A Comprehensive Review on Controlled Synthesis of Long-Chain Branched Polyolefins: Part 1, Single Catalyst Systems

Recent Advances in Controlled Production of Long-Chain Branched Polyolefins

Polyolefins, composed of carbon and hydrogen atoms, dominate global polymer production. This stems from the wide range of physical and mechanical properties that various polyolefins can cover. Their versatile properties are largely tuned by chain microstructure, including molar mass distribution, comonomer content, and long-chain branching (LCB). Specifically, LCB imparts unique characteristics, notably enhances processability crucial for downstream applications. Tailoring LCB structural features has encouraged academic and industrial efforts, chronicle in this review from a chemistry standpoint. While encompassing post-reaction modification based traditional methods like peroxide grafting, ionizing beam irradiation, and coupling reactions, the main focus is given to catalyst-centric strategies and innovative polymerization schemes. The advent of single-site catalysts-metallocenes and late transition metals catalysts-amplifies interest in tailored chemical methods, but the progress in LCB formation flourishes via tandem catalytic systems and bimetallic catalysts under controlled reaction conditions. Specifically, the breakthrough in coordinative chain transfer polymerization unveils a novel avenue for controlled LCB synthesis by sequential chain propagation, transfer, liberation, and enchainment. This short review highlights recent approaches for the production of LCB polyolefins that can provide a roadmap crucial for researchers in academia and industry, steering their efforts toward further advancements in the production of tailored polyolefin.

Chromium-Based Complexes Bearing Aminophosphine and Phosphine-Imine-Pyrryl Ligands for Selective Ethylene Tri/Tetramerization

A series of Cr-based complexes 6-10 bearing aminophosphine (P,N) ligands Ph₂P-L-NH₂ [L = CH₂CH₂ (1), L = CH₂CH₂CH₂ (2), and L = C₆H₄CH₂ (3)] and phosphine-imine-pyrryl (P,N,N) ligands 2-(Ph₂P-L-N=CH)C₄H₃NH [L = CH₂CH₂CH₂ (4) and L = C₆H₄CH₂ (5)] were prepared, and their catalytic properties were examined for ethylene tri/tetramerization. X-ray crystallographic analysis of complex 8 indicated the κ²-P,N bidentate coordination mode at the Cr(III) center and the distorted octahedral geometry of monomeric P,N-CrCl₃. Upon activation by methylaluminoxane (MAO), complexes 7-8 bearing P,N (PC₃N backbone) ligands 2-3 showed good catalytic reactivity for ethylene tri/tetramerization. On the other hand, complex 6 bearing the P,N (PC₂N backbone) ligand 1 was found active for non-selective ethylene oligomerization, while complexes 9-10 bearing P,N,N ligands 4-5 only produced polymerization products. In particular, the high catalytic activity of 458.2 kg/(g·Cr·h), excellent selectivity of 90.9% (1-hexene and 1-octene combined), and extremely low PE content of 0.1% were obtained with complex 7 in toluene at 45 °C and 45 bar. These results suggest that rational control of P,N and P,N,N ligand backbones, including a carbon spacer and rigidity of a carbon bridge, can lead to the high-performance catalyst for the ethylene tri/tetramerization process.

Chromium-Based Complexes Bearing N-Substituted Diphosphinoamine Ligands for Ethylene Oligomerization

A range of novel N-substituted diphosphinoamine (PNP) ligands Ph₂PN(R)PPh₂ [R = F₂CHCH₂ (1); R = Me₂CHCH₂ (2); R = Me₂CHCH₂CH₂ (3)] have been synthesized via one-step salt elimination reaction. The ligand-coordinated chromium carbonyls [Ph₂PN(R)PPh₂]Cr(CO)₄ (4-6) were further synthesized, and X-ray crystallography analysis of complex 6 revealed the κ²-P,P bidentate binding mode of Cr center and the molecular structure of PNP ligand 3. Then the catalytic ethylene oligomerization behaviors of PNP ligands 1-3 bridging chromium chloride complexes {[Ph₂PN(R)PPh₂]CrCl₂(μ-Cl)}₂ (7-9) were further discussed in depth. Experimental results showed that complex 7 with the strong electron-withdrawing F₂CHCH₂ group can promote the nonselective ethylene oligomerization, while both complex 8 and complex 9 with the electron-donating Me₂CHCH₂ and Me₂CHCH₂CH₂ groups can significantly enhance the selective ethylene tri/tetramerization. The good catalytic activity of 198.3 kg/(g Cr·h), the selectivity toward 1-hexene and 1-octene of 76.4%, and the low PE content of 0.2% were simultaneously achieved with the Al/Cr molar ratio of 600 using the complex 8/MMAO system at 45 °C and 45 bar. These excellent results were mainly attributed to the fact that the β-branching of bridging ligand 2 increased the steric bulk of the N-moiety for complex 8.

Cr/PCCP-Catalysed Selective Ethylene Oligomerization: Analysis of Various Conformations and the Hemilabile Methoxy Group

In this work, the effect of the hemilabile methoxy group in the Cr-based catalyst bearing (C6H5)2-P(CH2)2P-(C6H5)2 (PCCP) and (o-MeOC6H4)(C6H5)-P(CH2)2P-(C6H5)(o-MeOC6H4) (PCCPOMe) ligands on ethylene tri- and tetramerization were systematically investigated by...

