Electronic Properties of Ti Sites in Ziegler–Natta Catalysts

The role of organoaluminum and electron donors in propene insertion on the Ziegler-Natta catalyst

Alkyl aluminium plays a primary role in activating Ti within Ziegler-Natta (ZN) catalysts for propylene polymerization. We performed density functional calculations to explore the additional roles of AlEt3 and AlEt2Cl, in conjunction with diisobutyl phthalate (DIBP) internal donor and dicyclopentyl dimethoxysilane (DCPDMS) external donor, to enhance the stereoselectivity of propene insertion. Based on our calculated adsorption energies on the (MgCl2)13/TiCl2iBu cluster model for the ZN catalyst, the presence of DIBP on the cluster essentially facilitated AlEt2Cl adsorption while AlEt2Cl also promoted the adsorption of DIBP. The reaction between AlEt3 and DIBP on the cluster led to the extraction of DIBP, creating an available site for DCPDMS adsorption. While the stereoselectivity, represented by the difference in the activation energies between 1,2-re and 1,2-si insertions of propene, was negligible on the cluster containing only DIBP, it became significant on the clusters containing both AlEt2Cl and DIBP (and DCPDMS). AlEt2Cl plays a pivotal role in imposing steric effects near the Ti active site, thereby increasing stereoselectivity. Our findings suggest the importance of including AlEt2Cl alongside DIBP (and DCPDMS) in the ZN cluster model to investigate stereoselective propene insertion. Considering AlEt2Cl adsorption and AlEt3 reaction with internal donors is essential in developing Ziegler-Natta catalysts.

Well-Defined Ti Surface Sites in Ziegler-Natta Pre-Catalysts from 47/49Ti Solid-State Nuclear Magnetic Resonance Spectroscopy

Treatment of Ziegler-Natta (ZN) catalysts with BCl3 improves their activity by increasing the number of active sites. Here we show how 47/49Ti solid-state nuclear magnetic resonance (NMR) spectroscopy enables us to understand the electronic structure of the Ti surface sites present in such treated ZN pre-catalysts, prior to activation with alkyl aluminum. High-field (21.1 T) and low-temperature (∼100 K) NMR augmented by DFT modeling on the pre-catalyst and corresponding molecular analogues enables the detection of 47/49Ti NMR signatures and a molecular level understanding of the electronic structure of Ti surface sites. The associated Ti surface sites exhibit 49Ti NMR signatures (δiso, exp = -170 ppm; CQ, exp = 9.3 MHz; κ = 0.05) corresponding to well-defined fully chlorinated hexacoordinated Ti sites adsorbed on a distorted surface of the MgCl2 support, formed upon post-treatment with BCl3 and removal of the alkoxo ligands, paralleling the increased polymerization activity.

Tracking Coordination Environment and Reaction Intermediates in Homogeneous and Heterogeneous Epoxidation Catalysts via Ti L2,3-Edge Near-Edge X-ray Absorption Fine Structures

Ti-based molecules and materials are ubiquitous and play a major role in both homogeneous and heterogeneous catalytic processes. Understanding the electronic structures of their active sites (oxidation state, local symmetry, and ligand environment) is key to developing molecular-level structure-property relationships. In that context, X-ray absorption spectroscopy (XAS) offers a unique combination of elemental selectivity and sensitivity to local symmetry. Commonly, for early transition metals such as Ti, K-edge XAS is applied for in situ characterization and subsequent structural analysis with high sensitivity toward tetrahedral species. Ti L2,3-edge spectroscopy is in principle complementary and offers specific opportunities to interrogate the electronic structure of five-and six-coordinated species. It is, however, much more rarely implemented because the use of soft X-rays implies ultrahigh vacuum conditions. Furthermore, the interpretation of the data can be challenging. Here, we show how Ti L2,3-edge spectroscopy can help to obtain unique information about both homogeneous and heterogeneous epoxidation catalysts and develop a molecular-level relationship between spectroscopic signatures and electronic structures. Toward this goal, we first establish a spectral library of molecular Ti reference compounds, comprising various coordination environments with mono- and dimeric Ti species having O, N, and Cl ligands. We next implemented a computational methodology based on multiplet ligand field theory and maximally localized Wannier orbitals benchmarked on our library to understand Ti L2,3-edge spectroscopic signatures. We finally used this approach to track and predict the spectra of catalytically relevant intermediates, focusing on Ti-based olefin epoxidation catalysts.

