Mechanism of Initiation in the Phillips Ethylene Polymerization Catalyst: Ethylene Activation by Cr(II) and the Structure of the Resulting Active Site

Mechanistic Insights of Ethylene Polymerization on Phillips Chromium Catalysts

Silica-supported chromium oxide catalysts, also named Phillips chromium catalysts (PCCs), provide more than half of the world's production of high- and medium-density polyethylenes. PCCs are usually prepared in the Cr(VI)/SiO2 form, which is subjected to reductive activation. It has been explicitly proven that CO reduces Cr(VI) to Cr(II) species that initiate ethylene polymerization; ethylene activates Cr(VI) sites as well, but the nature of the catalytic species is complicated by the presence of the ethylene oxidation products. It is widely accepted that the catalytic species are of a Cr(III)-alkyl nature, but this common assumption faces the challenge of "extra" hydrogen: the formation of similar species under the action of even-electron reducing agents requires an additional H atom. Relatively recently, it was found that saturated hydrocarbons can also activate CrOx/SiO2, and alkyl fragments turn out to be bonded with a polyethylene chain. In recent years, there have been numerous experimental and theoretical studies of the structure and chemistry of PCCs at the different stages of preparation and activation. The use of modern spectral methods (such as extended X-ray absorption fine structure (EXAFS), X-ray absorption near-edge structure (XANES), and others); operando IR, UV-vis, EPR, and XAS spectroscopies; and theoretical approaches (DFT modeling, machine learning) clarified many essential aspects of the mechanisms of CrOx/SiO2 activation and catalytic behavior. Overall, the Cosse-Arlman mechanism of polymerization on Cr(III)-alkyl centers is confirmed in many works, but its theoretical support required the development of nontrivial and contentious mechanistic concepts of Cr(VI)/SiO2 or Cr(II)/SiO2 activation. On the other hand, conflicting experimental data continue to be obtained, and certain mechanistic concepts are being developed with the use of outdated models. Strictly speaking, the main question of what type of catalytic species, Cr(II), Cr(III), or Cr(IV), comes into polymerization still has not received an unambiguous answer. The role of the chemical nature of the support-through the prism of the nature, geometry, and distribution of the active sites-is also not clear in depth. In the present review, we endeavored to summarize and discuss the recent studies in the field of the preparation, activation, and action of PCCs, with a focus on existing contradictions in the interpretation of the experimental and theoretical results.

Active Sites in Cr(III)-Based Ethylene Polymerization Catalysts from Machine-Learning-Supported XAS and EPR Spectroscopy

The ethylene polymerization Phillips catalyst has been employed for decades and is central to the polymer industry. While Cr(III) alkyl species are proposed to be the propagating sites, there is so far no direct experimental evidence for such proposal. In this work, by coupling Surface organometallic chemistry, EPR spectroscopy, and machine learning-supported XAS studies, we have studied the electronic structure of well-defined silica-supported Cr(III) alkyls and identified the presence of several surface species in high and low-spin states, associated with different coordination environments. Notably, low-spin Cr(III) sites are shown to participate in ethylene polymerization, indicating that similar Cr(III) alkyl species could be involved in the related Phillips catalyst.

The role of agostic interaction in the mechanism of ethylene polymerisation using Cr(III) half-sandwich complexes: What dictates the reactivity?