Industrially relevant ethylene trimerization catalysts and processes

1-Hexene is one of the comonomers used to produce mainly low linear density polyethylene (LLDPE) and high-density polyethylene (HDPE). The production of 1-hexene by ethylene trimerization method gained much interest in petrochemical industry due to its high selectivity towards 1-hexene in comparison to traditional ethylene oligomerization method. In literature, many catalyst systems are reported for ethylene trimerization reaction, but only few of them qualify for the commercial applications. In the present review, activity and selectivity of commercially viable catalyst systems and amount of polyethylene formed as a by-product on using these catalyst systems were discussed. Special attention is given to Chevron Phillips ethylene trimerization technology which is one of the dominant technologies in the production of 1-hexene. The challenges such as fouling issues at commercial plant due to polyethylene by-product formation were discussed and the progress made to overcome the challenges were also discussed. New generation nontoxic titanium catalysts look promising and challenges involved in commercializing these catalysts were presented in the review.

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Comparative Analysis of Ethylene/Diene Copolymerization and Ethylene/Propylene/Diene Terpolymerization Using Ansa-Zirconocene Catalyst with Alkylaluminum/Borate Activator: The Effect of Conjugated and Nonconjugated Dienes on Catalytic Behavior and Polymer Microstructure

The copolymerization of ethylene‒diene conjugates (butadiene (BD), isoprene (IP) and nonconjugates (5-ethylidene-2-norbornene (ENB), vinyl norbornene VNB, 4-vinylcyclohexene (VCH) and 1, 4-hexadiene (HD)), and terpolymerization of ethylene-propylene-diene conjugates (BD, IP) and nonconjugates (ENB, VNB, VCH and HD) using two traditional catalysts of C₂-symmetric metallocene—silylene-bridged rac-Me₂Si(2-Me-4-Ph-Ind)₂ZrCl₂ (complex A) and ethylene-bridged rac-Et(Ind)₂ZrCl₂ (complex B)—with a [Ph₃C][B(C₆F₅)₄] borate/TIBA co-catalyst, were intensively studied. Compared to that in the copolymerization of ethylene diene, the catalytic activity was more significant in E/P/diene terpolymerization. We obtained a maximum yield of both metallocene catalysts with conjugated diene between 3.00 × 10⁶ g/mol_Mt·h and 5.00 × 10⁶ g/mol_Mt·h. ENB had the highest deactivation impact on complex A, and HD had the most substantial deactivation effect on complex B. A ¹H NMR study suggests that dienes were incorporated into the co/ter polymers’ backbone through regioselectivity. ENB and VNB, inserted by the edo double bond, left the ethylidene double bond intact, so VCH had an exo double bond. Complex A’s methyl and phenyl groups rendered it structurally stable and exhibited a dihedral angle greater than that of complex B, resulting in 1, 2 isoprene insertion higher than 1, 4 isoprene that is usually incapable of polymerization coordination. High efficiency in terms of co- and ter- monomer incorporation with higher molecular weight was found for complex 1. The rate of incorporation of ethylene and propylene in the terpolymer backbone structure may also be altered by the conjugated and nonconjugated dienes. ¹³C-NMR, ¹H-NMR, and GPC techniques were used to characterize the polymers obtained.

Assessing 1,9-Decadiene/Ethylene Copolymerization with Ziegler-Natta Catalyst to Access Long Chain-Branched Polyethylene

1,9-Decadiene/ethylene copolymerization is assessed as a way for Ziegler-Natta catalysts to access long chain-branched polyethylene (PE). A MgCl₂/9,9-bis-(methoxymethyl)fluorine/TiCl₄ catalyst with triethylaluminium as a cocatalyst is exemplified for the task. 1,9-Decadiene was found to induce a substantial comonomer effect on catalyst activity and continuing decreases of PE molecular weight. Both the double bonds of 1,9-decadiene were poorly reactive during polymerization, of which the polymer chain-attached was even much less reactive than the original one. As a consequence, at decreased feeds, 1,9-decadiene gave small amounts (<0.1 mol %) of pendant vinyl groups to PE without prompting the formation of long-chain branches. Long chain-branching was realized at increased 1,9-decadiene feeds, which was however accompanied by proportional gelation.

Slurry-phase ethylene polymerization processes: a review on multiscale modeling and simulations

Slurry polymerization processes using Zeigler–Natta catalysts, are most widely used for the production of polyethylene due to their several advantages over other processes. Significant advancements have been made in the modeling of these processes to obtain high-quality final products. The modeling work in this field has a very wide scope due to the great diversity of the catalyst types, polymerization processes, polymerization conditions, product qualities and microstructures that exist at the commercial scale. In this article, we have reviewed and discussed the slurry polymerization processes for the production of polyethylene and the multiscale modeling and simulation framework in slurry reactors. The multiscale modeling framework mainly comprises of the kinetic model, single-particle diffusion models, multiphase hydrodynamics, phase equilibria, reactor residence time distribution and the overall mass and heat balances. Guidelines to implement the multiscale mathematical modeling and simulation in slurry-phase olefin polymerization processes are proposed. Special focus is given on the need to reduce the computational effort for the simulation of industrial reactors so that the models can be used as an effective tool-kit for optimization studies using state-of-art algorithms.

