Discrete Ionic Complexes of Highly Isoselective Zirconocenes. Solution Dynamics, Trimethylaluminum Adducts, and Implications in Propylene Polymerization

Solution Structure and Dynamics of Hf-Al and Hf-Zn Heterobimetallic Adducts Mimicking Relevant Intermediates in Chain Transfer Reactions

Cationic cyclometalated hafnocenes [CpPrCpCH2CH2CH2Hf][B(C6F5)4] (4Pr) and [CpiBuCpCH2CH(Me)CH2Hf][B(C6F5)4] (4aiBu and 4biBu) were synthesized from the corresponding [(CpPr)2HfMe][B(C6F5)4] (1Pr) and [(CpiBu)2HfMe][B(C6F5)4] (1iBu) complexes via C-H activation. 4aiBu, 4biBu, and 4Pr, mimicking a propagating M-polymeryl species (M = transition metal) with or without a β-methyl branch on the metalated chains, serve to investigate whether and how the nature of the last inserted olefin molecules changes the structure, stability, and reactivity of the corresponding heterobimetallic complexes, formed in the presence of aluminum- or zinc-alkyl chain transfer agents (CTAs), which are considered relevant intermediates in coordinative chain transfer polymerization (CCTP) and chain shuttling polymerization (CSP) technologies. NMR and DFT data indicate no major structural difference between the resulting heterobridged complexes, all characterized by the presence of multiple α-agostic interactions. On the contrary, thermodynamic and kinetic investigations, concerning the reversible formation and breaking of heterobimetallic adducts, demonstrate that isomer 4aiBu, in which the β-Me is oriented away from the reactive coordination site on Hf, but not 4biBu, having the β-Me pointing in the opposite direction, is capable of reacting with CTAs. Quantification of kinetic rate constants highlights that the formation process is rate limiting and that the nature of the last inserted α-olefin unit modulates transalkylation kinetics. The reaction of 4aiBu, 4biBu, and 4Pr with diisobutylaluminum hydride (DiBAlH) allows the interception and characterization of new heterobinuclear and heterotrinuclear species, featuring both hydride and alkyl bridging moieties, which represent structural models of elusive intermediates in CCTP and CSP processes, capturing the instant when an alkyl chain has just transferred from a transition metal to a main group metal, while the two metals remain engaged in a single heterobimetallic intermediate.

MAO- and Borate-Free Activating Supports for Group 4 Metallocene and Post-Metallocene Catalysts of α-Olefin Polymerization and Oligomerization

Modern industry of advanced polyolefins extensively uses Group 4 metallocene and post-metallocene catalysts. High-throughput polyolefin technologies demand the use of heterogeneous catalysts with a given particle size and morphology, high thermal stability, and controlled productivity. Conventional Group 4 metal single-site heterogeneous catalysts require the use of high-cost methylalumoxane (MAO) or perfluoroaryl borate activators. However, a number of inorganic phases, containing highly acidic Lewis and Brønsted sites, are able to activate Group 4 metal pre-catalysts using low-cost and affordable alkylaluminums. In the present review, we gathered comprehensive information on MAO- and borate-free activating supports of different types and discussed the surface nature and chemistry of these phases, examples of their use in the polymerization of ethylene and α-olefins, and prospects of the further development for applications in the polyolefin industry.

The Highly Controlled and Efficient Polymerization of Ethylene

The highly controlled and efficient polymerization of ethylene is a very attractive but challenging target. Herein we report on a Coordinative Chain Transfer Polymerization catalyst, which combines a high degree of control and very high activity in ethylene oligo- or polymerization with extremely high chain transfer agent (triethylaluminum) to catalyst ratios (catalyst economy). Our Zr catalyst is long living and temperature stable. The chain length of the polyethylene products increases over time under constant ethylene feed or until a certain volume of ethylene is completely consumed to reach the expected molecular weight. Very high activities are observed if the catalyst elongates 60 000 or more alkyl chains and the polydispersity of the strictly linear polyethylene materials obtained are very low. The key for the combination of high control and efficiency seems to be a catalyst stabilized by only one strongly bound monoanionic N-ligand.