Unveiling Atomic-Scale Product Selectivity at the Cocatalyst-TiO2 Interface Using X-Ray Techniques: Insights into Interface Reactivity

The microstructure at the interface between the cocatalyst and semiconductor plays a vital role in concentrating photo-induced carriers and reactants. However, observing the atomic arrangement of this interface directly using an electron microscope is challenging due to the coverings of the semiconductor and cocatalyst. To address this, multiple metal-semiconductor interfaces on three TiO2 crystal facets (M/TiO2 ─N, where M represents Ag, Au, and Pt, and N represents the 001, 010, and 101 single crystal facets). The identical surface atomic configuration of the TiO2 facets allowed us to investigate the evolution of the microstructure within these constructs using spectroscopies and DFT calculations. For the first time, they observed the transformation of saturated Ti6c ─O bonds into unsaturated Ti5c ─O and Ti6c ─O─Pt bonds on the TiO2 ─010 facet after loading Pt. This transformation have a direct impact on the selectivity of the resulting products, leading to the generation of CO and CH4 at the Ti6c ─O─Pt and Pt sites, respectively. These findings pinpoint the pivotal roles played by the atomic arrangement at the M/TiO2 ─N interfaces and provide valuable insights for the development of new methodologies using conventional lab-grade equipment.

Geometry and Local Environment of Surface Sites in Vanadium-Based Ziegler-Natta Catalysts from 51V Solid-State NMR Spectroscopy

Since its emergence over 50 years ago, the structure of surface sites in Ziegler-Natta catalysts, which are responsible for a major fraction of the world's supply of polyethylene (PE) and polypropylene (PP), has remained elusive. This is in part due to the complexity of these systems that involve multiple synthetic steps and components, namely, the MgCl2 support, a transition-metal chloride, and several organic modifiers, known as donors, that are used prior and in some instances during the activation step with alkyl aluminum. Due to the favorable nuclear magnetic resonance (NMR) properties of V and its use in Ziegler-Natta catalysts, we utilize 51V solid-state NMR spectroscopy to investigate the structure of VOCl3 on MgCl2(thf)1.5. The resulting catalyst shows ethylene polymerization activity similar to that of its Ti analogues. Using carefully benchmarked density functional theory (DFT) calculations, the experimental 51V NMR signature was analyzed to elucidate the structure of the surface sites. Using this approach, we demonstrate that the 51V NMR signature contains information about the coordination environment, i.e., the type of ancillary ligand, and the morphology of the MgCl2 support. Analysis of the NMR signature shows that the adsorption of VOCl3 on MgCl2(thf)1.5 generates a well-defined hexacoordinated V-oxo species containing one alkoxy and four chloride ligands, whose local geometry results from the interaction with an amorphous MgCl2 surface. This study illustrates how NMR spectroscopy, which is highly sensitive to the local environment of the investigated nuclei, here V, enables us to identify the exact coordination sphere and to address the effect of the support morphology on surface site structures.

Evaluation of the Reactivity of Methanol and Hydrogen Sulfide Residues with the Ziegler-Natta Catalyst during Polypropylene Synthesis and Its Effects on Polymer Properties