Chromium-based catalysts play a significant role in the production of ultra-high molecular weight polyethylene, and half-sandwich functionalised-metallocene complexes were proven to be one of the most suitable candidates as catalysts for generating such large polymeric-length olefins. Earlier experimental studies on olefin polymerisation using a series of catalysts such as [L1-2CrCl2] (where L1 = 1-((pyridin-2-yl)methyl)indenyl (1) and L2 = 2-methyl-1-{[4-(yridinene-1-yl)yridine-2-yl]methyl}-1H-indenyl (2)) reveal significant variation where peripheral substitution on the ligand was found to influence the reactivity significantly. However, the specific ligand position that affects the reactivity has not been established. As these reactions are fast and robust, it is challenging to establish reactive intermediates via experiments, and therefore, mechanistic clues for such reactions are elusive. Here we have undertaken a detailed computational study by employing an array of DFT (uB3LYP-D3/def2-TZVP, CASSCF/NEVPT2, and DLPNO-CCSD(T) methods to explore the substituted and non-substituted pyridine-cyclo-pentadienyl chromium complexes and their influence on the catalytic activity in ethylene polymerisation. Our study not only unravels the catalytic pathway for olefin polymerisation for such Cr(III)-half-sandwich complexes but also reveals that the energetics of the formation of pseudo-three-coordinate alkyl intermediates is key to the variation in the reactivity observed. A detailed examination using MO and NBO analysis unveils the presence of a C-H⋯Cr agostic interaction that is found to significantly stabilise this intermediate when the pyridine ligand has strong electron-donating groups at its para position. The other substitutions, such as on the cyclopentadienyl ligand, neither yield the desired stability nor the desired interaction. Further studies on models support this proposal. In order to improve the efficiency and selectivity of catalytic systems in olefin polymerisation, we strongly advocate for the integration of agostic interactions as a crucial criterion in the design of future catalysts. Considering the prevalence of electron-deficient metal centres in successful olefin polymerisation catalysts, this research prompts a broader mechanistic inquiry to propose a unified approach for this industrially crucial reaction.

Ethylene polymerization with a crystallographically well-defined metal–organic framework supported catalyst

Crystallographic characterization of a heterogeneous ethylene polymerization catalyst elucidates a chromium–carbon bond after alkyl aluminum activation and provides mechanistic insights.

Deciphering the Phillips Catalyst by Orbital Analysis and Supervised Machine Learning from Cr Pre-edge XANES of Molecular Libraries

Unveiling the nature and the distribution of surface sites in heterogeneous catalysts, and for the Phillips catalyst (CrO₃/SiO₂) in particular, is still a grand challenge despite more than 60 years of research. Commonly used references in Cr K-edge XANES spectral analysis rely on bulk materials (Cr-foil, Cr₂O₃) or molecules (CrCl₃) that significantly differ from actual surface sites. In this work, we built a library of Cr K-edge XANES spectra for a series of tailored molecular Cr complexes, varying in oxidation state, local coordination environment, and ligand strength. Quantitative analysis of the pre-edge region revealed the origin of the pre-edge shape and intensity distribution. In particular, the characteristic pre-edge splitting observed for Cr(III) and Cr(IV) molecular complexes is directly related to the electronic exchange interactions in the frontier orbitals (spin-up and -down transitions). The series of experimental references was extended by theoretical spectra for potential active site structures and used for training the Extra Trees machine learning algorithm. The most informative features of the spectra (descriptors) were selected for the prediction of Cr oxidation states, mean interatomic distances in the first coordination sphere, and type of ligands. This set of descriptors was applied to uncover the site distribution in the Phillips catalyst at three different stages of the process. The freshly calcined catalyst consists of mainly Cr(VI) sites. The CO-exposed catalyst contains mainly Cr(II) silicates with a minor fraction of Cr(III) sites. The Phillips catalyst exposed to ethylene contains mainly highly coordinated Cr(III) silicates along with unreduced Cr(VI) sites.

Flowing-Air-Induced Transformation to Promote the Dispersion of the CrOx Catalyst for Propane Dehydrogenation

Highly dispersed chromium (Cr)-based catalysts are promising candidates for the catalytic dehydrogenation of propane (DHP). However, the easier aggregation of Cr species into crystalline Cr₂O₃ at the high-temperature calcination and reaction process is a big challenge, which severely restricts the improvement of activity and stability of the DHP reaction. Herein, a flowing-air-induced transformation method was first proposed, and the catalytic performance of the prepared Cr/MCM-41 catalysts was found to be significantly improved compared to that of the Cr-based catalyst prepared by the traditional calcination method, even better than that of most of the reported Cr-based catalysts and some noble metal-based catalysts. X-ray absorption spectroscopy and in situ Raman spectroscopy as well as other characterization techniques demonstrated that the in situ calcination in flowing air could not only effectively restrain the conversion of Cr(VI) into Cr(III) but also largely improve the dispersion of Cr species. Furthermore, DHP activity is found to have a positive correlation with the amount of monomeric Cr(VI) species, which is proved to be the precursor of active coordinatively unsaturated Cr sites. Our proposed flowing-air-induced transformation method provides a general strategy for preparing the highly dispersed Cr-based catalysts and other metal oxide materials with varied valence and exhibits potential application prospects in industry.

