Influence of Poisons Originating from Chemically Recycled Plastic Waste on the Performance of Ziegler–Natta Catalysts

Study of the Chemical Activities of Carbon Monoxide, Carbon Dioxide, and Oxygen Traces as Critical Inhibitors of Polypropylene Synthesis

This study outlines the investigation into how the compounds CO2, CO, and O2 interact with the active center of titanium (Ti) on the surface of MgCl2 and how these interactions impact the productivity of the Ziegler-Natta catalyst, ultimately influencing the thermal stability of the produced polypropylene. The calculations revealed that the adsorption energies of Ti-CO2-CO and O2 were -9.6, -12.5, and -2.32 Kcal/mol, respectively. Using the density functional theory in quantum calculations, the impacts of electronic properties and molecular structure on the adsorption of CO, O2, and CO2 on the Ziegler-Natta catalyst were thoroughly explored. Additionally, the Gibbs free energy and enthalpy of adsorption were examined. It was discovered that strong adsorption and a significant energy release (-16.2 kcal/mol) during CO adsorption could explain why this gas caused the most substantial reductions in the ZN catalyst productivity. These findings are supported by experimental tests showing that carbon monoxide has the most significant impact on the ZN catalyst productivity, followed by carbon dioxide, while oxygen exerts a less pronounced inhibitory effect.

Copolymerization of ethylene and isoprene via silicon bridge metallocene [rac-Me2Si(2-Me-4-Ph-Ind)2ZrCl2] catalyst: A new way to control the composition and microstructure of copolymers

The copolymerization of ethylene (E) with isoprene (Ip) was performed catalyzed by a symmetrical catalyst exhibiting a silicon bridge [rac-Me2Si(2-Me-4-Ph-Ind)2ZrCl2 with the combination of borate/TIBA activator. The effect of cocatalyst, Ip concentration, and polymerization temperature on the activity, molecular weight (Mw), distribution (MWD), comonomer composition, chain structure (regio- and stereoselectivity), and resulting side reactions were logically addressed. Gel-permeation chromatography (GPC) was used to characterize the Mw and polydispersity, while nuclear magnetic resonance (NMR) was employed for the chain structure of the polymers. The catalytic activity was significantly lower by increasing the Ip concentration in the feed, and the isoprene content in resulting polymers was lower under the reaction condition, leading to higher activity. Insertion of isoprene units in polymer structure demonstrates the higher regioselectivity for the 3,4 connections than the 1,4 connections and is expected to be a high-resistance polymer against acids. The MWD presented monomodal even with a higher concentration (1.44 mol/L) and did not appear as low Mw peaks of Ip. The Mw was higher with a broader MWD when purely TIBA was used as a cocatalyst, and it significantly reduced and presented a narrowed MWD with TEA in the cocatalyst. The higher efficiency of the catalyst for the higher insertion of Ip (C=C double bond) effectively modifies the polymer backbone. It is expected to be a promising candidate for easily degradable and favorable solutions for solving environmental problems caused by PE. wastes.

Dimethylformamide Impurities as Propylene Polymerization Inhibitor

This research study examined how the use of dimethylformamide (DMF) as an inhibitor affects the propylene polymerization process when using a Ziegler-Natta catalyst. Several experiments were carried out using TiCl4/MgCl2 as a catalyst, aluminum trialkyl as a cocatalyst, and different amounts of DMF. Then, we analyzed how DMF influences other aspects of the process, such as catalyst activity, molecular weight, and the number of branches in the polymer chains obtained, using experimental and computational methods. The results revealed that as the DMF/Ti ratio increases, the catalyst activity decreases. From a concentration of 5.11 ppm of DMF, a decrease in catalyst activity was observed, ranging from 45 TM/Kg to 44 TM/Kg. When the DMF concentration was increased to 40.23 ppm, the catalyst activity decreased to 43 TM/Kg, and with 75.32 ppm, it dropped even further to 39 TM/Kg. The highest concentration of DMF evaluated, 89.92 ppm, resulted in a catalyst productivity of 36.5 TM/Kg and lost productivity of 22%. In addition, significant changes in the polymer's melt flow index (MFI) were noted as the DMF concentration increased. When 89.92 ppm of DMF was added, the MFI loss was 75%, indicating a higher flowability of the polymer. In this study, it was found that dimethylformamide (DMF) exhibits a strong affinity for the titanium center of a Ziegler-Natta (ZN) catalyst, with an adsorption energy (Ead) of approximately -46.157 kcal/mol, indicating a robust interaction. This affinity is significantly higher compared to propylene, which has an Ead of approximately -5.2 kcal/mol. The study also revealed that the energy gap between the highest occupied molecular orbital (HOMO) of DMF and the lowest unoccupied molecular orbital (SOMO) of the Ziegler-Natta (ZN) catalyst is energetically favorable, with a value of approximately 0.311 eV.

Modified Magnesium Alkyls for Ziegler–Natta Catalysts

Magnesium alkyls such as butyl octyl magnesium and butyl ethyl magnesium are used as precursors for highly active and water-free magnesium chloride support materials for Ziegler–Natta catalysts. These alkyls show a high viscosity in hydrocarbon solvents which negatively affect their industrial application. Density functional theory (DFT) calculations supported the hypothesis that magnesium alkyls can form oligomeric chain structures responsible for the high viscosity. Heterocumulenes such as isocyanates, isothiocyanates and carbodiimides were studied as additives reducing the viscosity, supported by DFT calculations. The modified alkyls have further been tested in catalyst synthesis and in the polymerization of ethylene. The polymerization results showed high activities and similar polymer properties compared with a catalyst prepared without modified magnesium alkyl.