The Alkylaluminate/Gallate Trap: Metalation of Benzene by Heterobimetallic Yttrocene Complexes [Cp*2Y(MMe3R)] (M = Al, Ga)

Yttrocene derivatives [Cp*₂Y(MMe₄)] (Cp* = C₅Me₅; M = Al, Ga) and Cp*₂Y[Me₃Al{B(NDippCH)₂}] (Dipp = C₆H₃iPr₂-2,6) deprotonate benzene at elevated temperatures via the release of methane. The formation of [Cp*₂Y(Me₂MPh₂)] (M = Al, Ga), Cp*₂Y(MPh₄) (M = Al, Ga), Cp*₂Y[Me₂AlPh{B(NDippCH)₂}], and Cp*₂Y[AlPh₃{B(NDippCH)₂}] can be controlled via the temperature applied. The activation temperature and formation of the coordinatively unsaturated "reactive" [Cp*₂YMe] strongly depend on the coordination strength of the displaceable Lewis acids [AlMe₃]₂, GaMe₃, and [Me₂Al{B(NDippCH)₂}]₂. Hence, [Cp*₂Y(AlMe₄)] requires temperatures above 100 °C to metalate benzene, while Cp*₂Y[AlMe₃{B(NDippCH)₂}] undergoes C-H-bond activation even at ambient temperatures. A kinetic deuterium isotope effect was observed for the reactions in C₆D₆ solutions. Distinct differences in the stabilities of the bulky Group 13 anions ([Me₂MPh₂]^-, [MPh₄]^-, [Me₃Al{B(NDippCH)₂}]^-, [Me₂AlPh{B(NDippCH)₂}]^-, and [AlPh₃{B(NDippCH)₂}]^-) are assessed by detailed studies of the coordination chemistry with tetrahydrofuran (THF) and by variable-temperature ¹H NMR spectroscopy. Thus, increased steric bulk or a reduced Lewis acidity of the Group 13 metal center promote temperature-sensitive dissociation of trivalent Group 13 alkyl entities. Consequently, compound Cp*₂Y[AlPh₃{B(NDippCH)₂}] was found to engage in a dissociation equilibrium with [Cp*₂YPh] and AlPh₂{B(NDippCH)₂} in a C₆D₆ solution at ambient temperature. The reaction of Cp*₂Y[AlPh₃{B(NDippCH)₂}] with THF results in the concomitant formation of monometallic Cp*₂YPh(THF) and the solvent-separated ion pair [Cp*₂Y(THF)₂][AlPh₃{B(NDippCH)₂}].

Propylene Polymerization and Deactivation Processes with Isoselective {Cp/Flu} Zirconocene Catalysts

Industrially relevant single-site precatalysts used to produce isotactic polypropylene (iPP) include C2-symmetric {SBI} and C1-symmetric {Cp/Flu} complexes of group 4 metals. While the latter can produce iPPs with a higher degree of isotacticity, they also suffer from poor productivity compared to their {SBI} counterparts. Several causes for this trend have been suggested—2,1-Regioinsertions are frequently pointed out, as they are suspected to drive the catalyst into a dormant state. While this event does not seem to significantly impact the productivity of {SBI} systems, the influence of these regioerror is poorly documented for isoselective {Cp/Flu} precatalysts. To address this issue, new Ph2X(Cp)(Flu) (Ph2X = Ph2C, FluC, Ph2Si) proligands (2a–k) and some of the corresponding dichlorozirconocenes (3a–h,k) were synthesized. These new compounds were characterized and tested in homogeneous propylene polymerization at 60 °C and the amounts of regioerrors in the resulting polymers were examined by 13C NMR spectroscopy. A possible correlation between poor productivity and a high number of regioerrors was investigated and is discussed. Furthermore, a C-H activation process in the bulky nBu3C substituent upon activation of 4c (the dimethylated analog of 3c) by B(C6F5)3 has been evidenced by NMR; DFT calculations support this C-H activation as a deactivation mechanism.

