₂ZrCl₂, Et(2-MeInd)₂ZrCl₂, Me₂SiInd₂ZrCl₂, Ph₂CFluCpZrCl₂ and Me₂CFluCpZrCl₂) activated with methylaluminoxane (MAO) is reported. The so-called comonomer effect was seen in the catalytic activity of the Me₂SiInd₂ZrCl₂/MAO system. Incorporation of syndiotactic copolymers was greater than that of isotactic copolymers. The molecular weight of the isotactic copolymers was not affected significantly by the presence of the comonomer, but the molecular weights of the copolymers obtained with the syndioselective catalysts decreased with increasing comonomer concentration in the medium. Tensile properties were studied. Syndiotactic copolymers with incorporation of the order of 6 mol% of 1-octadecene presented elastomeric properties.     

Nonisothermal,uncontrolled homo- and copolymerization of ethylene using selected zirconocenes

Nonisothermal, uncontrolled polymerization, conducted in varying mixing regimes, offered a facile methodology to evaluate the influence of several important process development factors such as mixing, reaction exotherm, and thermal perturbations on the catalytic activity and kinetic stability, polymerization performance, and properties of the resulting polymers. Ethylene was homo- and copolymerized with hexene-1 under varying impeller speeds (hence, thermal perturbations), using Ind₂ZrCl₂ and Et(Ind)₂ZrCl₂ and the MAO cocatalyst. With respect to the effects of the above process development factors, the following was observed: The reaction exotherm profiles, tracing the polymerization history, qualitatively represented the kinetic profile and the catalytic stability. The unbridged Ind₂ZrCl₂ was shown to be more stable than the bridged Et(Ind)₂ZrCl₂. With change in the level of stirring from a diffusion-controlled regime to a nondiffusion-controlled, external gas–liquid mass-transfer resistance-free one, the reaction exotherm and the run time-average catalytic activity increased. So far as the influence of the chiral versus the achiral zirconocene structure is concerned, the copolymer composition distribution and soluble fraction generated by chiral Et(Ind)₂ZrCl₂ were more sensitive to the mixing conditions and thermal perturbations than were those produced by achiral Ind₂ZrCl₂. Et(Ind)₂ZrCl₂ produced higher molecular weight backbones, incorporated more hexene-1 and chain branching, and introduced less crystallinity in the copolymers than did Ind₂ZrCl₂. The influence of Ind₂ZrCl₂ on higher-weight homopolymer backbones was opposite to that of Et(Ind)₂ZrCl₂. Incorporation of hexene-1 significantly decreased the average molecular weights and density and increased the run-time-dependent average catalyst activity. A positive comonomer effect took place. The bulk polymer properties did not critically depend on the mixing state. Thermal perturbations broadened the polydispersity index. © 1998 John Wiley & Sons, Inc. J. Appl. Polym. Sci. 70: 137–147, 1998     

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     

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     

Synthesis of linear low density polyethylene with a nano-sized silica supported Cp2ZrCl2/MAO catalyst

A nano-sized silica supported Cp₂ZrCl₂/MAO catalyst was used to catalyze the copolymerization of ethylene/1-hexene and ethylene/1-octene to produce linear low-density polyethylene (LLDPE) in a batch reactor. Under identical reaction conditions, the nano-sized catalyst exhibited significantly higher polymerization activity, and produced copolymer with greater molecular weight and smaller polydispersity index than a corresponding micro-sized catalyst, which was ascribed to the much lower internal diffusion resistance of the nano-sized catalyst. Copolymer density decreased with the increase of polymerization temperature, probably due to the decrease of reactivity ratio r ₁ and ethylene solubility with increasing temperature. Polymerization activity of the nano-sized catalyst increased rapidly with increasing comonomer concentration. Ethylene/1-octene exhibited higher polymerization activity and had a stronger comonomer effect than ethylene/1-hexene.     