The study focused on the evaluation of the influence of inhibitory compounds such as hydrogen sulfide (H2S) and methanol (CH3OH) on the catalytic productivity and properties of the polymers in the polymerization process with the Ziegler-Natta catalyst. The investigation involved experimental measurements, computational calculations using DFT, and analysis of various parameters, such as molecular weight, melt flow index, xylene solubility, and reactivity descriptors. The results revealed a clear correlation between the concentration of H2S and methanol and the parameters evaluated. Increasing the H2S concentrations, on average by 0.5 and 1.0 ppm, resulted in a drastic decrease in the polymer's molecular weight. A directly proportional relationship was observed between the flow rate and the H2S concentration. In the case of methanol, the change occurred from 60 ppm, causing a sharp decrease in the molecular weight of the polymer, which translates into an increase in the fluidity index and a decrease in solubility in xylene. The presence of these inhibitors also affected the catalytic activity, causing a reduction in the productivity of the Ziegler-Natta catalyst. Computational calculations provided a deeper understanding of the molecular behavior and reactivity of the studied compounds. The computational calculations yielded significantly lower results compared to other studies, with values of -69.0 and -43.9 kcal/mol for the Ti-CH3OH and H2S interactions, respectively. These results indicate remarkable stability in the studied interactions and suggest that both adsorptions are highly favorable.

A combined experimental and molecular simulation study on stress generation phenomena during the Ziegler-Natta polyethylene catalyst fragmentation process

The morphology of particles obtained under different pre-polymerization conditions has been connected to the stress generation mechanism at the polymer/catalyst interface. A combination of experimental characterization techniques and atomistic molecular dynamics simulations allowed a systematic investigation of experimental conditions leading to a certain particle morphology, and hence to a final polymer with specific features. Atomistic models of nascent polymer phases in contact with magnesium dichloride surfaces have been developed and validated. Using these detailed models, in the framework of McKenna's hypothesis, the pressure increase due to the polymerization reaction has been calculated under different conditions and is in good agreement with experimental scenarios. This molecular scale knowledge and the proposed investigation strategy would allow the pre-polymerization conditions to be better defined and the properties of the nascent polymer to be tuned, ensuring proper operability along the whole polymer production process.

Transition Metal-(μ-Cl)-Aluminum Bonding in α-Olefin and Diene Chemistry

Olefin and diene transformations, catalyzed by organoaluminum-activated metal complexes, are widely used in synthetic organic chemistry and form the basis of major petrochemical processes. However, the role of M−(μ-Cl)−Al bonding, being proven for certain >C=C< functionalization reactions, remains unclear and debated for essentially more important industrial processes such as oligomerization and polymerization of α-olefins and conjugated dienes. Numerous publications indirectly point at the significance of M−(μ-Cl)−Al bonding in Ziegler−Natta and related transformations, but only a few studies contain experimental or at least theoretical evidence of the involvement of M−(μ-Cl)−Al species into catalytic cycles. In the present review, we have compiled data on the formation of M−(μ-Cl)−Al complexes (M = Ti, Zr, V, Cr, Ni), their molecular structure, and reactivity towards olefins and dienes. The possible role of similar complexes in the functionalization, oligomerization and polymerization of α-olefins and dienes is discussed in the present review through the prism of the further development of Ziegler−Natta processes and beyond.

A Novel Method for Dynamic Molecular Weight Distribution Determination in Organometallic Catalyzed Olefin Polymerizations

In this study, a mathematical model for the time evolution of molecular weight distribution (MWD) was developed. This temporal model is based on the well-known Ziegler–Natta polymerization mechanism and reaction kinetics by the parametric solving of related differential equations. However, due to the generality of the reactions involved, the model can be extended to the other type of catalysts, such as metallocenes, Phillips, etc. The superiority of this model lies in providing the possibility of a more precise prediction over the active sites and kinetic parameters using a simple mathematical equation, which leads to improved reactor design in large-scale production. The model uses a function to develop a methodology for MWD calculations. In this way, the transient response is limited to the first few minutes of the reaction; however, it is important as it demonstrates the establishment of the final MWD. According to the results, almost for practical conditions with negligible transfer resistances, the time dependency of the MWD has a transient interval, depending on the kinetic constants of polymerization reactions. Increasing the time to infinity results in an increase in MW and a widening in MWD, which confirms the experimental plots well. In short, the main advantage of our proposed model over the previous ones is its ability to predict the MWD even before the completion of the polymerization reaction. The results of the present model match well with those of the well-known Schulz–Flory distribution, which only predicts the final molecular weight distribution, thus confirming that the model is reliable and generalizable.