Progress in propylene homo- and copolymers using advanced transition metal catalyst systems

Recent progress on advanced transition metal catalysts for propylene polymerization and copolymerization are reviewed.

{Cyclopentadienyl/Fluorenyl}-Group 4 ansa-Metallocene Catalysts for Production of Tailor-Made Polyolefins

The development of new metallocene-based polymerization catalysts and innovative processes derived thereof still constitutes a challenge for the manufacturing of polyolefinic materials with tailored properties (e. g. particular microstructure or topology, ultra-high molecular weight, high melting transition, and their combinations) for contemporary commercial applications. This personal account summarizes our continuing endeavors to advance the family of industry-relevant stereoselective propylene polymerization catalysts based on C₁ -symmetric group 4 ansa-metallocenes incorporating multi-substituted fluorenyl-cyclopentadienyl {Cp/Flu} ligands. Within the framework of this project, valuable structural and catalytic data, harvested both for neutral metallocenes and for metallocenium ion-pairs, have been used for rational design of more efficient catalytic systems, reluctant towards side reactions, and for providing new stereoregular value-added polymer materials.

Experimental and Theoretical Study of Zirconocene-Catalyzed Oligomerization of 1-Octene

Zirconocene-catalyzed coordination oligomerization of higher α-olefins is of theoretical and practical interest. In this paper, we present the results of experimental and theoretical study of α-olefin oligomerization, catalyzed by (η⁵-C₅H₅)]₂ZrX₂1/1′ and O[SiMe₂(η⁵-C₅H₄)]₂ZrX₂2/2′ (X = Cl, Me) with the activation by modified methylalymoxane MMAO-12 or by perfluoroalkyl borate [PhNMe₂H][B(C₆F₅)₄] (NB^F) in the presence and in the absence of organoaluminium compounds, Al(CH₂CHMe₂)₃ (TIBA) and/or Et₂AlCl. Under the conditions providing a conventional mononuclear reaction mechanism, 1′ catalyzed dimerization with low selectivity, while 2′ initiated the formation of oligomers in equal mass ratio. The presence of TIBA and especially Et₂AlCl resulted in an increase of the selectivity of dimerization. Quantum chemical simulations of the main and side processes performed at the M-06x/ DGDZVP level of the density functional theory (DFT) allowed to explain experimental results involving traditional mononuclear and novel Zr-Al₁ and Zr-Al₂ mechanistic concepts.

Zirconocene-Catalyzed Dimerization of α-Olefins: DFT Modeling of the Zr-Al Binuclear Reaction Mechanism

Zirconocene-mediated selective dimerization of α-olefins usually occurs when precatalyst (η⁵-C₅H₅)₂ZrCl₂ is activated by minimal excess of methylalumoxane (MAO). In this paper, we present the results of density functional theory (DFT) simulation of the initiation, propagation, and termination stages of dimerization and oligomerization of propylene within the framework of Zr-Al binuclear mechanism at M-06x/DGDZVP level of theory. The results of the analysis of the reaction profiles allow to explain experimental facts such as oligomerization of α-olefins at high MAO/(η⁵-C₅H₅)₂ZrCl₂ ratios and increase of the selectivity of dimerization in the presence of R₂AlCl. The results of DFT simulations confirm the crucial role of the presence of chloride in the selectivity of dimerization. The molecular hydrogen was found in silico and proven experimentally as an effective agent that increases the rate and selectivity of dimerization.

