Ligands Make the Difference! Molecular Insights into CrVI/SiO2 Phillips Catalyst during Ethylene Polymerization

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experimental data continue to be obtained, and certain mechanistic concepts are being developed with the use of outdated models.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.

The Role of In Situ/Operando IR Spectroscopy in Unraveling Adsorbate-Induced Structural Changes in Heterogeneous Catalysis

Heterogeneous catalysts undergo thermal- and/or adsorbate-induced dynamic changes under reaction conditions, which consequently modify their catalytic behavior. Hence, it is increasingly crucial to characterize the properties of a catalyst under reaction conditions through the so-called "operando" approach. Operando IR spectroscopy is probably one of the most ubiquitous and versatile characterization methods in the field of heterogeneous catalysis, but its potential in identifying adsorbate- and thermal-induced phenomena is often overlooked in favor of other less accessible methods, such as XAS spectroscopy and high-resolution microscopy. Without detracting from these techniques, and while aware of the enormous value of a multitechnique approach, the purpose of this Review is to show that IR spectroscopy alone can provide relevant information in this field. This is done by discussing a few selected case studies from our own research experience, which belong to the categories of both "single-site"- and nanoparticle-based catalysts.

Site-Averaged Ab Initio Kinetics: Importance Learning for Multistep Reactions on Amorphous Supports

Single-atom centers on amorphous supports include catalysts for polymerization, partial oxidation, metathesis, hydrogenolysis, and more. The disordered environment makes each site different, and the kinetics exponentially magnifies these differences to make ab initio site-averaged kinetics calculations extremely difficult. This work extends the importance learning algorithm for efficient and precise site-averaged kinetics estimates to ab initio calculations and multistep reaction mechanisms. Specifically, we calculate site-averaged proton transfer relaxation rates on an ensemble of cluster models representing Brønsted acid sites on silica-alumina. We include direct and water-assisted proton transfer pathways and simultaneously estimate the water adsorption and activation enthalpies for forward and backward proton transfers. We use density functional theory (DFT) to obtain a site-averaged rate, somewhat like a turnover frequency, for the proton transfer relaxation rate. Finally, we show that importance learning can provide orders-of-magnitude acceleration over standard sampling methods for site-averaged rate calculations in cases where the rate is dominated by a few highly active sites.

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.

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.

Spectral Decomposition of X-ray Absorption Spectroscopy Datasets: Methods and Applications

X-ray absorption spectroscopy (XAS) today represents a widespread and powerful technique, able to monitor complex systems under in situ and operando conditions, while external variables, such us sampling time, sample temperature or even beam position over the analysed sample, are varied. X-ray absorption spectroscopy is an element-selective but bulk-averaging technique. Each measured XAS spectrum can be seen as an average signal arising from all the absorber-containing species/configurations present in the sample under study. The acquired XAS data are thus represented by a spectroscopic mixture composed of superimposed spectral profiles associated to well-defined components, characterised by concentration values evolving in the course of the experiment. The decomposition of an experimental XAS dataset in a set of pure spectral and concentration values is a typical example of an inverse problem and it goes, usually, under the name of multivariate curve resolution (MCR). In the present work, we present an overview on the major techniques developed to realize the MCR decomposition together with a selection of related results, with an emphasis on applications in catalysis. Therein, we will highlight the great potential of these methods which are imposing as an essential tool for quantitative analysis of large XAS datasets as well as the directions for further development in synergy with the continuous instrumental progresses at synchrotron sources.

In situ XAS study of the local structure and oxidation state evolution of palladium in a reduced graphene oxide supported Pd(ii) carbene complex during an undirected C–H acetoxylation reaction

In situ XAS is used to reveal the evolution of palladium species during an undirected C–H acetoxylation reaction.

Temperature-dependent dynamics of NH3-derived Cu species in the Cu-CHA SCR catalyst

In situ XAS and UV-vis–NIR spectroscopy shed light on Cu-speciation during NH₃ temperature-programmed desorption and surface reaction (TPSR) over a commercial Cu-chabazite deNO_x catalyst, expanding the fundamental knowledge required to unravel the NH₃-SCR mechanism across the whole operation-relevant temperature range.

Probing the Evolution of Palladium Species in Pd@MOF Catalysts during the Heck Coupling Reaction: An Operando X-ray Absorption Spectroscopy Study

The mechanism of the Heck C-C coupling reaction catalyzed by Pd@MOFs has been investigated using operando X-ray absorption spectroscopy (XAS) and powder X-ray diffraction (PXRD) combined with transmission electron microscopy (TEM) analysis and nuclear magnetic resonance (¹H NMR) kinetic studies. A custom-made reaction cell was used, allowing operando PXRD and XAS data collection using high-energy synchrotron radiation. By analyzing the XAS data in combination with ex situ studies, the evolution of the palladium species is followed from the as-synthesized to its deactivated form. An adaptive reaction mechanism is proposed. Mononuclear Pd(II) complexes are found to be the dominant active species at the beginning of the reaction, which then gradually transform into Pd nanoclusters with 13-20 Pd atoms on average in later catalytic turnovers. Consumption of available reagent and substrate leads to coordination of Cl^- ions to their surfaces, which causes the poisoning of the active sites. By understanding the deactivation process, it was possible to tune the reaction conditions and prolong the lifetime of the catalyst.