Polymer-supported metallocene catalysts for gas-phase ethylene polymerization

The use of hydroxylated chloromethylated-styrene/divinylbenzene copolymer as a support for three different catalysts, Cp₂ZrCl₂, [Ind]₂ZrCl₂ and (CH₃)₂Si[Ind]₂ZrCl₂ has been examined for the polymerization of ethylene in gas phase. The gas phase polymerization experiments were performed in a horizontal reactor by using Box-Behnken experimental design [Box and Wilson, 1951] to study the effects of temperature, ethylene partial pressure, and MAO cocatalyst level on polymerization. The measured average catalyst activities were empirically correlated with these three factors. Temperature appears to be the most important factor, which shows a first and second order effect on activity and also interacts with pressure and MAO. The kinetic study shows that these supported catalysts might contain two types of active sites, and the deactivation of sites follows a first order kinetic. This paper is dedicated to Professor Wha Young Lee on the occasion of his retirement from Seoul National University.     

Copolymerization of ethylene and 1-octene by homogeneous and different supported metallocenic catalysts

In this work, the performance of the homogeneous catalyst system based on Et(Flu)₂ZrCl₂/MAO was evaluated on the copolymerization of ethylene and 1-octene. Characteristics of some of the produced polymers were also investigated. A study was performed to compare this system with that of Cp₂ZrCl₂/MAO. The influence of different support materials for the Cp₂ZrCl₂ was also evaluated, using silica, MgCl₂, and the zeolite sodic mordenite NaM. An increase in activity was observed in relation to the comonomer addition for the two homogeneous catalysts. The copolymers produced by the Et(Flu)₂ZrCl₂/MAO system showed higher molecular weight and narrower molecular weight distribution. We verified that the catalyst supported on SiO₂ was the most active one, although the copolymers produced with the catalyst supported on NaM showed higher molecular weight and lower molecular weight distribution. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 724–730, 2001     

Study on process parameters in metallocene polymerizations,I. Apparent viscosity and macro-scale mass transfer

A heat balance reaction calorimeter was used to obtain information about the most informative process parameters in polymerizations carried out with Et[Ind]₂ZrCl₂-methylaluminoxane catalyst. The viscosity of the reaction mixture was found to increase dramatically during the homopolymerization of ethylene, but it could be controlled through appropriate selection of the reaction mixture medium. The mass transfer between the gas and liquid phases was the rate-determining step for the polymerization when the reaction mixture-based Reynolds number was below 2.500. The limited mass transfer between the gas and liquid phases was caused by the intensive activity of the metallocene catalyst and the increased viscosity of the reaction mixture.     

In situ copolymerization of ethylene to produce linear low‐density polyethylene by Ti(OBu)4/AlEt3‐MAO/SiO2/Et(Ind)2ZrCl2

Linear low‐density polyethylene (LLDPE) is produced in a reactor from single ethylene feed by combining Ti(OBu)₄/AlEt₃, capable of forming α‐olefins (predominantly 1‐butene), with SiO₂‐supported Et(Ind)₂ZrCl₂ (denoted MAO/SiO₂/Et(Ind)₂ZrCl₂), which is able to copolymerize ethylene and 1‐butene in situ with little interference in the dual‐functional catalytic system. The two catalysts in the dual‐functional catalytic system match well because of the employment of triethylaluminum (AlEt₃) as the single cocatalyst to both Ti(OBu)₄ and MAO/SiO₂/Et(Ind)₂ZrCl₂, exhibiting high polymerization activity and improved properties of the obtained polyethylene. There is a noticeable increment in catalytic activity when the amount of Ti(OBu)₄ in the reactor increases and 1‐butene can be incorporated by about 6.51 mol % in the backbone of polyethylene chains at the highest Ti(OBu)₄ concentration in the feed. The molecular weights (M_w), melting points, and crystallinity of the LLDPE descend as the amount of Ti(OBu)₄ decreases, which is attributed mainly to chain termination and high branching degree, while the molecular weight distribution remains within a narrow range as in the case of metallocene catalysts. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 2451–2455, 2004     

Dynamic Model of the Copolymerization of Propylene and 1-Hexene with the Me2Si(2-Me-Ind)2ZrCl2 Catalytic System: Effect of 1-Hexene Concentration

The effect of the concentration of 1-hexene on catalytic productivity, copolymer molecular weight, and comonomer incorporation was studied and modeled for the synthesis of isotactic polypropylene copolymers by using the Me₂Si(2-Me-Ind)₂ZrCl₂/MAO catalytic system. The method of moments was employed to simulate the system and to quantify the corresponding catalytic behavior. An increase in the catalytic yield, associated with the “comonomer effect,” together with a decrease in the copolymer average molecular weight, was found when the comonomer concentration was increased. In the range studied, a linear relation between comonomer incorporation and its concentration in the reactor was found. All these behaviors were simulated with a good fit between experimental and predicted values. An important change appears at the highest comonomer concentration studied, associated with modifications in the catalytic behavior, and the model presented here aids in quantifying this performance.     