Catalyst Speciation During ansa-Zirconocene-Catalyzed Polymerization of 1-Hexene Studied by UV-vis Spectroscopy-Formation and Partial Re-Activation of Zr-Allyl Intermediates

Catalyst speciation during polymerization of 1-hexene in benzene or toluene solutions of the catalyst precursor SBIZr(μ-Me)₂AlMe₂⁺ B(C₆F₅)₄⁻ (SBI = rac-dimethylsilyl-bis(1-indenyl)) at 23 °C is studied by following the accompanying UV-vis-spectral changes. These indicate that the onset of polymerization catalysis is associated with the concurrent formation of two distinct zirconocene species. One of these is proposed to consist of SBIZr-σ-polyhexenyl cations arising from SBIZr-Me⁺ (formed from SBIZr(μ-Me)₂AlMe₂⁺ by release of AlMe₃) by repeated olefin insertions, while the other one is proposed to consist of SBIZr-η³-allyl cations of composition SBIZr-η³-(1-R-C₃H₄)⁺ (R = n-propyl), formed by σ-bond metathesis between SBIZr-Me⁺ and 1-hexene under release of methane. At later reaction stages, all zirconocene-σ–polymeryl cations appear to decay to yet another SBIZr-allyl species, i.e., to cations of the type SBIZr-η³-(x-R-(3-x)-pol-C₃H₃)⁺ (pol = i-polyhexenyl, x = 1 or 2). Renewed addition of excess 1-hexene is proposed to convert these sterically encumbered Zr-allyl cations back to catalytically active SBIZr-σ–polymeryl cations within a few seconds, presumably by initial 1-hexene insertion into the η¹- isomer, followed by repeated additional insertions, while the initially formed, less crowded allyl cations, SBIZr-η³-(1-R-C₃H₄)⁺ appear to remain unchanged. Implications of these results with regard to the kinetics of zirconocene-catalyzed olefin polymerization are discussed.

Unexpected Precatalyst σ-Ligand Effects in Phenoxyimine Zr-Catalyzed Ethylene/1-Octene Copolymerizations

Recent decades have witnessed intense research efforts aimed at developing new homogeneous olefin polymerization catalysts, with a primary focus on metal-Cl or metal-hydrocarbyl precursors. Curiously, metal-NR₂ precursors have received far less attention. In this contribution, the Zr-amido complex FI₂ZrX₂ (FI = 2,4-di- tert-butyl-6-((isobutylimino)methyl)phenolate, X = NMe₂) is found to exhibit high ethylene polymerization activity and relatively high 1-octene coenchainment selectivity (up to 7.2 mol%) after sequential activation with trimethylaluminum, then Ph₃C⁺B(C₆F₅)₄^-. In sharp contrast, catalysts with traditional hydrocarbyl ligands such as benzyl and methyl give low 1-octene incorporation (0-1.0 mol%). This unexpected selectivity persists under scaled/industrial operating conditions and was previously inaccessible with traditional metal-Cl or -hydrocarbyl precursors. NMR, X-ray diffraction, and catalytic control experiments indicate that in this case an FI ligand is abstracted from FI₂Zr(NMe₂)₂ by trimethylaluminum in the activation process to yield a catalytically active cationic mono-FIZr species. Heretofore this process was believed to serve only as a major catalyst deactivation pathway to be avoided. This work demonstrates the importance of investigating diverse precatalyst monodentate σ-ligands in developing new catalyst systems, especially for group 4 olefin polymerization catalysts.

Modeling of Fluid Bed Reactor of Ethylene Di Chloride Production in Abadan Petrochemical Based on Three-Phase Hydrodynamic Model