100th Anniversary of Macromolecular Science Viewpoint: Polymers from Lignocellulosic Biomass. Current Challenges and Future Opportunities

Sustainable polymers from lignocellulosic biomass have the potential to reduce the environmental impact of commercial plastics while also offering significant performance and cost benefits relative to petrochemical-derived macromolecules. However, most currently available biobased polymers are hampered by insufficient thermomechanical properties, low economic feasibility (e.g., high relative cost), and reduced scalability in comparison to petroleum-based incumbents. Future biobased materials must overcome these limitations to be competitive in the marketplace. Additionally, sustainability challenges at the beginning and end of the polymer lifecycle need to be addressed using green chemistry practices and improved end-of-life waste management strategies. This viewpoint provides an overview of recent developments that can mitigate many concerns with present materials and discusses key aspects of next-generation, biobased polymers derived from lignocellulosic biomass.

Data-Driven Estimation of Significant Kinetic Parameters Applied to the Synthesis of Polyolefins

A data-driven strategy for the online estimation of important kinetic parameters was assessed for the copolymerization of ethylene with 1,9-decadiene using a metallocene catalyst at different diene concentrations and reaction temperatures. An initial global sensitivity analysis selected the significant kinetic parameters of the system. The retrospective cost model refinement (RCMR) algorithm was adapted and implemented to estimate the significant kinetic parameters of the model in real time. After verifying stability and robustness, experimental data validated the algorithm performance. Results demonstrate the estimated kinetic parameters converge close to theoretical values without requiring prior knowledge of the polymerization model and the original kinetic values.

Advances in Mathematical Modeling of Gas-Phase Olefin Polymerization

Mathematical modeling of olefin polymerization processes has advanced significantly, driven by factors such as the need for higher-quality end products and more environmentally-friendly processes. The modeling studies have had a wide scope, from reactant and catalyst characterization and polymer synthesis to model validation with plant data. This article reviews mathematical models developed for olefin polymerization processes. Coordination and free-radical mechanisms occurring in different types of reactors, such as fluidized bed reactor (FBR), horizontal-stirred-bed reactor (HSBR), vertical-stirred-bed reactor (VSBR), and tubular reactor are reviewed. A guideline for the development of mathematical models of gas-phase olefin polymerization processes is presented.

Preparation of "Constrained Geometry" Titanium Complexes of [1,2]Azasilinane Framework for Ethylene/1-Octene Copolymerization

The Me₂Si-bridged ansa-Cp/amido half-metallocene, [Me₂Si(η⁵-Me₄C₅)(N^tBu)]TiCl₂, termed a "constrained-geometry catalyst (CGC)", is a representative homogeneous Ziegler catalyst. CGC derivatives with the [1,2]azasilinane framework, in which the amide alkyl substituent is joined by the Si-bridge, were prepared, and the catalytic performances of these species was studied. Me₄C₅HSi(Me)(CH₂CH=CH₂)-NH(C(R)(R')CH=CH₂) (R, R' = H or methyl; Me₄C₅H = tetramethylcyclopentadienyl) was susceptible to ring closure metathesis (RCM) when treated with Schrock's Mo-catalyst to afford -Si(Me₄C₅H)(Me)CH₂CH=CHC(R)(R')NH- containing a six-membered ring framework. Using the precursors and the products of RCM, various CGC derivatives, i.e., [-Si(η⁵-Me₄C₅)(Me)CH₂CH=CHC(R)(H)N-]TiMe₂ (13, R = H; 15, R = Me), [-Si(η⁵-Me₄C₅)(Me)CH₂CH₂CH₂CH₂N]TiMe₂ (14), [(η⁵-Me₄C₅)Si(Me)(CH₂CH=CH₂)NCH₂CH=CH₂]TiMe₂ (16), [(η⁵-Me₄C₅)Si (Me)(CH=CH₂)NCH₂CH=CH₂]TiMe₂ (17), and [(η⁵-Me₄C₅)Si(Me)(CH₂CH₃)NCH₂CH₂CH₃]TiMe₂ (18), were prepared. The catalytic activity of the newly prepared complexes was lower than that of CGC when activated with [Ph₃C][B(C₆F₅)₄]/iBu₃Al. However, the catalytic activity of these species was improved by using tetrabutylaluminoxane ([iBu₂Al]₂O) instead of iBu₃Al and the activity of 14/[Ph₃C][B(C₆F₅)₄]/[iBu₂Al]₂O was comparable to that of CGC/[Ph₃C][B(C₆F₅)₄]/iBu₃Al (4.7 and 5.0 × 10⁶ g/mol-Ti, respectively). Advantageously, the newly prepared complexes produced higher molecular weight poly(ethylene-co-1-octene)s than CGC.