Influence of Metal-Alkyls on Early-Stage Ethylene Polymerization over a Cr/SiO2 Phillips Catalyst: A Bulk Characterization and X-ray Chemical Imaging Study

The Cr/SiO2 Phillips catalyst has taken a central role in ethylene polymerization since its invention in 1953. The uniqueness of this catalyst is related to its ability to produce broad molecular weight distribution (MWD) PE materials as well as that no co-catalysts are required to attain activity. Nonetheless, co-catalysts in the form of metal-alkyls can be added for scavenging poisons, enhancing catalyst activity, reducing the induction period, and tailoring polymer characteristics. The activation mechanism and related polymerization mechanism remain elusive, despite extensive industrial and academic research. Here, we show that by varying the type and amount of metal-alkyl co-catalyst, we can tailor polymer properties around a single Cr/SiO2 Phillips catalyst formulation. Furthermore, we show that these different polymer properties exist in the early stages of polymerization. We have used conventional polymer characterization techniques, such as size exclusion chromatography (SEC) and 13 C NMR, for studying the metal-alkyl co-catalyst effect on short-chain branching (SCB), long-chain branching (LCB) and molecular weight distribution (MWD) at the bulk scale. In addition, scanning transmission X-ray microscopy (STXM) was used as a synchrotron technique to study the PE formation in the early stages: allowing us to investigate the produced type of early-stage PE within one particle cross-section with high energy resolution and nanometer scale spatial resolution.

Tuning the Redox Chemistry of a Cr/SiO2 Phillips Catalyst for Controlling Activity, Induction Period and Polymer Properties

The Cr/SiO2 Phillips catalyst has taken a central role in ethylene polymerization ever since its discovery in 1953. This catalyst is unique compared to other ethylene polymerization catalysts, since it is active without the addition of a metal-alkyl co-catalyst. However, metal-alkyls can be added for scavenging poisons, enhancing the catalyst activity, reducing the induction period and altering polymer characteristics. Despite extensive research into the working state of the catalyst, still no consensus has been reached. Here, we show that by varying the type of metal-alkyl co-catalyst and its amount, the Cr redox chemistry can be tailored, resulting in distinct catalyst activities, induction periods, and polymer characteristics. We have used in-situ UV-Vis-NIR diffuse reflectance spectroscopy (DRS) for studying the Cr oxidation state during the reduction by tri-ethyl borane (TEB) or tri-ethyl aluminum (TEAl) and during subsequent ethylene polymerization. The results show that TEB primarily acts as a reductant and reduces Cr6+ with subsequent ethylene polymerization resulting in rapid polyethylene formation. TEAl generated two types of Cr2+ sites, inaccessible Cr3+ sites and active Cr4+ sites. Subsequent addition of ethylene also revealed an increased reducibility of residual Cr6+ sites and resulted in rapid polyethylene formation. Our results demonstrate the possibility of controlling the reduction chemistry by adding the proper amount and type of metal-alkyl for obtaining desired catalyst activities and tailored polyethylene characteristics.

Chromium complexes supported by the bidentate PN ligands: synthesis, characterization and application for ethylene polymerization

Chromium-based complexes are among the most important catalysts in the field of ethylene polymerization and oligomerization. Heterogeneous Cr Phillips catalysts account for more than one-third of the commercialized high density polyethylene (HDPE). In this contribution, chromium complexes, LCrCl3 (Cr1-Cr4: L = 2,6-R1-4-R2-C6H2-N[double bond, length as m-dash]CH-C6H4-2-PPh2; Cr1: R1 = H, R2 = H; Cr2: R1 = Me, R2 = H; Cr3: R1 = iPr, R2 = H; Cr4: R1 = Ph2CH, R2 = iPr), have been synthesized and characterized by elemental analysis, ESI and IR spectroscopy. The molecular structures of Cr3 and Cr4 are defined by X-ray diffraction, revealing a distorted octahedral geometry around the chromium center in both structures. In the presence of an aluminum cocatalyst, complexes Cr1-Cr4 show moderate to high activities toward ethylene polymerization. The nature of the catalysts and various reaction conditions, such as the nature and the amount of cocatalyst, reaction time and temperature, are investigated in detail. The results show that the title complexes have good thermal stability and the substituents on the ligands significantly affect the catalytic properties. Particularly, complex Cr4 can produce HDPE with a high molecular weight up to 68.3 × 104 g mol-1 due to the suppression of the chain transfer/termination by the introduction of bulky Ph2CH groups.