The catalytic process of ethylene oxychlorination can be split into two steps,uiz.ethylenechlorination with the reduction of cupric chloride and reoxidation of the cuprous chloride by hydrogen chloride and oxygen. The transient process of 1,2-dichloroethane formation was observed by selected ion chromatography using a mass spectrometer. While the reaction exhibited first-order kinetics in regard to the concentration of cupric chloride, the dependency on ethylene concentration was interpreted by a Wachi & Yousuke and Carrubba mechanism. Optimal performance was achieved by impregnating ea. 5 wt % of copper into y-alumina powder and 64% of the copper contained in the alumina powder contributed to the formation of 1,2-dichloroethane.this study, constant adverse reactions were calculated due to the experimental data obtained from Abadan Petrochemical Unit and the speed equation of Wachi was modified. The reaction occurs at three phases of bubble, cloud, and emulsion and by increasing temperature and input gas velocity and keeping all the other parameters constant in several steps, the substrate was investigated and the conversion of ethylene and gross value for each test were calculated. Thus, with the determination of kinetic and dynamic parameters, the proper mathematical model was chosen and using this model, the conversion percent of ethylene was calculated and its actual amount and the percentage of error were calculated and compared based on information obtained from Abadan Petrochemical reactor under different conditions.

A Theoretical Outlook on the Stereoselectivity Origins of Isoselective Zirconocene Propylene Polymerization Catalysts

The first three insertion steps of propylene for isoselective metallocenes from the one-carbon-bridged cyclopentadienyl-fluorenyl {Cp/Flu} and silicon-bridged ansa-bis(indenyl) {SBI} families were computed by using a theoretical method implementing the B3PW91 functional in combination with solvent corrections incorporated with the Solvation Model based on Density (SMD) continuum model. For C₁ -symmetric {Cp/Flu}-type metallocenes, two mechanisms of stereocontrol were validated theoretically: more facile and more stereoselective chain "stationary" insertion (or site epimerization backskip) and less stereoselective alternating mechanisms. For the C₂ -symmetric {SBI}-type system, the computation results were in complete agreement with the sole operating chain migratory insertion mechanism. The thermochemical data obtained through the study were used to predict microstructures of polypropylenes by using three-parameter and one-parameter statistical models for the two metallocene systems, respectively. The calculated meso/rac pentad distributions were found to be in good agreement with those determined experimentally for isotactic polypropylene samples obtained at different polymerization temperatures.

NMR spectroscopic identification of Ni(ii) species formed upon activation of (α-diimine)NiBr2 polymerization catalysts with MAO and MMAO

The ion pair [LNi^II(μ-Me)₂AlMe₂]⁺[MeMAO]⁻ is formed at the initial stage of LNiBr₂ activation with MAO, whereas [LNi^II–^tBu]⁺[MeMMAO]⁻ prevails in the LNiBr₂/MMAO system.

Non-traditional Ziegler-Natta catalysis in α-olefin transformations: reaction mechanisms and product design

This paper describes our recent results in the field of zirconocene-catalyzed α-oltfin transformations, and focuses on questions regarding the reaction mechanism, rational design of zirconocene pre-catalysts, as well as prospective uses of α-olefin products. It has been determined that a wide range of α-olefin-based products, namely vinylidene dimers, oligomers and polymers, can be prepared via catalysis by zirconocene dichlorides, activated by a minimal (10–20 eq.) amount of MAO. We assumed that in the presence of minimal quantities of MAO, various types of zirconocene catalysts form different types of catalytic particles. In the case of bis-cyclopentadienyl complexes, the reactive center is formed under the influence of R2AlCl, which makes the chain termination via β-hydride elimination significantly easier, with α-olefin dimers being formed as the primary product. Bis-indenyl complexes and their heteroanalogues, form stable cationic catalytic particles and effectively catalyze the polymerization. Mono-indenyl and mono-substituted bis-cyclopentadienyl-ansa complexes catalyze α-olefin oligomerization. Effective catalysts of dimerization, oligomerization and polymerization of α-olefins in the presence of minimal MAO quantities are proposed. Prospects of using α-olefin dimers, oligomers and polymers in the synthesis of branched hydrocarbon functional derivatives (dimers), high quality, low viscosity motor oils (oligomers), and thickeners and absorbents (polymers) are examined.

Synthesis and structure of the first discrete dinuclear cationic aluminum complexes

The preparation of discrete mono- and dicationic dinuclear aluminum complexes from the parent charge neutral dinuclear precursors has been studied. The first crystal structure of a dicationic dialuminum complex is reported.