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.

A Ziegler-type spherical cap model reveals early stage ethylene polymerization growth versus catalyst fragmentation relationships

Polyolefin catalysts are characterized by their hierarchically complex nature, which complicates studies on the interplay between the catalyst and formed polymer phases. Here, the missing link in the morphology gap between planar model systems and industrially relevant spherical catalyst particles is introduced through the use of a spherical cap Ziegler-type catalyst model system for the polymerization of ethylene. More specifically, a moisture-stable LaOCl framework with enhanced imaging contrast has been designed to support the TiCl₄ pre-active site, which could mimic the behaviour of the highly hygroscopic and industrially used MgCl₂ framework. As a function of polymerization time, the fragmentation behaviour of the LaOCl framework changed from a mixture of the shrinking core (i.e., peeling off small polyethylene fragments at the surface) and continuous bisection (i.e., internal cleavage of the framework) into dominantly a continuous bisection model, which is linked to the evolution of the estimated polyethylene volume and the fraction of crystalline polyethylene formed. The combination of the spherical cap model system and the used advanced micro-spectroscopy toolbox, opens the route for high-throughput screening of catalyst functions with industrially relevant morphologies on the nano-scale.

Ziegler-type polyolefin catalysts have proven to be hard to characterize. Here the authors present a model system consisting of patterned LaOCl spherical caps, simulating bulk particles while facilitating the use of micro(-spectro)scopic characterization techniques specifically aimed at surfaces.

Preventing Premature Convergence in Evolutionary Structure Determination of Complex Molecular Systems: Demonstration in Few-Nanometer-Sized TiCl4-Capped MgCl2 Nanoplates

The combination of genetic algorithm-based global search and local geometry optimization enables nonempirical structure determination for complex materials such as practical solid catalysts. However, premature convergence in the genetic algorithm hinders the determination of the global minimum for complicated molecular systems. Here, we implemented a distributed genetic algorithm based on the migration from a structure database for avoiding the premature convergence, and thus we realized the structure determination for TiCl₄-capped MgCl₂ nanoplates with experimentally consistent sizes. The obtained molecular models are featured with a realistic size and nonideal surfaces, representing actual primary particles of catalysts.

Exploring cocatalyst type effect on the Ziegler–Natta catalyzed ethylene polymerizations: experimental and DFT studies

Due to the important role of cocatalyst in the polymerization process employing industrially favored Ziegler–Natta catalysts, its effect on kinetic behavior, catalyst activity, and polymer properties is discussed. In this paper, triethyl aluminum (TEA) and triisobutyl aluminum (TIBA) have been used as the main cocatalyst ingredient with 10–20 mol percent of diethyl aluminum chloride (DEAC) and ethyl aluminum dichloride (EADC) cocatalysts, being neat TEA the cocatalysts with the highest activity. Moreover, TEA-DEAC and TEA-EADC cocatalysts revealed a built-up kinetic profile, while TIBA-DEAC and TIBA-EADC show a decay-type kinetic curve. According to melt flow index results, no considerable change in flowability was detected in the synthesized polyethylenes (PE). On the other hand, the ethylene insertion and chain termination mechanisms were investigated by means of density functional calculations using Ti active center located in (110) and (104) facets of the MgCl2 surface. To shed light on the bulkiness level of employed cocatalysts, buried volume (VBur) together with the two-dimensional map of cocatalyst systems were considered. Higher VBur of TIBA complex can explain its lower activity and decay type kinetic profile obtained by experimental studies.

The atomic defects on the (104) and (110) surfaces of the MgCl2-supported Ziegler–Natta catalyst: a periodic DFT study

This work presents a DFT study on the effects of atomic defects in the MgCl2-supported Ziegler–Natta catalyst. The adsorption behaviours of TiCl4 and internal donors on the ideal and defective MgCl2(104) and (110) surfaces were investigated.