Zirconium Modification Promotes Catalytic Activity of a Single-Site Cobalt Heterogeneous Catalyst for Propane Dehydrogenation

The effect of Zr modification on the catalytic activity of Co/SiO₂ was investigated for nonoxidative propane dehydrogenation. Isolated Zr on SiO₂ surface sites were prepared by organometallic synthesis using Zr(O ^t Bu)₄ as a precursor. The resulting Zr/SiO₂ support was functionalized with Co²⁺ ions via strong electrostatic adsorption. Spectroscopic (diffuse reflectance infrared Fourier transform spectroscopy, UV-vis, electron paramagnetic resonance) and microscopic characterization (transmission electron microscopy, scanning transition electron microscopy) results are consistent with single-site cobalt that preferentially associates with the mono-dispersed Zr at a variety of loadings and Co/Zr ratios. The oxidation state of Co in the as-prepared Co/SiO₂ and Co-Zr/SiO₂ was both +2 with tetrahedral and octahedral geometries, respectively. In situ X-ray absorption near edge structure and extended X-ray absorption fine structure results confirmed that the oxidation state of Co remained as +2 under reaction condition for both Co/SiO₂ and Co-Zr/SiO₂ samples and both catalysts have tetrahedral Co²⁺ as the active catalyst. Despite similar Co coordination environments, the catalytic activity and selectivity was significantly improved by the Zr modification of the silica support versus Co/SiO₂. This was attributed to the change in oxygen donor ability and Co-O bond strength of the ≡SiO-Zr-O sites of Co-Zr/SiO₂ compared with the ≡SiO- ligands in Co/SiO₂. These results show that tuning of the support SiO₂ oxygen donation ability by use of an anchoring site (e.g., ≡SiO-Zr-O^-) can be used to alter both rate and selectivity of propane dehydrogenation with single-site heterogeneous catalysts. These results also show some preference for Co²⁺ active sites to associate with ≡SiO-Zr-O^- sites over ≡SiO-.

Chemoselective Hydrogenation with Supported Organoplatinum(IV) Catalyst on Zn(II)-Modified Silica

Well-defined organoplatinum(IV) sites were grafted on a Zn(II)-modified SiO₂ support via surface organometallic chemistry in toluene at room temperature. Solid-state spectroscopies including XAS, DRIFTS, DRUV-vis, and solid-state (SS) NMR enhanced by dynamic nuclear polarization (DNP), as well as TPR-H₂ and TEM techniques revealed highly dispersed (methylcyclopentadienyl)methylplatinum(IV) sites on the surface ((MeCp)PtMe/Zn/SiO₂, 1). In addition, computational modeling suggests that the surface reaction of (MeCp)PtMe₃ with Zn(II)-modified SiO₂ support is thermodynamically favorable (Δ G = -12.4 kcal/mol), likely due to the increased acidity of the hydroxyl group, as indicated by NH₃-TPD and DNP-enhanced ¹⁷O{¹H} SSNMR. In situ DRIFTS and XAS hydrogenation experiments reveal the probable formation of a surface Pt(IV)-H upon hydrogenolysis of Pt-Me groups. The heterogenized organoplatinum(IV)-hydride sites catalyze the selective partial hydrogenation of 1,3-butadiene to butenes (up to 95%) and the reduction of nitrobenzene derivatives to anilines (up to 99%) with excellent tolerance of reduction-sensitive functional groups (olefin, carbonyl, nitrile, halogens) under mild reaction conditions.