Behavior of poly(ethylene‐co‐olefin) polymers as elastomeric materials

The properties of two new ethylene‐α‐olefin copolymers, namely, ethylene–1‐hexene copolymer (EHC) and ethylene–1‐octadecene copolymers (EOC), synthesized via metallocene catalysts were evaluated. The copolymerization was carried out in an autoclave reactor with Et(Indenyl)₂ZrCl₂/methylaluminoxane as a catalyst system. These single‐site catalysts (metallocene type) allow one to obtain very homogeneous copolymers with excellent control of the molecular weight distribution and proportion of comonomer incorporation. So, copolymers with 18 mol % comonomer in the case of EHC and 12 mol % for EOC were shaped, and activities around 100,000 kg of polymer mol^?1 of Zr bar^?1 h^?1 were reached. The properties of these copolymers were compared with other commercial elastomers, such as ethylene–propylene copolymers synthesized by Ziegler–Natta catalysts and an ethylene–octene copolymer obtained via metallocene catalysts. The results show that these new copolymers, in particular, EOC, had excellent elastomeric properties. Furthermore, they had a relatively low viscosity, which implied a good response during processing. Moreover, the effectiveness of these copolymers as impact modifiers for polyolefins was also studied. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3008–3015, 2004     

Rates and product properties of polyethylene produced by copolymerization of 1-hexene and ethylene in the gas phase with (n-BuCp)2ZrCl2 on supports with different pore sizes

The effects of catalyst support pore size and reaction conditions (T=40-100 °C; ethylene pressure=1.4 MPa; 1-hexene concentration=0-47 mol/m³) on gas-phase polymerization rates and product properties were studied. Catalysts were prepared by impregnation of mesoporous molecular sieves (pore sizes of 2.5-20 nm) with methylaluminoxane and (n-BuCp)₂ZrCl₂. Temperature rising elution fractionation, differential scanning calorimetry and size exclusion chromatography were used to characterize the products. The results showed that these catalysts contained multiple types of catalytic sites and that the types of sites were a strong function of the support pore size. Ethylene polymerization and 1-hexene incorporation rates were strong functions of support pore size, 1-hexene concentration, and temperature. Large-pored catalysts had higher 1-hexene incorporation rates and the rate of 1-hexene incorporation was a function of polymerization time. Highest polymerization rates were obtained at 80 °C and 1-hexene concentration of 4-12 mol/m³; high 1-hexene concentrations resulted in large decreases in polymerization rates.     

Crystallization analysis fractionation of ethene/1-hexene copolymers made with the MAO-activated dual-site (1,2,4-Me3Cp)2ZrCl2 and (Me5Cp)2ZrCl2 system

Different poly(ethene-co-1-hexene) samples with varying amounts of 1-hexene were characterized by crystallization analysis fractionation (Crystaf). The samples were synthesized with (1,2,4-Me₃Cp)₂ZrCl₂, (Me₅Cp)₂ZrCl₂, and a mixture of these two catalysts in a 1:1 molar ratio. In addition, preparative Crystaf was used to fractionate some of the samples made with the catalyst mixture into 1-hexene-rich and 1-hexene-poor fractions. These fractions were characterized by Crystaf, differential scanning calorimetry (DSC) and gel permeation chromatography (GPC), and compared with copolymers made under similar conditions using the individual catalysts. Both (1,2,4-Me₃Cp)₂ZrCl₂ and (Me₅Cp)₂ZrCl₂ produced copolymers with unimodal distribution of short chain branches (SCBD), as expected for single-site catalysts. The catalyst mixture produced copolymers with bimodal SCBDs when 0.38 mol/l or higher concentrations of 1-hexene were used. The high temperature peak results from crystallization of polymer chains with few comonomer units, and these are attributed to (Me₅Cp)₂ZrCl₂. The low temperature peak results from crystallization of polymer chains made by (1,2,4-Me₃Cp)₂ZrCl₂, and these chains contain many comonomer units. Direct evidence for relative activity enhancement of the (Me₅Cp)₂ZrCl₂ catalyst in the dual-site system was observed.